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Manual

WA500-6
WHEEL LOADER

SERIAL NUMBERS WA500-6 A92001 and UP

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

October 2008 Copyright 2008 Komatsu

Printed in USA DataKom Publications Division
00-1 ➁
FOREWORD CONTENTS
12
CONTENTS 00

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

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

20 STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

90 DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00-2 c WA500-6
FOREWORD

The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add

● Page to be replaced Replace

( ) Page to be deleted Discard

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● 00-1 c ● 00-11 c ● 10-2 c ● 10-31 c

● 00-2 c ● 00-12 c ● 10-3 c ● 10-32 c

● 00-2-1 c ● 00-13 c ● 10-4 c ● 10-33 c

● 00-2-2 c ● 00-14 c ● 10-5 c ● 10-34 c

● 00-2-3 c ● 00-15 c ● 10-6 c ● 10-35 c

● 00-2-4 c ● 00-16 c ● 10-7 c ● 10-36 c

● 00-2-5 c ● 00-17 c ● 10-8 c ● 10-37 c

● 00-2-6 c ● 00-18 c ● 10-9 c ● 10-38 c

● 00-2-7 c ● 00-19 c ● 10-10 c ● 10-39 c

● 00-2-8 c ● 00-20 c ● 10-11 c ● 10-40 c

● 00-2-9 c ● 00-21 c ● 10-12 c ● 10-41 c

● 00-2-10 c ● 00-22 c ● 10-13 c ● 10-42 c

● 00-2-11 c ❍ 00-23 c ● 10-14 c ● 10-43 c

● 00-2-12 c ❍ 00-24 c ● 10-15 c ● 10-44 c

● 00-2-13 c ❍ 00-25 c ● 10-16 c ● 10-45 c

● 00-2-14 c ❍ 00-26 c ● 10-17 c ● 10-46 c

● 00-2-15 c ● 10-18 c ● 10-47 c

● 00-2-16 c ● 01-1 c ● 10-19 c ● 10-48 c

❍ 00-2-17 c ● 01-2 c ● 10-20 c ● 10-49 c

❍ 00-2-18 c ● 01-3 c ● 10-21 c ● 10-50 c

● 01-4 c ● 10-22 c ● 10-51 c

● 00-3 c ● 01-5 c ● 10-23 c ● 10-52 c

● 00-4 c ● 01-6 c ● 10-24 c ● 10-53 c

● 00-5 c ● 01-7 c ● 10-25 c ● 10-54 c

● 00-6 c ● 01-8 c ● 10-26 c ● 10-55 c

● 00-7 c ❍ 01-9 c ● 10-27 c ● 10-56 c

● 00-8 c ❍ 01-10 c ● 10-28 c ● 10-57 c

● 00-9 c ● 10-29 c ● 10-58 c

● 00-10 c ● 10-1 c ● 10-30 c ● 10-59 c

WA500-6 WA500-6 00-2-1 ➁

FOREWORD

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● 10-60 c ● 10-93 c ● 10-126 c ● 10-159 c

● 10-61 c ● 10-94 c ● 10-127 c ● 10-160 c

● 10-62 c ● 10-95 c ● 10-128 c ● 10-161 c

● 10-63 c ● 10-96 c ● 10-129 c ● 10-162 c

● 10-64 c ● 10-97 c ● 10-130 c ● 10-163 c

● 10-65 c ● 10-98 c ● 10-131 c ● 10-164 c

● 10-66 c ● 10-99 c ● 10-132 c ● 10-165 c

● 10-67 c ● 10-100 c ● 10-133 c ● 10-166 c

● 10-68 c ● 10-101 c ● 10-134 c ● 10-167 c

● 10-69 c ● 10-102 c ● 10-135 c ● 10-168 c

● 10-70 c ● 10-103 c ● 10-136 c ● 10-169 c

● 10-71 c ● 10-104 c ● 10-137 c ● 10-170 c

● 10-72 c ● 10-105 c ● 10-138 c ● 10-171 c

● 10-73 c ● 10-106 c ● 10-139 c ● 10-172 c

● 10-74 c ● 10-107 c ● 10-140 c ● 10-173 c

● 10-75 c ● 10-108 c ● 10-141 c ● 10-174 c

● 10-76 c ● 10-109 c ● 10-142 c ● 10-175 c

● 10-77 c ● 10-110 c ● 10-143 c ● 10-176 c

● 10-78 c ● 10-111 c ● 10-144 c ● 10-177 c

● 10-79 c ● 10-112 c ● 10-145 c ● 10-178 c

● 10-80 c ● 10-113 c ● 10-146 c ● 10-179 c

● 10-81 c ● 10-114 c ● 10-147 c ● 10-180 c

● 10-82 c ● 10-115 c ● 10-148 c ● 10-181 c

● 10-83 c ● 10-116 c ● 10-149 c ● 10-182 c

● 10-84 c ● 10-117 c ● 10-150 c ● 10-183 c

● 10-85 c ● 10-118 c ● 10-151 c ● 10-184 c

● 10-86 c ● 10-119 c ● 10-152 c ● 10-185 c

● 10-87 c ● 10-120 c ● 10-153 c ● 10-186 c

● 10-88 c ● 10-121 c ● 10-154 c ● 10-187 c

● 10-89 c ● 10-122 c ● 10-155 c ● 10-188 c

● 10-90 c ● 10-123 c ● 10-156 c ● 10-189 c

● 10-91 c ● 10-124 c ● 10-157 c ● 10-190 c

● 10-92 c ● 10-125 c ● 10-158 c ● 10-191 c

00-2-2 ➁ WA500-6
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● 10-192 c ● 10-225 c ● 10-258 c ● 10-291 c

● 10-193 c ● 10-226 c ● 10-259 c ● 10-292 c

● 10-194 c ● 10-227 c ● 10-260 c ● 10-293 c

● 10-195 c ● 10-228 c ● 10-261 c ● 10-294 c

● 10-196 c ● 10-229 c ● 10-262 c ● 10-295 c

● 10-197 c ● 10-230 c ● 10-263 c ● 10-296 c

● 10-198 c ● 10-231 c ● 10-264 c ● 10-297 c

● 10-199 c ● 10-232 c ● 10-265 c ● 10-298 c

● 10-200 c ● 10-233 c ● 10-266 c ● 10-299 c

● 10-201 c ● 10-234 c ● 10-267 c ● 10-300 c

● 10-202 c ● 10-235 c ● 10-268 c ● 10-301 c

● 10-203 c ● 10-236 c ● 10-269 c ● 10-302 c

● 10-204 c ● 10-237 c ● 10-270 c ● 10-303 c

● 10-205 c ● 10-238 c ● 10-271 c ● 10-304 c

● 10-206 c ● 10-239 c ● 10-272 c ● 10-305 c

● 10-207 c ● 10-240 c ● 10-273 c ● 10-306 c

● 10-208 c ● 10-241 c ● 10-274 c ● 10-307 c

● 10-209 c ● 10-242 c ● 10-275 c ● 10-308 c

● 10-210 c ● 10-243 c ● 10-276 c ● 10-309 c

● 10-211 c ● 10-244 c ● 10-277 c ● 10-310 c

● 10-212 c ● 10-245 c ● 10-278 c ● 10-311 c

● 10-213 c ● 10-246 c ● 10-279 c ● 10-312 c

● 10-214 c ● 10-247 c ● 10-280 c ● 10-313 c

● 10-215 c ● 10-248 c ● 10-281 c ● 10-314 c

● 10-216 c ● 10-249 c ● 10-282 c ● 10-315 c

● 10-217 c ● 10-250 c ● 10-283 c ● 10-316 c

● 10-218 c ● 10-251 c ● 10-284 c ● 10-317 c

● 10-219 c ● 10-252 c ● 10-285 c ● 10-318 c

● 10-220 c ● 10-253 c ● 10-286 c ● 10-319 c

● 10-221 c ● 10-254 c ● 10-287 c ● 10-320 c

● 10-222 c ● 10-255 c ● 10-288 c ● 10-321 c

● 10-223 c ● 10-256 c ● 10-289 c ● 10-322 c

● 10-224 c ● 10-257 c ● 10-290 c ● 10-323 c

WA500-6 00-2-3 ➁
FOREWORD

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● 10-324 c ● 10-357 c ● 10-390 c ● 10-423 c

● 10-325 c ● 10-358 c ● 10-391 c ● 10-424 c

● 10-326 c ● 10-359 c ● 10-392 c ● 10-425 c

● 10-327 c ● 10-360 c ● 10-393 c ● 10-426 c

● 10-328 c ● 10-361 c ● 10-394 c ● 10-427 c

● 10-329 c ● 10-362 c ● 10-395 c ● 10-428 c

● 10-330 c ● 10-363 c ● 10-396 c ● 10-429 c

● 10-331 c ● 10-364 c ● 10-397 c ● 10-430 c

● 10-332 c ● 10-365 c ● 10-398 c ● 10-431 c

● 10-333 c ● 10-366 c ● 10-399 c ● 10-432 c

● 10-334 c ● 10-367 c ● 10-400 c ● 10-433 c

● 10-335 c ● 10-368 c ● 10-401 c ● 10-434 c

● 10-336 c ● 10-369 c ● 10-402 c ● 10-435 c

● 10-337 c ● 10-370 c ● 10-403 c ● 10-436 c

● 10-338 c ● 10-371 c ● 10-404 c ● 10-437 c

● 10-339 c ● 10-372 c ● 10-405 c ● 10-438 c

● 10-340 c ● 10-373 c ● 10-406 c ● 10-439 c

● 10-341 c ● 10-374 c ● 10-407 c ● 10-440 c

● 10-342 c ● 10-375 c ● 10-408 c ● 10-441 c

● 10-343 c ● 10-376 c ● 10-409 c ● 10-442 c

● 10-344 c ● 10-377 c ● 10-410 c ● 10-443 c

● 10-345 c ● 10-378 c ● 10-411 c ● 10-444 c

● 10-346 c ● 10-379 c ● 10-412 c ● 10-445 c

● 10-347 c ● 10-380 c ● 10-413 c ● 10-446 c

● 10-348 c ● 10-381 c ● 10-414 c ● 10-447 c

● 10-349 c ● 10-382 c ● 10-415 c ● 10-448 c

● 10-350 c ● 10-383 c ● 10-416 c ● 10-449 c

● 10-351 c ● 10-384 c ● 10-417 c ● 10-450 c

● 10-352 c ● 10-385 c ● 10-418 c ❍ 10-451 c

● 10-353 c ● 10-386 c ● 10-419 c ❍ 10-452 c

● 10-354 c ● 10-387 c ● 10-420 c ❍ 10-453 c

● 10-355 c ● 10-388 c ● 10-421 c ❍ 10-454 c

● 10-356 c ● 10-389 c ● 10-422 c ❍ 10-455 c

00-2-4 ➁ WA500-6
FOREWORD

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❍ 10-456 c ❍ 10-489 c ● 20-11 c ● 30-29 c

❍ 10-457 c ❍ 10-490 c ● 20-12 c ● 30-30 c

❍ 10-458 c ❍ 10-491 c () 20-13 ● 30-31 c

❍ 10-459 c ❍ 10-492 c () 20-14 ● 30-32 c

❍ 10-460 c ❍ 10-493 c ● 30-33 c

❍ 10-461 c ❍ 10-494 c ● 30-1 c ● 30-34 c

❍ 10-462 c ❍ 10-495 c ● 30-2 c ● 30-35 c

❍ 10-463 c ❍ 10-496 c ● 30-3 c ● 30-36 c

❍ 10-464 c ❍ 10-497 c ● 30-4 c ● 30-37 c

❍ 10-465 c ❍ 10-498 c ● 30-5 c ● 30-38 c

❍ 10-466 c ❍ 10-499 c ● 30-6 c ● 30-39 c

❍ 10-467 c ❍ 10-500 c ● 30-7 c ● 30-40 c

❍ 10-468 c ❍ 10-501 c ● 30-8 c ● 30-41 c

❍ 10-469 c ❍ 10-502 c ● 30-9 c ● 30-42 c

❍ 10-470 c ❍ 10-503 c ● 30-10 c ● 30-43 c

❍ 10-471 c ❍ 10-504 c ● 30-11 c ● 30-44 c

❍ 10-472 c ❍ 10-505 c ● 30-12 c ● 30-45 c

❍ 10-473 c ❍ 10-506 c ● 30-13 c ● 30-46 c

❍ 10-474 c ❍ 10-507 c ● 30-14 c ● 30-47 c

❍ 10-475 c ❍ 10-508 c ● 30-15 c ● 30-48 c

❍ 10-476 c ❍ 10-509 c ● 30-16 c ● 30-49 c

❍ 10-477 c ❍ 10-510 c ● 30-17 c ● 30-50 c

❍ 10-478 c ● 30-18 c ● 30-51 c

❍ 10-479 c ● 20-1 c ● 30-19 c ● 30-52 c

❍ 10-480 c ● 20-2 c ● 30-20 c ● 30-53 c

❍ 10-481 c ● 20-3 c ● 30-21 c ● 30-54 c

❍ 10-482 c ● 20-4 c ● 30-22 c ● 30-55 c

❍ 10-483 c ● 20-5 c ● 30-23 c ● 30-56 c

❍ 10-484 c ● 20-6 c ● 30-24 c ● 30-57 c

❍ 10-485 c ● 20-7 c ● 30-25 c ● 30-58 c

❍ 10-486 c ● 20-8 c ● 30-26 c ● 30-59 c

❍ 10-487 c ● 20-9 c ● 30-27 c ● 30-60 c

❍ 10-488 c ● 20-10 c ● 30-28 c ● 30-61 c

WA500-6 00-2-5 ➁
FOREWORD

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● 30-62 c ● 30-95 c ● 30-128 c ● 30-161 c

● 30-63 c ● 30-96 c ● 30-129 c ● 30-162 c

● 30-64 c ● 30-97 c ● 30-130 c ● 30-163 c

● 30-65 c ● 30-98 c ● 30-131 c ● 30-164 c

● 30-66 c ● 30-99 c ● 30-132 c ● 30-165 c

● 30-67 c ● 30-100 c ● 30-133 c ● 30-166 c

● 30-68 c ● 30-101 c ● 30-134 c ● 30-167 c

● 30-69 c ● 30-102 c ● 30-135 c ● 30-168 c

● 30-70 c ● 30-103 c ● 30-136 c ● 30-169 c

● 30-71 c ● 30-104 c ● 30-137 c ● 30-170 c

● 30-72 c ● 30-105 c ● 30-138 c ● 30-171 c

● 30-73 c ● 30-106 c ● 30-139 c ● 30-172 c

● 30-74 c ● 30-107 c ● 30-140 c ● 30-173 c

● 30-75 c ● 30-108 c ● 30-141 c ● 30-174 c

● 30-76 c ● 30-109 c ● 30-142 c ● 30-175 c

● 30-77 c ● 30-110 c ● 30-143 c ● 30-176 c

● 30-78 c ● 30-111 c ● 30-144 c ● 30-177 c

● 30-79 c ● 30-112 c ● 30-145 c ● 30-178 c

● 30-80 c ● 30-113 c ● 30-146 c ● 30-179 c

● 30-81 c ● 30-114 c ● 30-147 c ● 30-180 c

● 30-82 c ● 30-115 c ● 30-148 c ● 30-181 c

● 30-83 c ● 30-116 c ● 30-149 c ● 30-182 c

● 30-84 c ● 30-117 c ● 30-150 c ● 30-183 c

● 30-85 c ● 30-118 c ● 30-151 c ● 30-184 c

● 30-86 c ● 30-119 c ● 30-152 c ● 30-185 c

● 30-87 c ● 30-120 c ● 30-153 c ● 30-186 c

● 30-88 c ● 30-121 c ● 30-154 c ● 30-187 c

● 30-89 c ● 30-122 c ● 30-155 c ● 30-188 c

● 30-90 c ● 30-123 c ● 30-156 c ● 30-189 c

● 30-91 c ● 30-124 c ● 30-157 c ● 30-190 c

● 30-92 c ● 30-125 c ● 30-158 c ● 30-191 c

● 30-93 c ● 30-126 c ● 30-159 c ● 30-192 c

● 30-94 c ● 30-127 c ● 30-160 c ● 30-193 c

00-2-6 ➁ WA500-6
FOREWORD

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● 30-194 c () 30-227 b () 30-260 b () 30-293 b

● 30-195 c () 30-228 b () 30-261 b () 30-294 b

● 30-196 c () 30-229 b () 30-262 b () 30-295 b

● 30-197 c () 30-230 b () 30-263 b () 30-296 b

● 30-198 c () 30-231 b () 30-264 b () 30-297 b

● 30-199 c () 30-232 b () 30-265 b () 30-298 b

● 30-200 c () 30-233 b () 30-266 b () 30-299 b

● 30-201 c () 30-234 b () 30-267 b () 30-300 b

● 30-202 c () 30-235 b () 30-268 b () 30-301 b

● 30-203 c () 30-236 b () 30-269 b () 30-302 b

● 30-204 c () 30-237 b () 30-270 b () 30-303 b

● 30-205 c () 30-238 b () 30-271 b () 30-304 b

● 30-206 c () 30-239 b () 30-272 b () 30-305 b

● 30-207 c () 30-240 b () 30-273 b () 30-306 b

● 30-208 c () 30-241 b () 30-274 b () 30-307 b

● 30-209 c () 30-242 b () 30-275 b () 30-308 b

● 30-210 c () 30-243 b () 30-276 b () 30-309 b

● 30-211 c () 30-244 b () 30-277 b () 30-310 b

● 30-212 c () 30-245 b () 30-278 b () 30-311 b

● 30-213 c () 30-246 b () 30-279 b () 30-312 b

● 30-214 c () 30-247 b () 30-280 b () 30-313 b

● 30-215 c () 30-248 b () 30-281 b () 30-314 b

● 30-216 c () 30-249 b () 30-282 b () 30-315 b

● 30-217 c () 30-250 b () 30-283 b () 30-316 b

● 30-218 c () 30-251 b () 30-284 b

● 30-219 c () 30-252 b () 30-285 b ❍ 40-1 c

● 30-220 c () 30-253 b () 30-286 b ❍ 40-2 c

● 30-221 c () 30-254 b () 30-287 b ❍ 40-3 c

● 30-222 c () 30-255 b () 30-288 b ❍ 40-4 c

() 30-223 b () 30-256 b () 30-289 b ❍ 40-5 c

() 30-224 b () 30-257 b () 30-290 b ❍ 40-6 c

() 30-225 b () 30-258 b () 30-291 b ❍ 40-7 c

() 30-226 b () 30-259 b () 30-292 b ❍ 40-8 c

WA500-6 00-2-7 ➁
FOREWORD

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❍ 40-9 c ❍ 40-42 c ❍ 40-75 c ❍ 40-108 c

❍ 40-10 c ❍ 40-43 c ❍ 40-76 c ❍ 40-109 c

❍ 40-11 c ❍ 40-44 c ❍ 40-77 c ❍ 40-110 c

❍ 40-12 c ❍ 40-45 c ❍ 40-78 c ❍ 40-111 c

❍ 40-13 c ❍ 40-46 c ❍ 40-79 c ❍ 40-112 c

❍ 40-14 c ❍ 40-47 c ❍ 40-80 c ❍ 40-113 c

❍ 40-15 c ❍ 40-48 c ❍ 40-81 c ❍ 40-114 c

❍ 40-16 c ❍ 40-49 c ❍ 40-82 c ❍ 40-115 c

❍ 40-17 c ❍ 40-50 c ❍ 40-83 c ❍ 40-116 c

❍ 40-18 c ❍ 40-51 c ❍ 40-84 c ❍ 40-117 c

❍ 40-19 c ❍ 40-52 c ❍ 40-85 c ❍ 40-118 c

❍ 40-20 c ❍ 40-53 c ❍ 40-86 c ❍ 40-119 c

❍ 40-21 c ❍ 40-54 c ❍ 40-87 c ❍ 40-120 c

❍ 40-22 c ❍ 40-55 c ❍ 40-88 c ❍ 40-121 c

❍ 40-23 c ❍ 40-56 c ❍ 40-89 c ❍ 40-122 c

❍ 40-24 c ❍ 40-57 c ❍ 40-90 c ❍ 40-123 c

❍ 40-25 c ❍ 40-58 c ❍ 40-91 c ❍ 40-124 c

❍ 40-26 c ❍ 40-59 c ❍ 40-92 c ❍ 40-125 c

❍ 40-27 c ❍ 40-60 c ❍ 40-93 c ❍ 40-126 c

❍ 40-28 c ❍ 40-61 c ❍ 40-94 c ❍ 40-127 c

❍ 40-29 c ❍ 40-62 c ❍ 40-95 c ❍ 40-128 c

❍ 40-30 c ❍ 40-63 c ❍ 40-96 c ❍ 40-129 c

❍ 40-31 c ❍ 40-64 c ❍ 40-97 c ❍ 40-130 c

❍ 40-32 c ❍ 40-65 c ❍ 40-98 c ❍ 40-131 c

❍ 40-33 c ❍ 40-66 c ❍ 40-99 c ❍ 40-132 c

❍ 40-34 c ❍ 40-67 c ❍ 40-100 c ❍ 40-133 c

❍ 40-35 c ❍ 40-68 c ❍ 40-101 c ❍ 40-134 c

❍ 40-36 c ❍ 40-69 c ❍ 40-102 c ❍ 40-135 c

❍ 40-37 c ❍ 40-70 c ❍ 40-103 c ❍ 40-136 c

❍ 40-38 c ❍ 40-71 c ❍ 40-104 c ❍ 40-137 c

❍ 40-39 c ❍ 40-72 c ❍ 40-105 c ❍ 40-138 c

❍ 40-40 c ❍ 40-73 c ❍ 40-106 c ❍ 40-139 c

❍ 40-41 c ❍ 40-74 c ❍ 40-107 c ❍ 40-140 c

00-2-8 ➁ WA500-6
FOREWORD

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❍ 40-141 c ❍ 40-174 c ❍ 40-207 c ❍ 40-240 c

❍ 40-142 c ❍ 40-175 c ❍ 40-208 c ❍ 40-241 c

❍ 40-143 c ❍ 40-176 c ❍ 40-209 c ❍ 40-242 c

❍ 40-144 c ❍ 40-177 c ❍ 40-210 c ❍ 40-243 c

❍ 40-145 c ❍ 40-178 c ❍ 40-211 c ❍ 40-244 c

❍ 40-146 c ❍ 40-179 c ❍ 40-212 c ❍ 40-245 c

❍ 40-147 c ❍ 40-180 c ❍ 40-213 c ❍ 40-246 c

❍ 40-148 c ❍ 40-181 c ❍ 40-214 c ❍ 40-247 c

❍ 40-149 c ❍ 40-182 c ❍ 40-215 c ❍ 40-248 c

❍ 40-150 c ❍ 40-183 c ❍ 40-216 c ❍ 40-249 c

❍ 40-151 c ❍ 40-184 c ❍ 40-217 c ❍ 40-250 c

❍ 40-152 c ❍ 40-185 c ❍ 40-218 c ❍ 40-251 c

❍ 40-153 c ❍ 40-186 c ❍ 40-219 c ❍ 40-252 c

❍ 40-154 c ❍ 40-187 c ❍ 40-220 c ❍ 40-253 c

❍ 40-155 c ❍ 40-188 c ❍ 40-221 c ❍ 40-254 c

❍ 40-156 c ❍ 40-189 c ❍ 40-222 c ❍ 40-255 c

❍ 40-157 c ❍ 40-190 c ❍ 40-223 c ❍ 40-256 c

❍ 40-158 c ❍ 40-191 c ❍ 40-224 c ❍ 40-257 c

❍ 40-159 c ❍ 40-192 c ❍ 40-225 c ❍ 40-258 c

❍ 40-160 c ❍ 40-193 c ❍ 40-226 c ❍ 40-259 c

❍ 40-161 c ❍ 40-194 c ❍ 40-227 c ❍ 40-260 c

❍ 40-162 c ❍ 40-195 c ❍ 40-228 c ❍ 40-261 c

❍ 40-163 c ❍ 40-196 c ❍ 40-229 c ❍ 40-262 c

❍ 40-164 c ❍ 40-197 c ❍ 40-230 c ❍ 40-263 c

❍ 40-165 c ❍ 40-198 c ❍ 40-231 c ❍ 40-264 c

❍ 40-166 c ❍ 40-199 c ❍ 40-232 c ❍ 40-265 c

❍ 40-167 c ❍ 40-200 c ❍ 40-233 c ❍ 40-266 c

❍ 40-168 c ❍ 40-201 c ❍ 40-234 c ❍ 40-267 c

❍ 40-169 c ❍ 40-202 c ❍ 40-235 c ❍ 40-268 c

❍ 40-170 c ❍ 40-203 c ❍ 40-236 c ❍ 40-269 c

❍ 40-171 c ❍ 40-204 c ❍ 40-237 c ❍ 40-270 c

❍ 40-172 c ❍ 40-205 c ❍ 40-238 c ❍ 40-271 c

❍ 40-173 c ❍ 40-206 c ❍ 40-239 c ❍ 40-272 c

WA500-6 00-2-9 ➁
FOREWORD

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❍ 40-273 c ❍ 40-306 c ❍ 40-339 c ❍ 40-372 c

❍ 40-274 c ❍ 40-307 c ❍ 40-340 c ❍ 40-373 c

❍ 40-275 c ❍ 40-308 c ❍ 40-341 c ❍ 40-374 c

❍ 40-276 c ❍ 40-309 c ❍ 40-342 c ❍ 40-375 c

❍ 40-277 c ❍ 40-310 c ❍ 40-343 c ❍ 40-376 c

❍ 40-278 c ❍ 40-311 c ❍ 40-344 c ❍ 40-377 c

❍ 40-279 c ❍ 40-312 c ❍ 40-345 c ❍ 40-378 c

❍ 40-280 c ❍ 40-313 c ❍ 40-346 c ❍ 40-379 c

❍ 40-281 c ❍ 40-314 c ❍ 40-347 c ❍ 40-380 c

❍ 40-282 c ❍ 40-315 c ❍ 40-348 c ❍ 40-381 c

❍ 40-283 c ❍ 40-316 c ❍ 40-349 c ❍ 40-382 c

❍ 40-284 c ❍ 40-317 c ❍ 40-350 c ❍ 40-383 c

❍ 40-285 c ❍ 40-318 c ❍ 40-351 c ❍ 40-384 c

❍ 40-286 c ❍ 40-319 c ❍ 40-352 c ❍ 40-385 c

❍ 40-287 c ❍ 40-320 c ❍ 40-353 c ❍ 40-386 c

❍ 40-288 c ❍ 40-321 c ❍ 40-354 c ❍ 40-387 c

❍ 40-289 c ❍ 40-322 c ❍ 40-355 c ❍ 40-388 c

❍ 40-290 c ❍ 40-323 c ❍ 40-356 c ❍ 40-389 c

❍ 40-291 c ❍ 40-324 c ❍ 40-357 c ❍ 40-390 c

❍ 40-292 c ❍ 40-325 c ❍ 40-358 c ❍ 40-391 c

❍ 40-293 c ❍ 40-326 c ❍ 40-359 c ❍ 40-392 c

❍ 40-294 c ❍ 40-327 c ❍ 40-360 c ❍ 40-393 c

❍ 40-295 c ❍ 40-328 c ❍ 40-361 c ❍ 40-394 c

❍ 40-296 c ❍ 40-329 c ❍ 40-362 c ❍ 40-395 c

❍ 40-297 c ❍ 40-330 c ❍ 40-363 c ❍ 40-396 c

❍ 40-298 c ❍ 40-331 c ❍ 40-364 c ❍ 40-397 c

❍ 40-299 c ❍ 40-332 c ❍ 40-365 c ❍ 40-398 c

❍ 40-300 c ❍ 40-333 c ❍ 40-366 c ❍ 40-399 c

❍ 40-301 c ❍ 40-334 c ❍ 40-367 c ❍ 40-400 c

❍ 40-302 c ❍ 40-335 c ❍ 40-368 c ❍ 40-401 c

❍ 40-303 c ❍ 40-336 c ❍ 40-369 c ❍ 40-402 c

❍ 40-304 c ❍ 40-337 c ❍ 40-370 c ❍ 40-403 c

❍ 40-305 c ❍ 40-338 c ❍ 40-371 c ❍ 40-404 c

00-2-10 ➁ WA500-6
FOREWORD

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❍ 40-405 c ❍ 40-438 c ❍ 40-471 c ❍ 40-504 c

❍ 40-406 c ❍ 40-439 c ❍ 40-472 c ❍ 40-505 c

❍ 40-407 c ❍ 40-440 c ❍ 40-473 c ❍ 40-506 c

❍ 40-408 c ❍ 40-441 c ❍ 40-474 c ❍ 40-507 c

❍ 40-409 c ❍ 40-442 c ❍ 40-475 c ❍ 40-508 c

❍ 40-410 c ❍ 40-443 c ❍ 40-476 c ❍ 40-509 c

❍ 40-411 c ❍ 40-444 c ❍ 40-477 c ❍ 40-510 c

❍ 40-412 c ❍ 40-445 c ❍ 40-478 c ❍ 40-511 c

❍ 40-413 c ❍ 40-446 c ❍ 40-479 c ❍ 40-512 c

❍ 40-414 c ❍ 40-447 c ❍ 40-480 c ❍ 40-513 c

❍ 40-415 c ❍ 40-448 c ❍ 40-481 c ❍ 40-514 c

❍ 40-416 c ❍ 40-449 c ❍ 40-482 c ❍ 40-515 c

❍ 40-417 c ❍ 40-450 c ❍ 40-483 c ❍ 40-516 c

❍ 40-418 c ❍ 40-451 c ❍ 40-484 c ❍ 40-517 c

❍ 40-419 c ❍ 40-452 c ❍ 40-485 c ❍ 40-518 c

❍ 40-420 c ❍ 40-453 c ❍ 40-486 c ❍ 40-519 c

❍ 40-421 c ❍ 40-454 c ❍ 40-487 c ❍ 40-520 c

❍ 40-422 c ❍ 40-455 c ❍ 40-488 c ❍ 40-521 c

❍ 40-423 c ❍ 40-456 c ❍ 40-489 c ❍ 40-522 c

❍ 40-424 c ❍ 40-457 c ❍ 40-490 c ❍ 40-523 c

❍ 40-425 c ❍ 40-458 c ❍ 40-491 c ❍ 40-524 c

❍ 40-426 c ❍ 40-459 c ❍ 40-492 c ❍ 40-525 c

❍ 40-427 c ❍ 40-460 c ❍ 40-493 c ❍ 40-526 c

❍ 40-428 c ❍ 40-461 c ❍ 40-494 c ❍ 40-527 c

❍ 40-429 c ❍ 40-462 c ❍ 40-495 c ❍ 40-528 c

❍ 40-430 c ❍ 40-463 c ❍ 40-496 c ❍ 40-529 c

❍ 40-431 c ❍ 40-464 c ❍ 40-497 c ❍ 40-530 c

❍ 40-432 c ❍ 40-465 c ❍ 40-498 c ❍ 40-531 c

❍ 40-433 c ❍ 40-466 c ❍ 40-499 c ❍ 40-532 c

❍ 40-434 c ❍ 40-467 c ❍ 40-500 c ❍ 40-533 c

❍ 40-435 c ❍ 40-468 c ❍ 40-501 c ❍ 40-534 c

❍ 40-436 c ❍ 40-469 c ❍ 40-502 c ❍ 40-535 c

❍ 40-437 c ❍ 40-470 c ❍ 40-503 c ❍ 40-536 c

WA500-6 00-2-11 ➁
FOREWORD

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❍ 40-537 c ❍ 40-570 c ❍ 40-603 c ❍ 40-636 c

❍ 40-538 c ❍ 40-571 c ❍ 40-604 c ❍ 40-637 c

❍ 40-539 c ❍ 40-572 c ❍ 40-605 c ❍ 40-638 c

❍ 40-540 c ❍ 40-573 c ❍ 40-606 c ❍ 40-639 c

❍ 40-541 c ❍ 40-574 c ❍ 40-607 c ❍ 40-640 c

❍ 40-542 c ❍ 40-575 c ❍ 40-608 c ❍ 40-641 c

❍ 40-543 c ❍ 40-576 c ❍ 40-609 c ❍ 40-642 c

❍ 40-544 c ❍ 40-577 c ❍ 40-610 c ❍ 40-643 c

❍ 40-545 c ❍ 40-578 c ❍ 40-611 c ❍ 40-644 c

❍ 40-546 c ❍ 40-579 c ❍ 40-612 c ❍ 40-645 c

❍ 40-547 c ❍ 40-580 c ❍ 40-613 c ❍ 40-646 c

❍ 40-548 c ❍ 40-581 c ❍ 40-614 c ❍ 40-647 c

❍ 40-549 c ❍ 40-582 c ❍ 40-615 c ❍ 40-648 c

❍ 40-550 c ❍ 40-583 c ❍ 40-616 c ❍ 40-649 c

❍ 40-551 c ❍ 40-584 c ❍ 40-617 c ❍ 40-650 c

❍ 40-552 c ❍ 40-585 c ❍ 40-618 c ❍ 40-651 c

❍ 40-553 c ❍ 40-586 c ❍ 40-619 c ❍ 40-652 c

❍ 40-554 c ❍ 40-587 c ❍ 40-620 c ❍ 40-653 c

❍ 40-555 c ❍ 40-588 c ❍ 40-621 c ❍ 40-654 c

❍ 40-556 c ❍ 40-589 c ❍ 40-622 c ❍ 40-655 c

❍ 40-557 c ❍ 40-590 c ❍ 40-623 c ❍ 40-656 c

❍ 40-558 c ❍ 40-591 c ❍ 40-624 c ❍ 40-657 c

❍ 40-559 c ❍ 40-592 c ❍ 40-625 c ❍ 40-658 c

❍ 40-560 c ❍ 40-593 c ❍ 40-626 c ❍ 40-659 c

❍ 40-561 c ❍ 40-594 c ❍ 40-627 c ❍ 40-660 c

❍ 40-562 c ❍ 40-595 c ❍ 40-628 c ❍ 40-661 c

❍ 40-563 c ❍ 40-596 c ❍ 40-629 c ❍ 40-662 c

❍ 40-564 c ❍ 40-597 c ❍ 40-630 c ❍ 40-663 c

❍ 40-565 c ❍ 40-598 c ❍ 40-631 c ❍ 40-664 c

❍ 40-566 c ❍ 40-599 c ❍ 40-632 c ❍ 40-665 c

❍ 40-567 c ❍ 40-600 c ❍ 40-633 c ❍ 40-666 c

❍ 40-568 c ❍ 40-601 c ❍ 40-634 c ❍ 40-667 c

❍ 40-569 c ❍ 40-602 c ❍ 40-635 c ❍ 40-668 c

00-2-12 ➁ WA500-6
FOREWORD

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❍ 40-669 c ❍ 40-702 c ❍ 40-735 c ❍ 50-27 c

❍ 40-670 c ❍ 40-703 c ❍ 40-736 c ❍ 50-28 c

❍ 40-671 c ❍ 40-704 c ❍ 40-737 c ❍ 50-29 c

❍ 40-672 c ❍ 40-705 c ❍ 40-738 c ❍ 50-30 c

❍ 40-673 c ❍ 40-706 c ❍ 40-739 c ❍ 50-31 c

❍ 40-674 c ❍ 40-707 c ❍ 40-740 c ❍ 50-32 c

❍ 40-675 c ❍ 40-708 c ❍ 50-33 c

❍ 40-676 c ❍ 40-709 c ❍ 50-1 c ❍ 50-34 c

❍ 40-677 c ❍ 40-710 c ❍ 50-2 c ❍ 50-35 c

❍ 40-678 c ❍ 40-711 c ❍ 50-3 c ❍ 50-36 c

❍ 40-679 c ❍ 40-712 c ❍ 50-4 c ❍ 50-37 c

❍ 40-680 c ❍ 40-713 c ❍ 50-5 c ❍ 50-38 c

❍ 40-681 c ❍ 40-714 c ❍ 50-6 c ❍ 50-39 c

❍ 40-682 c ❍ 40-715 c ❍ 50-7 c ❍ 50-40 c

❍ 40-683 c ❍ 40-716 c ❍ 50-8 c ❍ 50-41 c

❍ 40-684 c ❍ 40-717 c ❍ 50-9 c ❍ 50-42 c

❍ 40-685 c ❍ 40-718 c ❍ 50-10 c ❍ 50-43 c

❍ 40-686 c ❍ 40-719 c ❍ 50-11 c ❍ 50-44 c

❍ 40-687 c ❍ 40-720 c ❍ 50-12 c ❍ 50-45 c

❍ 40-688 c ❍ 40-721 c ❍ 50-13 c ❍ 50-46 c

❍ 40-689 c ❍ 40-722 c ❍ 50-14 c ❍ 50-47 c

❍ 40-690 c ❍ 40-723 c ❍ 50-15 c ❍ 50-48 c

❍ 40-691 c ❍ 40-724 c ❍ 50-16 c ❍ 50-49 c

❍ 40-692 c ❍ 40-725 c ❍ 50-17 c ❍ 50-50 c

❍ 40-693 c ❍ 40-726 c ❍ 50-18 c ❍ 50-51 c

❍ 40-694 c ❍ 40-727 c ❍ 50-19 c ❍ 50-52 c

❍ 40-695 c ❍ 40-728 c ❍ 50-20 c ❍ 50-53 c

❍ 40-696 c ❍ 40-729 c ❍ 50-21 c ❍ 50-54 c

❍ 40-697 c ❍ 40-730 c ❍ 50-22 c ❍ 50-55 c

❍ 40-698 c ❍ 40-731 c ❍ 50-23 c ❍ 50-56 c

❍ 40-699 c ❍ 40-732 c ❍ 50-24 c ❍ 50-57 c

❍ 40-700 c ❍ 40-733 c ❍ 50-25 c ❍ 50-58 c

❍ 40-701 c ❍ 40-734 c ❍ 50-26 c ❍ 50-59 c

WA500-6 00-2-13 ➁
FOREWORD

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❍ 50-60 c ❍ 50-93 c ❍ 50-126 c ❍ 50-159 c

❍ 50-61 c ❍ 50-94 c ❍ 50-127 c ❍ 50-160 c

❍ 50-62 c ❍ 50-95 c ❍ 50-128 c ❍ 50-161 c

❍ 50-63 c ❍ 50-96 c ❍ 50-129 c ❍ 50-162 c

❍ 50-64 c ❍ 50-97 c ❍ 50-130 c ❍ 50-163 c

❍ 50-65 c ❍ 50-98 c ❍ 50-131 c ❍ 50-164 c

❍ 50-66 c ❍ 50-99 c ❍ 50-132 c ❍ 50-165 c

❍ 50-67 c ❍ 50-100 c ❍ 50-133 c ❍ 50-166 c

❍ 50-68 c ❍ 50-101 c ❍ 50-134 c ❍ 50-167 c

❍ 50-69 c ❍ 50-102 c ❍ 50-135 c ❍ 50-168 c

❍ 50-70 c ❍ 50-103 c ❍ 50-136 c ❍ 50-169 c

❍ 50-71 c ❍ 50-104 c ❍ 50-137 c ❍ 50-170 c

❍ 50-72 c ❍ 50-105 c ❍ 50-138 c ❍ 50-171 c

❍ 50-73 c ❍ 50-106 c ❍ 50-139 c ❍ 50-172 c

❍ 50-74 c ❍ 50-107 c ❍ 50-140 c ❍ 50-173 c

❍ 50-75 c ❍ 50-108 c ❍ 50-141 c ❍ 50-174 c

❍ 50-76 c ❍ 50-109 c ❍ 50-142 c ❍ 50-175 c

❍ 50-77 c ❍ 50-110 c ❍ 50-143 c ❍ 50-176 c

❍ 50-78 c ❍ 50-111 c ❍ 50-144 c ❍ 50-177 c

❍ 50-79 c ❍ 50-112 c ❍ 50-145 c ❍ 50-178 c

❍ 50-80 c ❍ 50-113 c ❍ 50-146 c ❍ 50-179 c

❍ 50-81 c ❍ 50-114 c ❍ 50-147 c ❍ 50-180 c

❍ 50-82 c ❍ 50-115 c ❍ 50-148 c ❍ 50-181 c

❍ 50-83 c ❍ 50-116 c ❍ 50-149 c ❍ 50-182 c

❍ 50-84 c ❍ 50-117 c ❍ 50-150 c ❍ 50-183 c

❍ 50-85 c ❍ 50-118 c ❍ 50-151 c ❍ 50-184 c

❍ 50-86 c ❍ 50-119 c ❍ 50-152 c ❍ 50-185 c

❍ 50-87 c ❍ 50-120 c ❍ 50-153 c ❍ 50-186 c

❍ 50-88 c ❍ 50-121 c ❍ 50-154 c ❍ 50-187 c

❍ 50-89 c ❍ 50-122 c ❍ 50-155 c ❍ 50-188 c

❍ 50-90 c ❍ 50-123 c ❍ 50-156 c ❍ 50-189 c

❍ 50-91 c ❍ 50-124 c ❍ 50-157 c ❍ 50-190 c

❍ 50-92 c ❍ 50-125 c ❍ 50-158 c ❍ 50-191 c

00-2-14 ➁ WA500-6
FOREWORD

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❍ 50-192 c ❍ 50-225 c ❍ 50-258 c ❍ 50-291 c

❍ 50-193 c ❍ 50-226 c ❍ 50-259 c ❍ 50-292 c

❍ 50-194 c ❍ 50-227 c ❍ 50-260 c ❍ 50-293 c

❍ 50-195 c ❍ 50-228 c ❍ 50-261 c ❍ 50-294 c

❍ 50-196 c ❍ 50-229 c ❍ 50-262 c ❍ 50-295 c

❍ 50-197 c ❍ 50-230 c ❍ 50-263 c ❍ 50-296 c

❍ 50-198 c ❍ 50-231 c ❍ 50-264 c ❍ 50-297 c

❍ 50-199 c ❍ 50-232 c ❍ 50-265 c ❍ 50-298 c

❍ 50-200 c ❍ 50-233 c ❍ 50-266 c ❍ 50-299 c

❍ 50-201 c ❍ 50-234 c ❍ 50-267 c ❍ 50-300 c

❍ 50-202 c ❍ 50-235 c ❍ 50-268 c ❍ 50-301 c

❍ 50-203 c ❍ 50-236 c ❍ 50-269 c ❍ 50-302 c

❍ 50-204 c ❍ 50-237 c ❍ 50-270 c ❍ 50-303 c

❍ 50-205 c ❍ 50-238 c ❍ 50-271 c ❍ 50-304 c

❍ 50-206 c ❍ 50-239 c ❍ 50-272 c ❍ 50-305 c

❍ 50-207 c ❍ 50-240 c ❍ 50-273 c ❍ 50-306 c

❍ 50-208 c ❍ 50-241 c ❍ 50-274 c ❍ 50-307 c

❍ 50-209 c ❍ 50-242 c ❍ 50-275 c ❍ 50-308 c

❍ 50-210 c ❍ 50-243 c ❍ 50-276 c ❍ 50-309 c

❍ 50-211 c ❍ 50-244 c ❍ 50-277 c ❍ 50-310 c

❍ 50-212 c ❍ 50-245 c ❍ 50-278 c ❍ 50-311 c

❍ 50-213 c ❍ 50-246 c ❍ 50-279 c ❍ 50-312 c

❍ 50-214 c ❍ 50-247 c ❍ 50-280 c ❍ 50-313 c

❍ 50-215 c ❍ 50-248 c ❍ 50-281 c ❍ 50-314 c

❍ 50-216 c ❍ 50-249 c ❍ 50-282 c ❍ 50-315 c

❍ 50-217 c ❍ 50-250 c ❍ 50-283 c ❍ 50-316 c

❍ 50-218 c ❍ 50-251 c ❍ 50-284 c ❍ 50-317 c

❍ 50-219 c ❍ 50-252 c ❍ 50-285 c ❍ 50-318 c

❍ 50-220 c ❍ 50-253 c ❍ 50-286 c ❍ 50-319 c

❍ 50-221 c ❍ 50-254 c ❍ 50-287 c ❍ 50-320 c

❍ 50-222 c ❍ 50-255 c ❍ 50-288 c ❍ 50-321 c

❍ 50-223 c ❍ 50-256 c ❍ 50-289 c ❍ 50-322 c

❍ 50-224 c ❍ 50-257 c ❍ 50-290 c ❍ 50-323 c

WA500-6 00-2-15 ➁
FOREWORD

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❍ 50-324 c ❍ 50-357 c ❍ 50-390 c 90-22 ➀

❍ 50-325 c ❍ 50-358 c ❍ 50-391 c 90-23 ➀

❍ 50-326 c ❍ 50-359 c ❍ 50-392 c 90-24 ➀

❍ 50-327 c ❍ 50-360 c ❍ 50-393 c 90-25 ➀

❍ 50-328 c ❍ 50-361 c ❍ 50-394 c 90-26 ➀

❍ 50-329 c ❍ 50-362 c ❍ 50-395 c 90-27 ➀

❍ 50-330 c ❍ 50-363 c ❍ 50-396 c 90-28 ➀

❍ 50-331 c ❍ 50-364 c ❍ 50-397 c 90-29 ➀

❍ 50-332 c ❍ 50-365 c ❍ 50-398 c 90-30 ➀

❍ 50-333 c ❍ 50-366 c ❍ 50-399 c 90-31 ➀

❍ 50-334 c ❍ 50-367 c ❍ 50-400 c 90-32 ➀

❍ 50-335 c ❍ 50-368 c 90-33 ➀

❍ 50-336 c ❍ 50-369 c 90-1 ➀ 90-34 ➀

❍ 50-337 c ❍ 50-370 c 90-2 ➀ 90-35 ➀

❍ 50-338 c ❍ 50-371 c 90-3 ➀ 90-36 ➀

❍ 50-339 c ❍ 50-372 c 90-4 ➀ 90-37 ➀

❍ 50-340 c ❍ 50-373 c 90-5 ➀ 90-38 ➀

❍ 50-341 c ❍ 50-374 c 90-6 ➀ 90-39 ➀

❍ 50-342 c ❍ 50-375 c 90-7 ➀ 90-40 ➀

❍ 50-343 c ❍ 50-376 c 90-8 ➀ 90-41 ➀

❍ 50-344 c ❍ 50-377 c 90-9 ➀ 90-42 ➀

❍ 50-345 c ❍ 50-378 c 90-10 ➀ 90-43 ➀

❍ 50-346 c ❍ 50-379 c 90-11 ➀ 90-44 ➀

❍ 50-347 c ❍ 50-380 c 90-12 ➀ 90-45 ➀

❍ 50-348 c ❍ 50-381 c 90-13 ➀ 90-46 ➀

❍ 50-349 c ❍ 50-382 c 90-14 ➀ 90-47 ➀

❍ 50-350 c ❍ 50-383 c 90-15 ➀ 90-48 ➀

❍ 50-351 c ❍ 50-384 c 90-16 ➀ 90-49 ➀

❍ 50-352 c ❍ 50-385 c 90-17 ➀ 90-50 ➀

❍ 50-353 c ❍ 50-386 c 90-18 ➀ 90-51 ➀

❍ 50-354 c ❍ 50-387 c 90-19 ➀ 90-52 ➀

❍ 50-355 c ❍ 50-388 c 90-20 ➀ 90-53 ➀

❍ 50-356 c ❍ 50-389 c 90-21 ➀ 90-54 ➀

00-2-16 ➁ WA500-6
FOREWORD

Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev

90-55 ➀

90-56 ➀

90-57 ➀

90-58 ➀

90-59 ➀

90-60 ➀

90-61 ➀

90-62 ➀

90-63 ➀

90-64 ➀

90-65 ➀

90-66 ➀

90-67 ➀

90-68 ➀

90-69 ➀

90-70 ➀

90-71 ➀

90-72 ➀

90-73 ➀

90-74 ➀

90-75 ➀

90-76 ➀

WA500-6 00-2-17 ➁
FOREWORD

00-2-18 ➁ WA500-6
FOREWORD
12
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety and take the necessary actions to deal with the situation.
General Precautions
Mistakes in operation are extremely dangerous. Read the
OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the
precautions given on the decals which are fixed to the
machine.
2. When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
• Always wear safety glasses when hitting parts with
a hammer.
• Always wear safety glasses when grinding parts
with a grinder, etc.
3. If welding repairs are needed, always have a trained,
experienced welder carry out the work. When carrying
out welding work, always wear welding gloves, apron,
glasses, cap, and other clothes suited for welding work.
WARNING! Never modify, weld, cut, or drill on
any part of a ROPS structure.
Doing so may weaken the structure
which could lead to possible failure
in a rollover situation.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before starting
work, hang UNDER REPAIR signs on the controls in
the operator’s compartment.
5. Keep all tools in good condition and learn the correct
way to use them.
WA500-6
SAFETY
00
00
00
00
6. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
while working.
Preparations for Work 00
1. Before adding oil or making repairs, park the machine
on hard, level ground and block the wheels or tracks to
prevent the machine from moving.
2. Before starting work, lower the blade, ripper, bucket, or
any other work equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure to
lock all the control levers and hang warning signs on
them.
3. When disassembling or assembling, support the
machine with blocks, jacks, or stands before starting
work.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
handrails, ladders, or steps when getting on or off the
machine. Never jump on or off the machine. If it is
impossible to use the handrails, ladders, or steps, use a
stand to provide safe footing.
Precautions During Work 00
1. When removing the oil filler cap, drain plug, or
hydraulic pressure measuring plugs, loosen them slowly
to prevent the oil from spurting out. Before
disconnecting or removing components of the oil, water,
or air circuits, first remove the pressure completely from
the circuit.
2. The water and oil in the circuits are hot when the engine
is stopped; be careful not to get burned. Wait for the oil
and water to cool before carrying out any work on the
oil or water circuits.
00-3 ➁
FOREWORD
3. Before starting work, remove the leads from the battery.
ALWAYS remove the lead from the negative (-)
terminal first.
4. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains, and hooks are not
damaged. Always use lifting equipment which has
ample capacity. Install the lifting equipment at the
correct places. Use a hoist or crane and operate slowly
to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist or
crane.
5. When removing covers which are under internal
pressure or under pressure from a spring, always leave
two bolts in position on opposite sides. Slowly release
the pressure and then slowly loosen the bolts to remove
the covers.
6. When removing components, be careful not to break or
damage the wiring. Damaged wiring may cause
electrical fires.
7. When removing piping, stop the fuel or oil from spilling
out. If any fuel or oil drips on the floor, wipe it up
immediately. Fuel or oil on the floor can cause you to
slip, or can even start fires.
8. Gasoline or other fuels should never be used to clean
parts. Clean parts with appropriate solvents.
9. Be sure to assemble all parts again in their original
places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they
will not be damaged by contact with other parts
when the machine is being operated.
00-4 ➁
SAFETY
10. When installing high-pressure hoses, make sure that
they are not twisted. Damaged tubes are dangerous; be
extremely careful when installing tubes for high-
pressure circuits. Also check that connecting parts are
correctly installed.
11. When assembling or installing parts, always use the
specified tightening torques. When installing protective
parts such as guards or parts which vibrate violently or
rotate at high speed, be particularly careful to check that
they are installed correctly.
12. When aligning two holes, never insert your fingers or
hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the
measuring tool is correctly assembled before taking any
measurements.
14. Be careful when removing or installing the tracks of
track-type machines. When removing the track, the
track separates suddenly; never let anyone stand at
either end of the track.
15. When jump-starting the machine, only use a machine of
similar size and voltage. Never use an arc welder or
other electrical generating equipment to jump-start the
machine. Carefully review the safety and procedures for
jump-starting the machine.
WA500-6
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the
quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct
way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual contains the necessary technical
information for operations performed in a service workshop.
For ease of understanding, the manual is divided into the
following sections. These sections are further divided into
each main group of components.
General
This section lists the general machine dimensions,
performance specifications, component weights, and fuel,
coolant, and lubricant specification charts.
Structure, Function, and Maintenance Standard
This 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. In addition, this section gives the judgment
standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice.
Contact your distributor for the latest information.
WA500-6
GENERAL
00
Standard Value Table
This section explains the standard values for a new machine
and judgment 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.
Testing and Adjusting
This section explains checks to be made before and after
performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
Troubleshooting
This section includes the troubleshooting charts correlating
Problems to Causes.
Disassembly and Assembly
This section explains the order to be followed when
removing, installing, disassembling, or assembling each
component, as well as precautions to be taken for these
operations.
Diagrams and Schematics
This section has the foldout drawings for the machine.
00-5 ➁
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00

Volumes 00 Revised Edition Mark 00

Shop manuals are issued as a guide to carrying out repairs. When a manual is revised, an edition mark (bcd…) is
They are divided as follows: recorded on the bottom, outside corner of the pages.

Chassis volume: Issued for every machine model Revisions 00

Engine volume: Issued for each engine series

Revised pages are shown at the LIST OF REVISED PAGES
between the title page and SAFETY page.
Electrical volume: One issued to cover all models

Attachment volume: One issued to cover all models Symbols 00

These various volumes are designed to avoid duplication of So that the shop manual can be of ample practical use,
information. Therefore to deal with all repairs for any model, important places for safety and quality are marked with the
it is necessary that chassis, engine, electrical, and attachment following symbols.
manuals be available.
Symbol Item Remarks
Distribution and Updating 00

Special safety precautions are

Safety necessary when performing the
Any additions, amendments, or other changes will be sent to work.
your distributors. Get the most up-to-date information before
Special technical precautions or
you start any work.
other precautions for preserving
★ Caution
standards are necessary when
Filing Method 00
performing the work.

1. See the page number on the bottom of the page. File the Weight of parts or systems.
Caution necessary when selecting
pages in correct order. Weight
hoisting wire or when working
posture is important, etc.
2. Following examples show how to read the page number:
Places that require special
Example: Tightening
attention for tightening torque
torque
during assembly.
10 - 3
Places to be coated with adhesives
Coat
and lubricants, etc.
Item number (10. Structure and Function)
Places where oil, water, or fuel
Oil, water
Consecutive page number for each item must be added, and the capacity.

Places where oil or water must be

3. Additional pages: Additional pages are indicated by a Drain drained, and quantity to be
hyphen (-) and numbered after the page number. File as drained.
in the example.

Example:

10-4
10-4-1
Added pages
10-4-2

10-5

00-6 ➁ WA500-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS 00

Hoisting 00
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
WARNING! Heavy parts (25 kg (55 lb) or
can result. Hooks have maximum strength at the middle
more) must be lifted with a hoist
etc. In the DISASSEMBLY AND portion.
ASSEMBLY section, every part
weighing 25 kg or more is
indicated clearly with the symbol.

★ If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the
relative parts.

2. Check for existence of another part causing interface

with the part to be removed.

Wire Ropes 00
3. Do not sling a heavy load with one rope alone, but sling
with two or more ropes symmetrically wound on to the
1. Use adequate ropes depending on the weight of parts to load.
be hoisted. Refer to the following table:
WARNING! Slinging with one rope may
Wire Ropes cause turning of the load during
hoisting, untwisting of the rope,
(Standard “Z” or “S” twist ropes without galvanizing) or slipping of the rope from its
original winding position on the
Rope Diameter Allowable Load load, which can result in a
mm kN tons dangerous accident.

10 9.8 1.0
11.2 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0

★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.

WA500-6 00-7 ➁
FOREWORD HOISTING INSTRUCTIONS
4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
increase with the hanging angles.

The table shows the variation of allowable load (kg)

when hoisting is made with two ropes, each of which is
allowed to sling up to 1000 kg vertically, at various
hanging angles.

When two ropes sling a load vertically, up to 2000 kg of

total weight can be suspended. This weight becomes
1000 kg when two ropes make a 120° hanging angle. On
the other hand, two ropes are subject to an excessive
force as large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150°.

00-8 ➁ WA500-6
FOREWORD PUSH-PULL COUPLER

PUSH-PULL COUPLER 00

WARNING! Before carrying out the following work, release the

residual pressure from the hydraulic tank. For
details, see Releasing Residual Pressure in
Hydraulic Circuit in the Testing and Adjusting
section.

WARNING! Even if the residual pressure is released from the

hydraulic tank, some hydraulic oil flows out when
the hose is disconnected. Prepare a container to
receive the oil.

Type 1 00

Disconnection 00

1. Release the residual pressure from the hydraulic tank. For details,
see Releasing Residual Pressure in Hydraulic Circuit in the
Testing and Adjusting section.

2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm (0.14 in).
Do not hold the rubber cap portion (4).

3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.

4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare a container to receive the oil.

Connection 00

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

2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm (0.14 in). This
does not indicate an abnormality.

WA500-6 00-9 ➁
FOREWORD PUSH-PULL COUPLER

Type 2 00

Disconnection 00

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

2. Hold in the condition in Step 1 and turn the lever (4) to the right
(clockwise).

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

Connection 00

1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect the body.

00-10 ➁ WA500-6
FOREWORD PUSH-PULL COUPLER

12
Type 3 00

Disconnection 00

1. Hold the mouthpiece of the tightening portion and push the

body (2) in straight until sliding prevention ring (1) contacts
surface (a) of the hexagonal portion at the male end.

2. Hold in the condition in Step 1 and push until the cover (3)
contacts surface (a) of the hexagonal portion at the male end.

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

Connection 00

1. Hold the mouthpiece of the tightening portion and push the

body (2) in straight until the slide prevention ring (1) contacts
surface (a) of the hexagonal portion at the male end to connect the
body.

WA500-6 00-11 ➁
FOREWORD COATING MATERIALS

12
COATING MATERIALS 00

★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main Applications, Features
• Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 • Used for plastics (except polyethylene,
(2 pcs.) container
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal, and non-metal.
• Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g • Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive • Used as adhesive or sealant for metal,
LT-3 Hardening Can
and hardening glass, or plastic.
agent:
agent)
500 g
Adhesives

Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container
Holtz • Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
• Quick hardening-type adhesive.
Three
Polyethylene • Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container • Used mainly for adhesion of metals,
1735
rubbers, plastics, and woods.
• Quick hardening-type adhesive.
Aron- • Quick cure-type (maximum strength after
Polyethylene
alpha 790-129-9130 50 g 30 minutes).
container
201 • Used mainly for adhesion of rubbers,
plastics, and metals.
• Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperature.
• Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
• Features: Resistance to heat
Gasket • Used as sealant for flange surfaces and
sealant bolts at high temperature locations; used to
LG-3 790-129-9070 1 kg Can prevent seizure.
• Used as sealant for heat-resistant gasket for
high-temperature locations such as engine
precombustion chamber, exhaust pipe.

00-12 ➁ WA500-6
FOREWORD COATING MATERIALS

Category Code Part No. Quantity Container Main Applications, Features

• Features: Resistance to water, oil
• Used as sealant for flange surface, thread.
• Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
• Used as sealant for mating surfaces of final
drive case, transmission case.
• Used as sealant for various threads, pipe
Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container • Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Gasket • Features: Silicon-based, resistant to heat,
sealant cold.
LG-6 09940-00011 250 g Tube • Used as sealant for flange surface, thread.
• Used as sealant for oil pan, final drive case,
etc.
• Features: Silicon-based, quick hardening
type.
LG-7 09920-00150 150 g Tube
• Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three
• Used as heat-resisting sealant for repairing
bond 790-129-9090 100 g Tube
engines.
1211
• Used as lubricant for sliding parts (to
Molybdenum

LM-G 09940-00051 60 g Can

disulphide

prevent squeaking).
lubricant

• Used to prevent seizure or scuffing of the

LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
• Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA • Used for normal temperature, light load
G2-CA SYG2-400CA-A Various Various bearing at places in contact with water or
Grease SYG2-160CA steam.
SYG2-160CNCA
disulphide lubricant
Molybdenum

400 g
SYG2-400M Belows type • Used for places with heavy load.
(10 per case)

WA500-6 00-13 ➁
FOREWORD STANDARD TIGHTENING TORQUE

12
STANDARD TIGHTENING TORQUE 00

Standard Tightening Torques of Bolts and Nuts 00

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in the DISASSEMBLY AND
ASSEMBLY section. The following table corresponds to the bolts in Figure A.

Thread Diameter of Bolt Width across Flat Tightening Torque

mm mm N•m lbf ft
6 10 11.8 – 14.7 8.7 – 10.8
8 13 27 – 34 19.9 – 25.1
10 17 59 – 74 43.5 – 54.6
12 19 98 – 123 72.3 – 90.7
14 22 157 – 196 115.8 – 144.6
16 24 245 – 309 180.7 – 227.9
18 27 343 – 427 253.0 – 314.9
20 30 490 – 608 361.4 – 448.4
22 32 662 – 829 488.3 – 611.4
24 36 824 – 1,030 607.8 – 759.7
27 41 1,180 – 1,470 870.3 – 1,084.2
30 46 1,520 – 1,910 1,121.1 – 1,408.7
33 50 1,960 – 2,450 1,445.6 – 1,807.0
36 55 2,450 – 3,040 1,807.0 – 2,242.2
39 60 2,890 – 3,630 2,131.6 – 2,677.4

★ Figure A

00-14 ➁ WA500-6
FOREWORD STANDARD TIGHTENING TORQUE

The following table corresponds to the bolts in Figure B.

Thread Diameter of Bolt Width across Flat Tightening Torque

mm mm N•m lbf ft
6 10 5.9 – 9.8 4.4 – 7.2
8 13 13.7 – 23.5 10.1 – 17.3
10 14 34.3 – 46.1 25.3 – 34.0
12 27 74.5 – 90.2 54.9 – 66.5

★ Figure B

Tightening Torques for Hose Nuts 00

★ Use these torques for hose nuts.

Thread Diameter Width across Flat Tightening Torque
Nominal No.
mm mm N•m lbf ft
02 14 19 19.6 – 29.4 14.5 – 21.7
03 18 24 29.4 – 68.6 21.7 – 50.6
04 22 27 58.9 – 98.1 44.4 – 72.4
05 24 32 107.9 – 166.7 79.6 – 123.0
06 30 36 147.1 – 205.9 108.5 – 151.9
10 33 41 147.1 – 245.1 108.5 – 180.8
12 36 46 196.2 – 294.2 144.7 – 217.0
14 42 55 245.2 – 343.2 180.9 – 253.1

WA500-6 00-15 ➁
FOREWORD STANDARD TIGHTENING TORQUE

Tightening Torques for Split Flange Bolts 00

★ Tighten split flange bolts to the torque in this table, unless otherwise specified.
Thread Diameter Width across Flat Tightening Torque
mm mm N•m lbf ft
10 14 59 – 74 43.5 – 54.6
12 17 98 – 123 72.3 – 90.7
16 22 235 – 285 173.3 – 210.2

Tightening Torque for Flared Nuts 00

★ Use these torques for flared part of nut.

Thread Diameter Width across Flat Tightening Torque
mm mm N•m lbf ft
14 19 24.5 ±4.9 18.0 ±3.6
18 24 49 ±19.6 36.1 ±14.4
22 27 78.5 ±19.6 57.8 ±14.4
24 32 137.3 ±29.4 101.2 ±21.6
30 36 176.5 ±29.4 130.1 ±21.6
33 41 196.1 ±49 144.6 ±36.1
36 46 245.2 ±49 180.8 ±36.1
42 55 294.2 ±49 216.9 ±36.1

Tightening Torques for O-Ring Boss Piping Joints 00

★ Tighten the O-ring boss piping joints to the torques in this table, unless otherwise specified.

Thread Diameter Width across Flat Tightening Torque - N•m (lbf ft)
Norminal No.
mm mm Range Target
02 14 35 – 63 (25.8 – 46.5) 44 (32.5)
03, 04 20 84 – 132 (62.0 – 97.4) 103 (76.0)
Varies depending on
05, 06 24 128 – 186 (94.4 – 137.2) 157 (115.8)
type of connector.
10, 12 33 363 – 480 (267.7 – 354.0) 422 (311.3)
14 42 746 – 1,010 (550.2 – 744.9) 883 (651.3)

00-16 ➁ WA500-6
FOREWORD STANDARD TIGHTENING TORQUE

Tightening Torques for O-Ring Boss Plugs 00

★ Tighten the O-ring boss plugs to the torques in this table, unless otherwise specified.

Thread Diameter Width across Flat Tightening Torque - N•m (lbf ft)
Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 (4.3 – 6.5) 7.35 (5.4)
10 10 17 9.8 – 12.74 (7.2 – 9.4) 11.27 (8.3)
12 12 19 14.7 – 19.6 (10.8 – 14.5) 17.64 (3.0)
14 14 22 19.6 – 24.5 (14.5 – 18.1) 22.54 (16.6)
16 16 24 24.5 – 34.3 (18.1 – 25.3) 29.4 (21.7)
18 18 27 34.3 – 44.1 (25.3 – 32.5) 39.2 (28.9)
20 20 30 44.1 – 53.9 (32.5 – 39.8) 49.0 (36.1)
24 24 32 58.8 – 78.4 (43.4 – 57.8) 68.6 (50.6)
30 30 32 93.1 – 122.5 (68.7 – 90.4) 107.8 (79.5)
33 33 – 107.8 – 147.0 (79.5 – 108.4) 124.4 (91.8)
36 36 36 127.4 – 176.4 (94.0 – 130.1) 151.9 (112.0)
42 42 – 181.3 – 240.1 (133.7 – 177.1) 210.7 (155.4)
52 52 – 274.4 – 367.5 (202.4 – 271.1) 323.4 (238.5)

Tightening Torques for Hoses (Taper Seal Type and Face Seal Type) 00

★ Tighten the hoses (taper seal type and face seal type) to the torques in this table, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.

Taper Seal
Tightening Torque - N•m {lbf ft}) Face Seal Type
Type
Nominal Width
Size of across Nominal Thread
Hose Flats Thread size Size Root Diameter (mm)
Range Target
(mm) Threads per inch, (Reference)
Thread series
34 – 54 (25.0 – 39.8) – 9/16 – 18UN 14.3
02 19 44 (32.4)
34 – 63 (25.0 – 46.4) 14 – –
22 54 – 93 (39.8 – 68.5) 74 (54.5) – 11/16 –16UN 17.5
03
24 59 – 98 (43.5 – 72.2) 78 (57.5) 18 – –
04 27 84 – 132 (61.9 – 97.3) 103 (75.9) 22 13/16 – 16UN 20.6
05 32 128 – 186 (94.4 – 137.1) 157 (115.7) 24 1 - 14UNS 25.4
06 36 177 – 245 (130.5 – 180.7) 216 (159.3) 30 1 3/16 – 12UN 30.2
(10) 41 177 – 245 (130.5 – 180.7) 216 (159.3) 33 - –
(12) 46 197 – 294 (145.3 – 216.8) 245 (180.7) 36 – –
(14) 55 246 – 343 (181.4 – 252.9) 294 (216.8) 42 – –

WA500-6 00-17 ➁
FOREWORD STANDARD TIGHTENING TORQUE

Tightening Toques for Face Seal Joints 00

★ 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 torques shown in the following table.
★ Apply the following torques to the face seal joint while their threaded parts are coated with engine oil (wetted).

Outer Tightening Torque N•m (lbf ft) Face Seal

Width
Diameter of Nominal No. –
across Flats Thread Diameter (mm)
Pipe Range Target Number of Threads,
(mm) (Reference)
(mm) Type of Thread
8 19 14 – 16 (10.3 – 11.8) 15 (11.1) 9/16 –18UN 14.3
10 22 24 – 27 (17.7 – 19.9) 25.5 (18.8) 11/16 –16UN 17.5
12 24 (27) 43 – 47 (31.7 – 34.7) 45 (33.2) 13/16 –16UN 20.6
15 (16) 30 (32) 60 – 68 (44.3 – 50.2) 64 (47.2) 1 –14UN 25.4
22 (20) 36 90 – 95 (66.4 – 70.1) 92.5 (68.2) 1-3/16 – 12UN 30.2

00-18 ➁ WA500-6
FOREWORD ELECTRIC WIRE CODE

12
ELECTRIC WIRE CODE 00

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.

Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

Classification by Thickness 00

Copper Wire
Nominal Cable O.D. Current
Number of Diameter of Cross Section Applicable Circuit
Number (mm) Rating (A)
Strands Strand (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting

Classification by Color and Code 00

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Primary

Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR – BW RW YR GW LW
2 Black & Yellow & Green &
Color White & Red – Red & White Blue & White
White Red White
Code WB – BY RB YB GR LR
3 White & Black & Yellow &
Color – Red & Black Green & Red Blue & Red
Black Yellow Black
Code WL – BR RY YG GY LY
Auxiliary

4 Red & Yellow & Green & Blue &

Color White & Blue – Black & Red
Yellow Green Yellow Yellow
Code WG – – RG YL GB LB
5 White & Yellow & Green &
Color – – Red & Green Blue & Black
Green Blue Black
Code – – – RL YW GL –
6 Yellow & Green &
Color – – – Red & Blue –
White Blue

WA500-6 00-19 ➁
FOREWORD CONVERSION TABLES

12
CONVERSION TABLES 00

Method of Using the Conversion Table 00

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.

A. Locate the number 50 in the vertical column at the left side; take this as b; then draw a horizontal line from b.

B. Locate the number 5 in the row across the top; take this as c; then draw a perpendicular line down from c.

C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.

A. The number 550 does not appear in the table; divide by 10 (move the decimal one place to the left) to convert it to
55 mm.

B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.

C. The original value (550 mm) was divided by 10; multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.

c
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
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
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

00-20 ➁ WA500-6
FOREWORD CONVERSION TABLES

12

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

WA500-6 00-21 ➁
FOREWORD CONVERSION TABLES

12

Liter to U.S. Gallon 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

Liter to U.K. Gallon 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

00-22 ➁ WA500-6
FOREWORD CONVERSION TABLES

12

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 1352.63 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

WA500-6 00-23 ➁
FOREWORD CONVERSION TABLES

12

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

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

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

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119

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

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

00-24 ➁ WA500-6
FOREWORD CONVERSION TABLES

Temperature: Fahrenheit Centigrade Conversion

A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the
accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or
Centigrade degrees. If you want to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If you want to convert
from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the
corresponding Fahrenheit temperature on the right.

°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

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

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

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

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

WA500-6 00-25 ➁
FOREWORD CONVERSION TABLES

MEMORANDUM

00-26 ➁ WA500-6
 01 GENERAL

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
Specification Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
FUEL, COOLANT, AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8

WA500-6 01-1 ➁
GENERAL SPECIFICATIONS

SPECIFICATIONS

Dimension Drawing

01-2 ➁ WA500-6
GENERAL SPECIFICATIONS

Specification Tables
Machine Model Name WA500-6
Serial Number A92001 and up
Operating weight kg (lb) 32,230 (71,054.9)
Weight

Front wheel load kg (lb) 15,090 (33,267.7)

Rear wheel load kg (lb) 17,140 (37,787.2)
Bucket capacity (Heaped)
with Bolt-on cutting edge (BOC) m3 (yd3) 5.6 (7.3)

Rated load kN (lbf) 90.7 (20,390.2)

Travel speed F1 km/h (mph) 7.7 (4.8)
Travel speed F2 km/h (mph) 12.5 (7.8)
Travel speed F3 km/h (mph) 22.3 (13.9)
Travel speed F4 km/h (mph) 34.9 (21.7)
Performance

Travel speed R1 km/h (mph) 8.6 (5.3)

Travel speed R2 km/h (mph) 13.0 (8.1)
Travel speed R3 km/h (mph) 24.8 (15.4)
Travel speed R4 km/h (mph) 37.5 (23.3)
Maximum drawbar pull (Forward) kN (lbf) 288.3 (64,812.4)
Maximum drawbar pull (Reverse) kN (lbf) 256.4 (57,641.0)
Gradeability deg. 25
Minimum turning radius
mm (in) 6,430 (253.1)
(Center of outside tire)
Turning radius (BOC tip) (with BOC) mm (in) 7,650 (301.2)
Overall length (with BOC) mm (in) 9,815 (386.4)
Overall width mm (in) 3,190 (125.6)
Bucket width (with BOC) mm (in) 3,400 (133.9)
Overall height (ROPS at cab top) mm (in) 3,785 (149.0)
Overall height with bucket lifted up mm (in) 6,430 (253.1)
Wheelbase mm (in) 3,780 (148.8)
Dimension

Tread mm (in) 2,400 (94.5)

Minimum ground clearance mm (in) 450 (17.7)
Maximum hinge pin height of bucket mm (in) 4,755 (187.2)
Dumping clearance (with BOC) mm (in) 3,295 (129.7)
Dumping reach (with BOC) mm (in) 1,500 (59.1)
Bucket tilt-forward angle deg. 46
Bucket tilt-back angle
deg. 50
(Operating posture)
Digging depth (Approx. 10°) mm (in) 435 (17.1)

★ BOC: Abbreviation for Bolt-On Cutting edge

WA500-6 01-3 ➁
GENERAL SPECIFICATIONS

Machine Model Name WA500-6

Serial Number A92001 and up
Model name SAA6D140E-5
4-cycle, water-cooled, direct injection type with turbocharger,
Type
air-cooled aftercooler and water-cooled EGR
Number of cylinders – Bore x Stroke mm (in) 6 – 140 x 165 (0.23 – 5.51 x 6.50)
Total piston displacement l (gal) 15.2 (4.0)
Flywheel horsepower kW (HP) /rpm 263 (353) /1,900
Engine

Max. torque N•m (lbf ft /rpm 178.9 (131.9) /1,250

Performance

Rated fuel consumption g/kWh (g/HPh) 216.2 {161}

Max. speed at no load rpm 2,150
Min. speed at no load rpm 675
Starting motor 24 V, 11 kW
Alternator 24 V, 75 A
Battery 12 V, 170 Ah x 2
Torque converter 3-element, 1-stage, 2-phase
Power Train

Transmission Planetary type, multi-disc type, forward-reverse 4-stage

Reduction gear unit Spiral bevel gear type, splash lubrication type
Differential Straight bevel gear type
Final drive Planetary gear single-reduction type, splash lubrication type
Drive wheel Front and rear wheel drive
Axle

Front axle Fixed frame, full-float type

Rear axle Center pin support type, full-float type
Size 29.5-25-33-22PR(L3)
Tires

Rim size 25.00 x 25WTB

Inflation pressure(Front wheel) 440 (63.8)
kPa (psi)
(Rear wheel) 392 (56.9)
Independent front and rear wheel brakes,
Foot brake enclosed wet multi-disc type
Brake

Full hydraulic type

Drive shaft braking system of wet disc type
Hand brake
Hydraulically released spring-driven type
Steering system
Steering
System

Type Articulated steering

Structure Fully-hydraulic power steering

01-4 ➁ WA500-6
GENERAL SPECIFICATIONS

Machine Model Name WA500-6

Serial Number A92001 and up
321 (84.8) /min
Work equipment hydraulic pump l (gal) /min
Variable displacement piston pump HPV190
Hydraulic Pump Delivery

120 (31.7) /min

Steering pump l (gal) /min
Variable displacement piston pump LPV90
70 (18.5) /min
Cooling fan pump l (gal) /min
Variable displacement piston pump LPV45
189 (49.9) / min
Power train pump l (gal) /min
Gear pump SAR (3) 112
94 (24.8) /min
Hydraulic cooling pump l (gal) /min
Gear pump SAL (3) 80
Hydraulic System

54 (14.3) /min
EPC and brake pump l (gal) /min
Gear pump SAR (1) 28)
Control Valve

34.3 (4,974.8)
Set pressure for work equipment MPa (psi)
3-spool type with HI valve

24.5 (3,553.4)
Set pressure for steering system MPa (psi)
Spool type
Number of lift cylinders Double-acting piston type 2
mm (in)
Bore x Stroke 160 x 898 (6.3 x 35.4)
Cylinder

Number of bucket cylinders Double-acting piston type 1

mm (in)
Bore x Stroke 185 x 675 (7.3 x 26.6)
Number of steering cylinders Double-acting piston type 2
mm (in)
Bore x Stroke 100 x 486 (3.9 x 19.1)
Motor
Fan motor Fixed displacement piston type: LMF40
Work Equipment

Work equipment
Type of link Single link

Shape of bucket cutting edge Straight bolt-on cutting edge

WA500-6 01-5 ➁
GENERAL WEIGHT TABLE

WEIGHT TABLE

WARNING! This weight table is prepared for your reference when handling or transporting the
components.

Unit: kg (lb)
Machine Model Name WA500-6
Serial Number A92001 and up
Engine (dry weight) 1,700 (3,747.9)
Radiator (including air conditioner condenser) (dry weight) 326 (718.7)
Torque converter (including drive gear) (dry weight) 558 (1,230.2)
Transmission (dry weight) 1,106 (2,438.3)
Center drive shaft 45 (99.2)
Front drive shaft 45 (99.2)
Rear drive shaft 40 (88.2)
Center support 42 (92.6)
Front axle 2,250 (4,960.4)
Rear axle 2,084 (4,594.4)
Front differential 368 (811.3)
Rear differential 390 (859.8)
Planetary carrier assembly (1 piece) 69 (152.1)
Wheel hub (1 piece) 114 (251.3)
Axle pivot (front) 104 (229.3)
Axle pivot (rear) 126 (277.8)
Wheel (1 piece) 267 (588.6)
Tire (standard: 29.5-25-22PR L3) (1 piece) 532 (1,172.9)
Steering demand valve 24 (52.9)
Steering cylinder (1 piece) 53 (116.8)
Hydraulic tank (dry weight) 412 (908.3)
Work equipment hydraulic pump 106 (233.7)
Power train, EPC pump 22 (48.5)
Steering pump 39 (86.0)
Hydraulic cooling pump 13 (28.7)
Cooling fan pump 25 (55.1)
Torque converter oil cooler 70 (154.3)
Fan motor 13.4 (29.5)
Fan 29.1 (64.2)
Work equipment valve 110 (242.5)
Lift cylinder (1 piece) 282 (621.7)
Bucket cylinder 289 (637.1)
Engine hood 265 (584.2)
Radiator guard 355 (782.6)
Front frame 2,565 (5,654.9)
Rear frame 2,650 (5,842.2)
Bucket link (including bushing) 157 (346.1)

01-6 ➁ WA500-6
GENERAL WEIGHT TABLE

Unit: kg (lb)
Machine Model Name WA500-6
Serial Number A92001 and up
Bell crank (including bushing) 754 (1,662.3)
Lift arm (including bushing) 2,105 (4,640.7)
Bucket (5.2 m3 with teeth and segment edge) 2,960 (6,525.7)
3 3,005 (6,624.9)
Bucket (5.6 m with bolt-on cutting edge)
Counterweight 2,480 (5,467.5)
Fuel tank 220 (485.0)
Battery (1 piece) 56 (123.5)
Cab (including console box and dashboard) 987 (2,176.0)
Air conditioner unit 33 (72.8)
Operator seat 36 (79.4)

WA500-6 01-7 ➁
GENERAL FUEL, COOLANT, AND LUBRICANTS

FUEL, COOLANT, AND LUBRICANTS

★ For details about the notes (Notes 1, 2, etc.) in the table, see the Operation & Maintenance Manual.
Ambient Temperature
Type of
Reservoir -22 -4 14 32 50 68 86 104 122 F°
Fluid
-30 -20 -10 0 10 20 30 40 50 C°

EO15W40-DH
API CI-4
Engine Oil Pan
JASO DH-1
EO30-DH

Transmission
case (Note #1)
Powertrain oil TO10

Hydraulic
System
Engine Oil EO10W30-DH

Axle Axle oil AXO80 (Note #2)

ASTM D S15/500 No. 2

Fuel Tank Diesel fuel
No.1

Hypergrease G2-T,G2-TE
Pins
(Note #3)
Lithium EP G2-L1
grease

Cooling system Supercoolant AF-NAC

Engine Oil Transmission Hydraulic Front Rear Cooling

Reservoirs Capacity Fuel Tank
Pan Case System Axle Axle System

Liters 45 95 460 87 81 473 120

Specified
US gal 11.9 25.1 121.5 23.0 21.4 125.0 31.7

Liters 45 (37) 76 337 87 81 – –

Refill
US gal 11.9 (9.8) 20.1 89.0 23.0 21.4 – –

★ Value in brackets () applies to the oil level of engine oil pan alone.

01-8 ➁ WA500-6
GENERAL FUEL, COOLANT, AND LUBRICANTS
Remark
Use diesel fuel only.
This engine uses an electronically controlled high-pressure fuel injection system to obtain good fuel economy
and low emissions. For this reason, it requires high-precision parts and good lubrication. If kerosene or other
fuel with low lubricating ability is used, there will be a big drop in durability.

Note 1: Power train of oil has different properties from engine oil. Be sure to use the recommended oil.
Note 2: Axle oil AXO80 prevents squealing from the brakes and LSD (Limited Slip Differential).
Note 3: Hypergrease (G2-T, G2-TE) has a high performance. When it is necessary to improve the lubricating ability of the
grease in order to prevent squeaking of pins and bushings, the use of G2-T or G2-TE is recommended.

WA500-6 01-9 ➁
GENERAL FUEL, COOLANT, AND LUBRICANTS

MEMORANDUM

01-10 ➁ WA500-6
 10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD

ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Engine and Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Drive Line Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Without Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
With Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Power Train Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Without Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Power Transmitting Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
With Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Power-Transmitting Route: Lockup Clutch Disengaged . . . . . . . . . . . . . . . . . . . . . . 10-40
Power-Transmitting Route: Lockup Clutch Engaged . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Torque Converter Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
Transmission with Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
Disc Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
Power Transmitting Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
Transmission Control Valve (without Lockup Clutch) . . . . . . . . . . . . . . . . . . . . . . . 10-72
Transmission Control Value (with Lockup Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
ECMV (Electronic Control Modulation Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
Pressure Control Valve and Fill Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Operation of ECMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
For Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Main Relief Valve and Torque Converter Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
Lubrication Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
Torque Converter Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
Torque Converter Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
Center Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102

WA500-6 10-1 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS

Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104

Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
Front Differential (with Limited Slip Differential) . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
Rear Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
Rear Differential (with Limited Slip Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
Limited Slip Differential (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125
Steering Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
Steering Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
Safety Suction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
Stop Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-143
Joystick Steering Lever Linkage (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
Emergency Steering (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
Diverter Valve (for emergency steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
PPC Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
Accumulator (for Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
Parking Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
Emergency Parking Brake Release Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
UNDERCARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
Axle Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
Center Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
Hydraulic Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
Work Equipment Control Lever Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
Cooling Fan Motor LMF40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-202
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
Suction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-207
Reversible Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
Cooling Fan Pump LPV45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-218
Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-222

10-2 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS

Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-224

Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-229
LS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-232
CO Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-232
Work Equipment Hydraulic Pump HPV190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-234
LS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-242
PC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-250
PC-EPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-258
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-262
CLSS (Closed Center Load-Sensing System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-276
Function and Operation of Each Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-282
Pressure Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-282
LS Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-288
LS Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-290
ECSS Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-292
Accumulator Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-293
Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-294
Accumulator (for PPC Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-299
Work Equipment Electric Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-301
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-306
Work Equipment Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-306
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-310
Bucket 5.6 M3 (with Bolt-On Cutting Edge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-310
Bucket 5.2 M3 (with Teeth and Segment Edge) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-312
Bucket Positioner and Boom Kickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-313
Work Equipment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-314
CAB AND ITS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-316
ROPS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-316
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-318
Air Conditioner Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-318
Cooling Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-319
Air Conditioner Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-320
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-321
Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-323
Air Conditioner Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-324
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-327
Machine Monitor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-327
Machine Monitor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-329
Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-336
Machine Monitor Operation Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-338
Items Displayed on Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-339
Character Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-350
Operator Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-351
Service Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-354
Service Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-355
Electrical System Failure History Display Function . . . . . . . . . . . . . . . . . . . . . . . . 10-359
Mechanical System Failure History Display Function . . . . . . . . . . . . . . . . . . . . . . 10-361
Real-Time Monitor Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-362
Engine Reduced-Cylinder (Cylinder Cut-out) Function . . . . . . . . . . . . . . . . . . . . . 10-368

WA500-6 10-3 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS

No Injection Cranking Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-369

Adjustment Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-370
Maintenance Monitoring Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-372
Operating Information Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-376
Optional Device Selecting Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-378
Machine Serial Number Input Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-378
Model Selection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-378
Load Meter Function (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-379
Rear Side of Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-386
Connector Signal Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-388
Work Equipment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-395
Work Equipment Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-395
Work Equipment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-397
Remote Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-405
Lift Arm Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-407
Semi-Automatic Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-412
Pump Swash Plate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-415
Joystick Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-419
Real-Time Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-421
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-426
Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-427
Transmission Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-430
Electrical Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-430
Transmission Controller Gear Shifting Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-432
Auto-Shift Points Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-436
Transmission Controller Protection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-437
Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-439
Transmission Cutoff Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-442
ECSS Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-444
Economy Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-445
Cooling Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-446
Right FNR Switch Control (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-450
Joystick Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-451
Real-Time Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-454
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-461
Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-462
ELECTRONIC TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-466
Combination Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-468
Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-470
Engine Stopping Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-472
Preheating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-474
Parking Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-476
Backup and Stop Lamp circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-481
Small Lamp and Head Lamp Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-483
Working Lamp Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-484
Horn Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-485
Wiper and Window Washer Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-486
Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-489
Input Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-489

10-4 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS

Output Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-489

Left Brake Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-490
Transmission Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-491
Torque Converter Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-491
Hydraulic Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-491
Axle Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-491
Kickdown Hold Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-492
Joystick Knob (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-493
Right FNR Switch (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-494
Lift Arm Angle Sensor (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-495
Loader Pump Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-496
Lift Arm Cylinder Bottom Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-496
Lift Arm Cylinder Head Pressure Sensor (Load Meter) (if equipped) . . . . . . . . . . 10-496
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-498
Parking Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-499
Stop Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-499
Air Cleaner Clogging Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-500
Transmission Clogging Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-501
Steering Oil Pressure Sensor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-502
Radiator Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-503
Brake Accumulator Pressure Switch (front and rear) . . . . . . . . . . . . . . . . . . . . . . . 10-504
Battery Electrolyte Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-505
Accelerator Pedal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-506
Emergency Brake Pressure Switch (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-507
Emergency Brake Pressure Switch (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-507
KOMTRAX Terminal System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-508
KOMTRAX Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-509
Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-510

WA500-6 10-5 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS

MEMORANDUM

10-6 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM

ENGINE AND COOLING SYSTEM

Cooling System

1. Radiator A. Aftercooler outlet

2. Aftercooler B. Coolant inlet
3. Hydraulic oil cooler C. Coolant inlet
4. Coolant subtank D. Aftercooler inlet
5. Coolant level sensor E. Hydraulic oil cooler outlet
6. Torque converter oil cooler F. Hydraulic cooler inlet
7. Air conditioner G. Coolant outlet
8. Cooling fan

9. Cooling fan motor

10. Fan guard

WA500-6 10-7 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM

10-8 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
Specifications

Hydraulic Oil Hydraulic Oil Torque Converter

Radiator Aftercooler
Cooler (1) Cooler (2) Oil Cooler
Aluminum tube Straight fin
Core type PTO-OL PTO-OL PTO-LS
in 4-column 10-hole tube type
Fin pitch 4.0/2P 100 x 385 x 17 100 x 558 x 17 6.0/2P 150 x 620 x 20-stage
mm (in) (0.16/2P) (3.9 x 15.2 x 0.7) (3.9 x 22.0 x 0.7) (0.24/2P) (5.9 x 24.4 x 20-stage)
Total heat dissipation
surface 59.90 1.2187 1.829 21.57 3.254
(644.76) (13.118) (19.687) (232.18) (35.026)
m2 (ft2)
Cross-sectional area of
flow 50.845
— — — —
(7.881)
cm2 (in2)
Pressure valve cracking
70 ±15
pressure — — — —
(10.15 ±2.18)
kPa (psi)
Vacuum valve cracking
0–5
pressure — — — —
(0 – 0.73)
kPa (psi)

WA500-6 10-9 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM

Engine and Transmission Mounting

10-10 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM

Unit: mm (in)
No Check Item Criteria Remedy
Shim thickness: 0.5 mm (0.020 in), 1.0 mm (0.039 in)
1 Shim thickness of mount (Shim thickness and number of shims used to be the same as that
employed on the actual machine.)
Clearance between stopper and A clearance of 1.5 mm (0.059 in) minimum to be provided
2
support between the stopper and support.
Adjust
Shim thickness: 0.5 mm (0.020 in), 1.0 mm (0.039 in)
3 Shim thickness of mount (Shim thickness and number of shims used to be the same as that
employed on the actual machine.)
Clearance between stopper bolt A clearance of 1 to 1.5 mm (0.039 to 0.059 in) minimum to be
4
and bracket provided between the stopper and bracket.

Torque Values

Designation N•m lbf ft

D 235 – 285 173.33 – 210.20

E 662 – 829 488.27 – 611.44

WA500-6 10-11 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

POWER TRAIN
Drive Line Components

10-12 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Outline

• The power from engine (1) is transmitted to torque converter (2) through the flywheel and ring gear. Torque converter (2)
converts the transmitted toque according to the fluctuation of the load by using oil as a medium and then transmits the
power to the input shaft of transmission (3).

The engine power is also transmitted through the pump drive gear (PTO) of torque converter (2) to steering pump (4),
torque converter charging pump (5), EPC pump (6), cooling pump (7), work equipment pump (8), and fan pump (9) to
drive these pumps.

• Transmission (3) operates six hydraulic clutches through the solenoid valve-based operation of the directional spool and
gearshift spool to select one of four gear speeds in the forward or reverse travel direction.

Selection of a speed is done by using the electrically-controlled switch.

• Multi-disc type parking brake (10) is installed on the transmission. The power from the front side output shaft is
transmitted through center drive shaft (11) and front drive shaft (13) to front differential (14). On the rear side, the power
is transmitted to rear differential (19) from rear drive shaft (18).

• The power being transmitted to front differential (14) and rear differential (19) is then transmitted to the axle shaft.

• The power from the axle shaft is reduced in speed by final drives (15) and (20) and then transmitted to tires (17) and (22)
through the planetary carrier.

WA500-6 10-13 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

System Diagram
Without Lockup Clutch

10-14 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Engine
2. Torque converter
3. Transmission
4. Steering pump
5. Torque converter charging pump
6. EPC and brake pump
7. Hydraulic cooling pump
8. Work equipment pump
9. Cooling fan pump
10. Parking brake
11. Center drive shaft
12. Center support
13. Front drive shaft
14. Front differential
15. Front final drive
16. Wet-type multi-disc brake
17. Front tire
18. Rear drive shaft
19. Rear differential
20. Rear final drive
21. Wet-type multi-disc brake
22. Rear tire

WA500-6 10-15 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

With Lockup Clutch

10-16 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Engine
2. Torque converter
3. Transmission
4. Steering pump
5. Torque converter charging pump
6. EPC and brake pump
7. Hydraulic cooling pump
8. Work equipment pump
9. Cooling fan pump
10. Parking brake
11. Center drive shaft
12. Center support
13. Front drive shaft
14. Front differential
15. Front final drive
16. Wet-type multi-disc brake
17. Front tire
18. Rear drive shaft
19. Rear differential
20. Rear final drive
21. Wet-type multi-disc brake
22. Rear tire
23. Lockup clutch (if equipped)

WA500-6 10-17 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Joint

10-18 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Ring gear

Unit: mm (in)
No. Check Item Criteria Remedy
Backlash of engine side drive gear and torque
2 0.059 – 0.240 (0.0023 – 0.0094) Replace
converter case gear

Torque Values

Designation N•m lbf ft

A 98 – 123 72.28 – 90.72

Outline

• The ring gear is installed to the flywheel of the engine.

The internal teeth of the ring gear are meshed with the external teeth of the torque converter lockup clutch housing to
transmit the power from the engine to the torque converter.

WA500-6 10-19 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Drive Shaft

10-20 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Front drive shaft

2. Center support
3. Center drive shaft
4. Rear drive shaft

WARNING! Observe the following precautions for the tightening torque of the spider mounting bolts.

1. There are two types (new and old type) of the spider mounting bolts which have the same part number.
★ Different tightening torques are specified for the new bolt and the old bolt.

2. Since the new and old bolts cannot be distinguished from each other by appearance, the existing spider mounting bolts
cannot be reused. You must use a new spider mounting bolt.
★ The specified torque for the new bolt is lower than that for the old bolt. Accordingly, if the new bolt is tightened to the
torque for the old bolt, it may be broken during operation and the machine may not be able to travel.

3. When retightening, removing, or installing the bolts, you must replace the existing bolts with new bolts and tighten them
to the torque specified for them.
★ A new part number is set for the new bolt. For the new part number, see the Parts Book.

* Spider mounting bolts (A, C, E): 107 – 127 N•m (78.9 – 93.7 lbf ft)

* Bolts of new tightening torque (new bolt values)

Shaft mounting bolts (B, D, F): 98 – 123 N•m (72.3 – 90.7 lbf ft)

Torque Values

Designation N•m lbf ft

G 490 – 608 361.40 – 448.44

WA500-6 10-21 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

10-22 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Outline

• The power from the engine is transmitted through the torque converter, transmission, and transfer. From the transfer, part
of the power is then transmitted to the rear axle through rear drive shaft (4). The remaining portion of the power is
transmitted to the front axle through center drive shaft (3), center support (2), and front drive shaft (1).

• The drive shafts have the following purpose besides simple power transmission.

• When the positions of the transmission and front and rear axles change because of the traveling or working impacts
during articulation or travel of the machine, the drive shafts absorb the fluctuations in the angle and length by using
the universal joint and slip joint so that the power may be transmitted without damaging the parts.

WA500-6 10-23 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Power Train Piping Diagram

10-24 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Transmission
2. Torque converter
3. Transmission control valve
4. Power train pump
5. Torque converter oil cooler
6. Torque converter oil filter

WA500-6 10-25 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Torque Converter
Without Lockup Clutch
(Torque converter, PTO, and input transfer)

10-26 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

A. From main relief valve

B. From transmission control valve
C. Torque converter outlet oil pressure pickup port
D. To transfer case

1. Hydraulic and brake cooling pump (if equipped) mount port

2. Cooling fan pump mount port
3. Transmission input shaft speed sensor
4. Input transfer
5. Torque converter and PTO
6. Work equipment hydraulic pump mount port
7. Steering pump, power train pump, and EPC brake pump mount port
8. Torque converter regulator valve

Torque Values

Designation N•m lbf ft Designation N•m lbf in

FF 24.5 – 34.3 18.07 – 25.30 EE 9.8 – 12.7 86.74 – 112.40

GG 34.3 – 44.1 25.30 – 32.53

HH 19.6 – 29.4 14.46 – 21.68

JJ 53.9 – 63.7 39.75 – 46.98

KK 49.0 – 68.6 36.14– 50.60

Specifications

Type 3-element, 1-stage, 1-phase

Stall torque ratio 2.84

WA500-6 10-27 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Flywheel
2. Pilot
3. Drive case
4. Turbine
5. Stator
6. Pump
7. PTO idler gear (Number of teeth: 51)
8. Stator shaft
9. Torque converter output shaft
10. Input transfer drive gear (Number of teeth: 59)
11. Transmission input shaft
12. Input transfer driven gear (Number of teeth: 47)
13. PTO drive gear (Number of teeth: 88)
14. Spacer
15. Boss

10-28 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No. Check Item Criteria Remedy
Backlash between PTO idler
1 0.192 – 0.492 (0.008 –0.019)
gear and PTO gear A
Backlash between PTO idler
2 0.192 – 0.492 (0.008 –0.019)
gear and PTO gear B
Tolerance
Standard size
Shaft Hole
Tolerance for fitness
3 of bearing in PTO Outside 0 (0) -0.010 (-0.00039)
100 (3.94)
gear A (Small) diameter -0.015 (-0.0006) -0.045 (-0.00177)
Inside +0.030 (+0.0012) 0 (0)
55 (2.17)
diameter +0.011 (+0.0004) -0.015 (-0.0006)
Outside 0 (0) +0.026 (+0.00102) Replace
Tolerance for fitness diameter 150 (5.91)
-0.018 (-0.0007) -0.014 (-0.00055)
4 of bearing in PTO
gear A (Large) Inside +0.035 (+0.0014) 0 (0)
85 (3.35)
diameter +0.013 (+0.0005) -0.020 (-0.0008)
Outside 0 (0) -0.010 (-0.00039)
Tolerance for fitness diameter 100 (3.94)
-0.015 (-0.0006) -0.045 (-0.00177)
5 of bearing in PTO
gear B (Small) Inside +0.030 (+0.0012) 0 (0)
55 (2.17)
diameter +0.011 (+0.0004) -0.015 (-0.0006)
Outside 0 (0) +0.026 (+0.00102)
Tolerance for fitness diameter 125 (4.92)
-0.018 (-0.0007) -0.014 (-0.00055)
6 of bearing in PTO
gear B (Large) Inside +0.030 (+0.0012) 0 (0)
70 (2.76)
diameter +0.011 (+0.0004) -0.015 (-0.0006)

7. PTO gear A (Number of teeth: 84)

8. PTO gear B (Number of teeth: 84)

WA500-6 10-29 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12

Torque Values

Designation N•m lbf ft Designation N•m lbf in

B 441 – 490 325.26 – 361.40 G 9.8 – 12.7 86.74 – 112.40

C 49.0 – 58.8 36.14 – 43.37

D 153 – 190 112.85 – 140.14

E 59 – 74 43.52 – 54.58

F 98 – 123 72.28 – 90.72

10-30 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Tolerance Repair Limit
1 Outside diameter of pilot -0.040 (-0.0016) Repair by hard
80 (3.15) 79.92 (3.15)
-0.070 (-0.0028) chromium-plating
Inside diameter of sleeve seal ring +0.030 (+0.0012) or replace
65 (2.56) 65.1 (2.56)
contact surface –0 (0)
2 -0.01 (-0.0004)
Wear of output shaft seal Width 3 (0.12) 2.7 (0.11)
-0.03 (-0.0012) Replace
ring
Thickness 2.7 (0.11) ±0.1 (±0.0039) 2.55 (0.10)
Repair by hard
Inside diameter of PTO drive gear seal +0.040 (0.0016)
3 170 (6.70) 170.5 (6.71) chromium-plating
ring contact surface –0 (0)
or replace
Tolerance
Standard Size
Shaft Hole
Tolerance for fitness of Outside –0.(0)000 -0.028 (-0.0011)
4 125 (4.92)
PTO idler gear bearing diameter -0.020 (-0.0008) -0.068 (-0.0027)
Inside +0.012 (+0.0005) –0 (0).000
70 (2.76)
diameter -0.007 (-0.0003) -0.015 (-0.0006)
Outside –0 (0)0 -0.012 (-0.0005)
Tolerance for fitness of 150 (5.91)
diameter -0.020 (-0.0008) -0.052 (-0.0020)
5 input transfer drive gear
bearing (Large) Inside +0.059 (+0.0023) –0 (0)00
85 (3.35)
diameter +0.037 (+0.0015) -0.020 (-0.0008)
Outside –0 (0)0 -0.012 (-0.0005)
Tolerance for fitness of 140 (5.51)
diameter -0.020 (-0.0008) -0.052 (-0.0020)
6 input transfer drive gear
bearing (Small) Inside +0.051 (+0.0020) –0.(0)000
80 (3.15)
diameter +0.032 (+0.0013) -0.015 (-0.0006)
Outside –0 (0)000 -0.012 (-0.0005) Replace
Tolerance for fitness of 125 (4.92)
diameter -0.020 (-0.0008) -0.052 (-0.0020)
7 input transfer driven gear
bearing Inside +0.051 (+0.0020) –0.(0)000
80 (3.15)
diameter +0.032 (+0.0013) -0.015 (-0.0006)
Backlash between PTO drive gear and
8 0.192 – 0.492 (0.0076 – 0.0194)
PTO idler gear
Backlash between input transfer drive
9 0.190 – 0.486 (0.0075 – 0.0191)
gear and driven gear
Standard Clearance Clearance Limit
Clearance between cage and case of 0.40 – 1.60 (0.016 – 0.063)
10
input transfer drive gear (Standard shim thickness: —
1.0 (0.039))
0.60 – 1.80 (0.024 – 0.071)
Clearance between cage and case of
11 (Standard shim thickness: —
input transfer driven gear
1.0 (0.039))

WA500-6 10-31 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Power Transmitting Route

• The power from the engine is transmitted to drive case (2) through flywheel (1).

• The power being transmitted to drive case (2) rotates pump (3) and PTO drive gear (4).

• The power being transmitted to pump (3) rotates turbine (6) and boss (7) using oil as the medium, and then is transmitted
to output shaft (8).

• The power being transmitted to output shaft (8) is then transmitted to transmission input shaft (11) through drive gear (9)
and driven gear (10).

• The power being transmitted to PTO drive gear (4) is then transmitted through PTO idler gear (5) and the PTO gear, and
then is used as the pump driving power.

10-32 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Oil Flow

• The oil flows to the torque converter relief valve through the main relief valve; there the valve regulates the oil pressure to
below the set pressure. The oil flows to pump (4) through inlet port (A) and oil passage of case (1), stator shaft (2), and
spacer (3).

• The oil is given a centrifugal force by pump (4) and then enters turbine (5) to transmit its energy to turbine (5).

• The oil from turbine (5) is sent to stator (6) and then returned to pump (4). Part of this oil is sent to the oil cooler through
stator (6), oil passage of stator shaft (2), outlet port (B), and the torque converter regulator valve.

WA500-6 10-33 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

With Lockup Clutch

(Torque converter, PTO, and input transfer)

10-34 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

A. From main relief valve

B. From lockup clutch ECMV
C. From transmission control valve
D. Torque converter outlet oil pressure pickup port
E. To transfer case

1. Hydraulic and brake cooling pump (if equipped) mount port

2. Cooling fan pump mount port
3. Transmission input shaft speed sensor
4. Input transfer
5. Torque converter and PTO
6. Work equipment hydraulic pump mounting port
7. Steering pump, power train, and PPC pump mounting port
8. Torque converter regulator valve

Torque Values

Designation N•m lbf ft Designation N•m lbf in

FF 53.9 – 63.7 39.75 – 46.98 LL 9.8 – 12.7 86.74 – 112.40

GG 49.0 – 68.6 36.14 – 50.60

HH 34.3 – 44.1 25.30 – 32.53

JJ 19.6 – 29.4 14.46 – 21.68

KK 24.5 – 34.3 18.07 – 25.30

Specifications

Type 3-element, 1-stage, 2-phase

Stall torque ratio 2.73

WA500-6 10-35 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Flywheel 11. Input transfer drive gear (Number of teeth: 59)

2. Pilot 12. Transmission input shaft
3. Lockup clutch housing 13. Input transfer driven gear (Number of teeth: 47)
4. Turbine 14. PTO drive gear (Number of teeth: 88)
5. Stator 15. Spacer
6. Drive case 16. Free wheel
7. Pump 17. Race
8. PTO idler gear (Number of teeth: 51) 18. Lockup clutch disc
9. Stator shaft 19. Lockup clutch piston
10. Torque converter output shaft 20. Boss

10-36 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No. Check Item Criteria Remedy
Backlash between PTO idler gear
1 0.192 – 0.492 (0.0076 – 0.0194)
and PTO gear A
Backlash between PTO idler gear
2 0.192 – 0.492 (0.0076 – 0.0194)
and PTO gear B
Tolerance
Standard Size
Shaft Hole
Tolerance for fitness of
3 bearing in PTO gear A Outside –0 (0).000 -0.010 (-0.00039)
100 (3.94)
(Small) diameter -0.015 (-0.0006) -0.045 (-0.00177)
Inside +0.030 (+0.0012) –0.(0).000
55 (2.17)
diameter +0.011 (+0.0004) -0.015 (-0.0006)
Outside –0 (0)..000 +0.026 (+0.00102) Replace
Tolerance for fitness of 150 (5.91)
diameter -0.018 (-0.0007) -0.014 (-0.00055)
4 bearing in PTO gear A
(Large) Inside +0.035 (+0.0014) – 0 (0)..000
85 (3.35)
diameter +0.013 (+0.0005) -0.020 (-0.0008)
Outside –0.(0).000 -0.010 (-0.00039)
Tolerance for fitness of 100 (3.94)
diameter -0.015 (-0.0006) -0.045 (-0.00177)
5 bearing in PTO gear B
(Small) Inside +0.030 (+0.0012) –0.(0).000
55 (2.17)
diameter +0.011 (+0.0004) -0.015 (-0.0006)
Outside –0 (0)..000 +0.026 (+0.00102)
Tolerance for fitness of 125 (4.92)
diameter -0.018 (-0.0007) -0.014 (-0.00055)
6 bearing in PTO gear B
(Large) Inside +0.030 (+0.0012) –0.(0).000
70 (2.76)
diameter +0.011 (+0.0004) -0.015 (-0.0006)

7. PTO gear A (Number of teeth: 84)

8. PTO gear B (Number of teeth: 84)

WA500-6 10-37 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Torque Values

Designation N•m lbf ft Designation N•m lbf in

A 441 – 490 325.26 – 361.40 F 9.8 – 12.7 86.74 – 112.40

B 49.0 – 58.8 36.14 – 43.37

C 153 – 190 112.85 – 140.14

D 59 – 74 43.52 – 54.58

E 98 – 123 72.28 – 90.72

10-38 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Tolerance Repair Limit
1 Outside diameter of pilot -0.040 (-0.0016) Repair by hard
80 (3.15) 79.92 (3.15)
-0.070 (-0.0028) chromium-plating
Inside diameter of pilot seal ring +0.025 (+0.0010) or replace
2 40 (1.57) 40.1 (1.58)
contact surface –0.(0)000
-0.01 (-0.0004)
Wear of output shaft seal Width 3 (0.12) 2.7 (0.11)
2 -0.03 (-0.0012) Replace
ring
Thickness 1.7 (0.07) ±0.1 (±0.0040) 1.55 (0.06)
Repair by hard
Inside diameter of stator shaft seal ring +0.030 (+0.0012)
65 (2.56) 65.1 (2.56) chromium-plating
contact surface –0.(0)000
or replace
3
-0.01 (-0.0004)
Wear of output shaft seal Width 3 (0.12) 2.7 (0.11)
-0.03 (-0.0012) Replace
ring
Thickness 2.7 (0.11) ±0.1 (±0.0040) 2.55 (0.10)
Repair by hard
Inside diameter of PTO drive gear seal +0.040 (+0.0016)
4 170 (6.70) 170.5 (6.71) chromium-plating
ring contact surface –0.(0)000
or replace
Inside diameter of race free wheel
5 102.555 (4.038) ±0.008 (±0.0003) 102.585 (4.039)
transfer surface
Inside diameter of stator shaft free +0.004 (+0.00016)
6 83.6 (3.29) 83.57 (3.29)
wheel transfer surface -0.009 (-0.00035)
Inside diameter of sliding portion of +0.015 (+0.0006)
7 83.71 (3.30) 83.79 (3.30)
bushing –0 (0).000
8 Thickness of sliding portion of bushing 6 (0.24) ±0.05 (±0.00197) 5.5 (0.22)
9 Thickness of clutch disc 5.4 (0.21) ±0.1 (±0.0040) 4.9 (0.19)
Tolerance
Standard Size
Shaft Hole
Tolerance for fitness of Outside 0 (0).000 -0.028 (-0.0011)
10 125 (4.92)
PTO idler gear bearing diameter -0.020 (-0.0008) -0.068 (-0.0027)
Inside +0.012 (+0.0005) 0.(0)000
70 (2.76)
diameter -0.007 (-0.0003) -0.015 (-0.0006)
Outside 0 (0).000 -0.012 (-0.0005)
Tolerance for fitness of 150 (5.91)
diameter -0.020 (-0.0008) -0.052 (-0.00204)
11 input transfer drive gear
Inside +0.059 (+0.0023) 0.(0)000
bearing (Large) 85 (3.35)
diameter +0.037 (+0.0015) -0.020 (-0.0008)
Outside 0 (0)00 -0.012 (-0.0005) Replace
Tolerance for fitness of 140 (5.51)
diameter -0.020 (-0.0008) -0.052 (-0.00204)
12 input transfer drive gear
Inside +0.051 (+0.0020) 0.(0)0
bearing (Small) 80 (3.15)
diameter +0.032 (+0.0013) -0.015 (-0.0006)
Outside –0 (0)00 -0.012 (-0.0005)
Tolerance for fitness of 125 (4.92)
diameter -0.020 (-0.0008) -0.052 (-0.00204)
13 input transfer driven gear
Inside +0.051 (+0.0020) –0.(0)00
bearing 80 (3.15)
diameter +0.032 (+0.0013) -0.015 (-0.0006)
Backlash between PTO drive gear and
14 0.192 – 0.492 (0.0076 – 0.0194)
PTO idler gear
Backlash between input transfer drive
15 0.190 – 0.486 (0.0075 – 0.0191)
gear and driven gear
Standard Clearance Clearance Limit
Clearance between cage and case of 0.40 – 1.60 (0.016 – 0.063)
16
input transfer drive gear (Standard shim thickness: —
1.0 (0.039))
0.60 – 1.80 (0.024 – 0.071)
Clearance between cage and case of
17 (Standard shim thickness: —
input transfer driven gear
1.0 (0.039))

WA500-6 10-39 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Power-Transmitting Route: Lockup Clutch Disengaged

• Drive case (3) is disconnected from boss (9) and turbine (8) and lockup torque converter works as an ordinary torque
converter.

• The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and the PTO gear, and
then used as the pump driving power.

10-40 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Power-Transmitting Route: Lockup Clutch Engaged

• Drive case (3) is connected to boss (9) and turbine (8) and lockup torque converter is locked up.

• The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and the PTO gear, and
then used as the pump driving power.

WA500-6 10-41 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Oil Flow

• The oil flows to the torque converter relief valve through the main relief valve; there the value regulates the oil pressure to
below the set pressure. The oil flows to pump (4) through inlet port (A) and oil passage of case (1), stator shaft (2), and
spacer (3).

• The oil is given a centrifugal force by pump (4) and then it enters turbine (5) to transmit its energy to turbine (5).

• The oil from turbine (5) is sent to stator (6) and then returned to pump (4). Part of this oil is sent to the oil cooler through
stator (6), oil passage of stator shaft (2), outlet port (B), and torque converter regulator valve.

10-42 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Torque Converter Regulator Valve

A. From torque converter

B. To oil cooler
C. Drain
D. Torque converter outlet port oil pressure pickup port

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between Size Shaft Hole Clearance Limit
1
spool and valve body 32 -0.050 (-0.0020) +0.025 (+0.0010) 0.050 – 0.091 0.111
(1.26) -0.066 (-0.0026) + 0 (0).000 (0.0020 – 0.0036) (0.0044)
Standard Size Repair Limit Replace
Free Installed
Installed Length Installed Load Free Length
2 Valve spring Length Load
126.6 106.5 205 N 195 N
122.8 (4.83)
(4.98) (4.19) (46.09 lbf) (43.84 lbf)

3. Spool
4. Valve body

Torque Values

Designation N•m lbf in

AA 9.8 – 12.7 86.74 – 112.40

Outline

• This valve is provided at the torque converter outlet circuit in order to secure an optimum performance of the torque
converter by adjusting its set oil pressure.

Set pressure: . . . . . . . . . . . . . . . 0.42 ±0.05 MPa (60.92 ±7.25 psi)

WA500-6 10-43 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Operation

• The oil from the torque converter is conducted to chamber (D)

through port (A) and orifice (a).

• When the oil pressure force generated in chamber (D) is less than
the tension of spring (1), spool (2) is pressed to the left, closing
port (A) and port (B).

• If the oil pressure force generated in chamber (D) becomes greater

than the tension of spring (1), spool (2) is pressed to the right,
opening port (A) and port (B).

10-44 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

MEMORANDUM

WA500-6 10-45 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Transmission
(transmission, transfer, and parking brake)

Transmission with Lockup Clutch

.

10-46 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Transfer
2. Parking brake
3. Transmission
4. Emergency steering pump mounting port
5. Oil filler tube mounting port
6. Speed sensor
7. Lubrication relief valve
8. Transmission control valve
9. Torque converter drain tube mounting port
10. Drain valve
11. Drain plug
12. Transmission lubricant temperature sensor
13. Strainer

Torque Values

Designation N•m lbf ft Designation N•m lbf in

AA 98.0 – 123.0 72.28 – 90.72 KK 9.8 – 12.7 86.74 – 112.40

BB 128.0 – 185.0 94.41 – 136.45

CC 44.1 – 53.9 32.53 – 39.75

DD 34.3 – 63.7 25.30 – 46.98

EE 49.0 – 68.6 36.14 – 50.60

FF 72.6 – 146.0 53.55 – 107.68

GG 58.8 – 78.4 43.37 – 57.82

HH 49.0 – 78.4 36.14 – 57.82

JJ 29.4 – 49.0 21.68 – 36.14

WA500-6 10-47 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

10-48 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

A. To torque converter
B. To parking brake emergency release valve
C. To lockup clutch (if equipped)
D. To parking brake emergency release valve (to parking brake)
E. From oil cooler
F. From power train pump
G. From parking brake emergency release valve
H. To input transfer lubrication
J. Parking brake oil pressure pickup port
K. From main relief valve
L. From lockup clutch ECMV (if equipped)
M. From F clutch ECMV (to F clutch)
N. To 4th clutch
P. From R clutch ECMV (to R clutch)
R. From 3rd clutch ECMV (to 3rd clutch)
S. To 2nd clutch
T. To transmission and transfer lubrication
U. From lubrication relief valve
V. From 2nd clutch ECMV
W. From 4th clutch ECMV
X. To 1st clutch
Y. From 1st clutch ECMV

WA500-6 10-49 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12

10-50 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Transmission input shaft 24. 2nd piston return spring

2. Tie bolt 25. 2nd clutch piston
3. R ring gear (Hub) 26. 2nd clutch housing
4. R planetary pinion (Number of teeth: 24) 27. 3rd and 4th carriers
5. R ring gear (Number of teeth: 70) 28. 3rd piston return spring
6. F planetary pinion (Number of teeth: 23) 29. 3rd clutch piston
7. F ring gear (Number of inside teeth: 75) 30. 3rd and 4th clutch housings
8. 4th ring gear (Number of inside teeth: 73) 31. 4th clutch piston
9. 4th planetary pinion (Number of teeth: 28) 32. 4th piston return spring
10. 3rd planetary pinion (Number of teeth: 20) 33. F and 4th clutch cages
11. 3rd ring gear (Number of inside teeth: 76) 34. F piston return spring
12. 2nd ring gear (Number of teeth: 76) 35. F sun gear (Number of teeth: 29)
13. 2nd planetary pinion (Number of teeth: 20) 36. F carrier
14. 1st hub 37. F clutch piston
15. Transmission output shaft (4th sun gear) (Number of teeth: 17) 38. R and F clutch housings
16. Transfer input gear (Number of teeth: 50) 39. R clutch piston
17. 2nd sun gear (Number of teeth: 36) 40. Washer spring
18. 1st clutch housing 41. R piston return spring
19. 1st clutch piston 42. R carrier
20. 2nd carrier 43. Clutch disc
21. 3rd sun gear (Number of teeth: 36) 44. Clutch plate
22. 1st piston return spring 45. R clutch cage
23. 2nd clutch housing 46. R sun gear (Number of teeth: 22)

WA500-6 10-51 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Outline

• The transmission consists of the united planetary gear mechanism and disc clutch that provides four forward and four
reverse gear speeds.

• The transmission selects a single rotating direction and a single gear speed by fixing the planetary gear mechanism and
two of six disc clutches by using ECMV.

• The transmission transmits the power (being transmitted to the transmission input shaft) to the output shaft after selecting
a single speed from the 1st to 4th speeds both in forward and reverse travel. In this case, the gear speed change is done by
F and R clutches plus combinations of four speed clutches.

Number of Plates and Discs Used

Clutch No. Number of Plates Number of Discs

R clutch 6 7
F clutch 6 7
4th clutch 3+2 4
3rd clutch 2+2 3
2nd clutch 2+1 3
1st clutch 3+2 4

Combinations of Clutches at Respective Gear Speeds and Reduction Ratio

Gear Speed Clutch Used Reduction Ratio

Forward 1st speed F x 1st 3.586
Forward 2nd speed F x 2nd 1.935
Forward 3rd speed F x 3rd 1.153
Forward 4th speed F x 4th 0.677
Neutral — —
Reverse 1st speed R x 1st 3.182
Reverse 2nd speed R x 2nd 1.717
Reverse 3rd speed R x 3rd 1.023
Reverse 4th speed R x 4th 0.601

10-52 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Transfer idler gear (Number of teeth: 71)

2. Transfer output gear (Number of teeth: 72)
3. Output shaft
4. Front coupling
5. Rear coupling
6. Parking brake

WA500-6 10-53 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

10-54 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Repair Limit
Installed Installed Installed
Free Length Free Length
1 R clutch spring (10 springs) Length Load Load
48.1 N 41.2 N
77 (3.03) 70.2 (2.76) 72.4 (2.85)
(10.81 lbf) (9.26 lbf)
37.3 N 31.4 N
2 F clutch spring (10 springs) 77 (3.03) 71.7 (2.82) 72.4 (2.85)
(8.39 lbf) (7.06 lbf)
59.8 N 51.0 N
3 4th clutch spring (10 springs) 48.5 (1.91) 44.2 (1.74) 45.6 (1.80)
(13.44 lbf) (11.47 lbf)
94.1 N 80.4 N
4 3rd clutch spring (10 springs) 39.8 (1.57) 33 (1.30) 37.4 (1.47)
(21.15 lbf) (18.07 lbf)
67.7 N 57.9 N
5 2nd clutch spring (10 springs) 39.8 (1.57) 34.9 (1.37) 37.4 (1.47)
(15.22 lbf) (13.02 lbf ft)
110 N 93.2 N
6 1st clutch spring (10 springs) 46 (1.81) 39 (1.54) 43.2 (1.70)
(24.73 lbf) (20.95 lbf)

Total assembled thickness of 7 discs Standard Size Tolerance Repair Limit

7
and 6 plates for R clutch 54.2 (2.13) ±0.36 (±0.014) 50.5 (1.99)
Total assembled thickness of 7 discs
8 54.2 (2.13) ±0.36 (±0.014) 50.5 (1.99)
and 6 plates for F clutch
Total assembled thickness of 4 discs
9 45.0 (1.77) ±0.30 (±0.012) 41.8 (1.65)
and 5 plates for 4th clutch
Total assembled thickness of 3 discs Replace
10 35.0 (1.38) ±0.26 (±0.010) 32.6 (1.28)
and 4 plates for 3rd clutch
Total assembled thickness of 3 discs
11 26.4 (1.04) ±0.24 (±0.009) 24.8 (0.98)
and 3 plates for 2nd clutch
Total assembled thickness of 4 discs
12 45.0 (1.77) ±0.30 (±0.012) 41.8 (1.65)
and 5 plates for 1st clutch

Thickness of clutch R, F, 2nd 5.0 (0.197) ±0.1 (±0.004) 4.5 (0.18)

13
disc 4th, 3rd, 1st 5.0 (0.197) ±0.1 (±0.004) 4.2 (0.17)
R, F 3.2 (0.126) ±0.1 (±0.004) 2.9 (0.11)

Thickness of clutch 4th, 3rd, 1st 5.0 (0.197) ±0.1 (±0.004) 4.5 (0.18)
14
plate 3.2 (0.126) ±0.1 (±0.004) 2.9 (0.11)
2nd
5.0 (0.197) ±0.1 (±0.004) 4.5 (0.18)
0.01 (-0.0004)
Wear of R spacer Width 4.5 (0.177) 4.05 (0.16)
15 -0.03 (-0.0012)
seal ring
Thickness 5.2 (0.205) ±0.12 (±0.005) 5.05 (0.199)
-0.01 (-0.0004)
Wear of R clutch Width 4.0 (0.157) 3.60 (0.14)
16 -0.03 (-0.0012)
cage seal ring
Thickness 5.0 (0.197) ±0.15 (±0.006) 4.85 (0.19)
-0.01 (-0.0004)
Wear of F clutch Width 4.0 (0.157) 3.60 (0.14)
17 -0.04 (-0.0016)
cage seal ring
Thickness 5.0 (0.197) ±0.15 (±0.006) 4.85 (0.19)

WA500-6 10-55 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No. Check Item Criteria Remedy
-0.01 (-0.0004)
Wear of seal ring of Width 4.0 (0.157) 3.60 (0.14)
18 -0.04 (-0.0016)
3rd and 4th carrier
Thickness 5.0 (0.197) ±0.15 (±0.006) 4.85 (0.19)
-0.01 (-0.0004)
Wear of 3rd spacer Width 3.0 (0.118) 2.70 (0.11)
19 -0.03 (-0.0012)
seal ring
Thickness 3.3 (0.130) ±0.1 (±0.004) 3.15 (0.124)
-0.01 (-0.0004)
Wear of 1st clutch Width 4.5 (0.177) 4.05 (0.16)
20 -0.03 (-0.0012)
cage seal ring
Thickness 5.8 (0.228) ±0.15 (±0.006) 5.65 (0.22)
-0.01 (-0.0004)
Wear of output shaft Width 3.0 (0.118) 2.70 (0.11)
21 -0.03 (-0.0012)
seal ring
Thickness 3.1 (0.122) ±0.1 (±0.004) 2.95 (0.116)
-0.01 (-0.0004
Wear of output shaft Width 2.5 (0.098) 2.25 (0.09)
22 -0.03 (-0.0012)
seal ring
Thickness 1.7 (0.067) ±0.1 (±0.004) 1.55 (0.06)
Backlash between R, F 0.13 – 0.32 (0.0051 – 0.0126)
23 sun gear and
planetary pinion 3rd, 2nd 0.12 – 0.33 (0.0047 – 0.0130)

Backlash between
24 output shaft and 4th 0.11 – 0.30 (0.0043 – 0.0118) Replace
planetary pinion
Backlash between R, F 0.15 – 0.38 (0.0059 – 0.0150)
25 planetary pinion and
ring gear 4th, 3rd, 2nd 0.13 – 0.36 (0.0051 – 0.0142)

Backlash between transfer input gear

26 0.19 – 0.48 (0.0075 – 0.0189)
and idler gear
Tolerance
Standard Size
Shaft Hole Hole
Tolerance for fitness
27 of transfer input gear Outside 0 (0) -0.012 (-0.0005)
160 (6.30)
bearing (Rear) diameter -0.025 (-0.0010) -0.052 (-0.0020)
Inside +0.045 (+0.0018) 0 (0)
90 (3.54)
diameter +0.023 (+0.0009) -0.020 (-0.0008)
Outside 0 (0) 0 (0)
Tolerance for fitness 160 (6.30)
diameter -0.025 (-0.0010) -0.040 (-0.0016)
28 of transfer input gear
bearing (Front) Inside +0.045 (+0.0018) 0 (0)
90 (3.54)
diameter +0.023 (+0.0009) -0.020 (-0.0008)
Standard Clearance Clearance Limit

29 Clearance between cage and case 1.61 – 2.39 (0.063 – 0.094)

(Standard shim thickness: —
2.0 (0.079))

10-56 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Torque Values

Designation N•m lbf ft

B 157 – 177 115.80 – 130.55
C 98.0 – 123.0 72.28 – 90.72
D 58.8 – 73.5 43.37 – 54.21

WA500-6 10-57 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

10-58 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Tolerance Repair Limit
Outside diameter of coupling oil
1 –0 (0).000 Repair by hard
seal contact surface (Rear) 105 (4.13) 104.8 (4.13)
-0.087 (-0.0034) chromium-plating
Outside diameter of coupling oil –0.(0)000 or replace
2 105 (4.13) 104.8 (4.13)
seal contact surface (Front) -0.087 (-0.0034)
Backlash between idler gear and
3 0.19 – 0.48 (0.007 – 0.019)
output gear
Tolerance
Standard Size
Shaft Hole
Tolerance for fitness of Outside –0.(0)000 –0.(0)000
4 180 (7.09)
idler gear bearing diameter -0.025 (-0.0010) -0.040 (-0.0016)
Inside +0.059 (+0.0023) –0 (0).000
100 (3.94)
diameter +0.037 (+0.0015) -0.020 (-0.0008)
Outside –0.(0)000 -0.014 (-0.0006)
Tolerance for fitness of diameter 190 (7.48)
-0.030 (-0.0012) -0.060 (-0.0024)
5 output shaft bearing
(Rear) Inside +0.059 (+0.0023) –0.(0)000
105 (4.13) Replace
diameter +0.037 (+0.0015) -0.020 (-0.0008)
Outside –0.(0)000 -0.020 (-0.0008)
Tolerance for fitness of diameter 150 (5.91)
-0.020 (-0.0008) -0.040 (-0.0016)
6 output gear bearing
(Front) Inside +0.045 (+0.0018) –0.(0)000
85 (3.35)
diameter +0.023 (+0.0009) -0.020 (-0.0008)
Standard Clearance Clearance Limit
Clearance between cage and 0.63 – 1.37 (0.025 – 0.054)
7
case (Standard shim thickness: —
1.0 (0.039))
0.48 – 1.32 (0.019 – 0.052)
Clearance between cover and
8 (Standard shim thickness: —
cage
0.5 (0.020))

Torque Values

Designation N•m lbf ft

C 98.0 – 123.0 72.28 – 90.72

D 824 – 1030 607.75 – 759.69

WA500-6 10-59 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Disc Clutch
Structure

• Disc clutch is used for fixing ring gear (1). It consists of piston (2),
plate (3), disc (4), pin (5), return spring (6), and washer (8).

• Inside teeth of disc (4) are engaged with outside teeth of ring
gear (1).

• Plate (3) is assembled to clutch housing (7) with pin (5).

Operation

When clutch is engaged (fixed)

• The oil from ECMV is sent under pressure to the rear side of
piston (2) through the oil passage of housing (7) and pushes
piston (2) to the left.

• Piston (2) contacts plate (3) closely against disc (4) to stop rotation
of disc (4) by using the friction force generated between them.

• Since inside teeth of disc (4) are engaged with outside teeth of ring
gear (1), movement of ring gear (1) is stopped.

When clutch is disengaged (released)

• As the oil from ECMV is stopped, piston (2) is pushed back to the
right by return spring (6).

• The friction force between plates (3) and discs (4) is released and
ring gear (1) is released.

• Washer spring (8) is installed between plate (3) of the pin block
and plate (3). This spring quickens return of piston (2) as the clutch
is disengaged by providing smooth separation of plate (3) and
disc (4). At the same time, it is used to prevent dragging.

10-60 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

MEMORANDUM

WA500-6 10-61 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Power Transmitting Route

Forward 1st Gear Speed

10-62 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

WA500-6 10-63 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Forward 2nd Gear Speed

10-64 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

WA500-6 10-65 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Forward 3rd Gear Speed

10-66 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Forward 4th Gear Speed

WA500-6 10-67 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Reverse 1st Gear Speed

10-68 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

WA500-6 10-69 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Transfer
Outline

★ The transfer is installed in the output side of the transmission and fixed to the transmission case with the bolt.

Operation

Power transmitting route

10-70 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

MEMORANDUM

WA500-6 10-71 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Transmission Control Valve (without Lockup Clutch)

10-72 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

A. 1st clutch oil pressure pickup port

B. 4th clutch oil pressure pickup port
C. 3rd clutch oil pressure pickup port
D. F clutch oil pressure pickup port
E. R clutch oil pressure pickup port
F. Torque converter relief pressure pickup port
G. Main relief oil pressure pickup port
H. From power train pump
J. 2nd clutch oil pressure pickup port
K. To PTO and input transfer lubrication
L. To parking brake emergency release valve (to parking brake)
M. To parking brake emergency release valve

1. 1st clutch ECMV

2. 4th clutch ECMV
3. 3rd clutch ECMV
4. F clutch ECMV
5. Parking brake solenoid valve
6. R clutch ECMV
7. Main relief valve and torque converter relief valve
8. Last chance filter
9. 2nd clutch ECMV
10. Check valve

Torque Values

Designation N•m lbf ft Designation N•m lbf in

AA 19.6 – 24.5 14.46 – 18.07 EE 6.9 – 7.8 61.07 – 69.04
BB 24.5 – 34.3 18.07 – 25.30 LL 9.8 – 12.7 86.74 – 112.40
CC 47.0 – 53.9 34.67 – 39.75
DD 7.8 – 9.8 5.75 – 7.23
FF 93.1 – 122.5 68.67 – 90.35
GG 128 – 186 94.41 – 137.19
HH 15.7 – 19.6 11.58 – 14.46
JJ 34.3 – 44.1 25.30 – 32.53
KK 44.1 – 53.9 32.53 – 39.75

WA500-6 10-73 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Operation Table of ECMV

ECMV
F R 1st 2nd 3rd 4th
Gear Speed
A ❍
N
M ❍ ❍ ❍ ❍
F1 ❍ ❍
F2 ❍ ❍
F3 ❍ ❍
F4 ❍ ❍
R1 ❍ ❍
R2 ❍ ❍
R3 ❍ ❍
R4 ❍ ❍
A: Automatic shifting
M: Manual shifting

★ When the directional lever is in the N (Neutral) position during manual shifting, the speed clutch for the gear speed
selected with the gear shift lever operates.

Outline

• The oil from the pump flows to the transmission control valve through the oil filter. Oil flow is divided into the main relief
circuit and clutch actuation circuit.

• The pressure of the oil sent to the clutch actuation circuit is regulated by the main relief valve, and then used to actuate the
clutch and parking brake through the last chance filter. The oil relieved from the main relief valve is supplied to the torque
converter.

• When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to the command
current from the transmission controller in order to reduce the gear shifting shocks. The ECMV also keeps the clutch
pressure constant during travel.

• If the F, R, or 1st – 4th ECMV is selected, the regulated oil pressure is supplied to the selected clutch to set the
transmission in the desired gear speed.

10-74 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

MEMORANDUM

WA500-6 10-75 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Transmission Control Value (with Lockup Clutch)

10-76 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

A. 1st clutch oil pressure pickup port

B. 4th clutch oil pressure pickup port
C. 3rd clutch oil pressure pickup port
D. F clutch oil pressure pickup port
E. R clutch oil pressure pickup port
F. Torque converter relief pressure pickup port
G. Main relief oil pressure pickup port
H. From power train pump
J. Lockup clutch ECMV oil pressure pickup port
K. 2nd clutch oil pressure pickup port
L. To PTO and input transfer lubrication
M. To parking brake emergency release valve (to parking brake)
N. To parking brake emergency release valve

1. 1st clutch ECMV

2. 4th clutch ECMV
3. 3rd clutch ECMV
4. F clutch ECMV
5. Parking brake solenoid valve
6. R clutch ECMV
7. Main relief valve and torque converter relief valve
8. Last chance filter
9. Lockup clutch ECMV
10. 2nd clutch ECMV
11. Check valve

Torque Values

Designation N•m lbf ft Designation N•m lbf in

AA 24.5 – 34.3 18.07 – 25.30 CC 7.8 – 9.8 69.04 – 86.74
BB 47.0 – 53.9 34.67 – 39.75 DD 6.9 – 7.8 61.07 – 69.04
EE 93.1 – 122.5 68.67 – 90.35 KK 9.8 – 12.7 86.74 – 112.40
FF 128 – 186 94.41 – 137.19
GG 15.7 – 19.6 11.58 – 14.46
HH 34.3 – 44.1 25.30 – 32.53
JJ 44.1 – 53.9 32.53 – 39.75
LL 19.6 – 24.5 14.46 – 18.07

WA500-6 10-77 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Operation Table of ECMV

ECMV 2n
F R 1st 3rd 4th L/U
Gear Speed d
A ❍
N
M ❍ ❍ ❍ ❍
F1 ❍ ❍
F2 ❍ ❍ ❍
F3 ❍ ❍ ❍
F4 ❍ ❍ ❍
R1 ❍ ❍
R2 ❍ ❍ ❍
R3 ❍ ❍ ❍
R4 ❍ ❍ ❍
L/U: Lockup clutch ECMV
A: Automatic shifting
M: Manual shifting

★ When the directional lever is in the N (Neutral) position during manual shifting, the speed clutch for the gear speed
selected with the gear shift lever operates.

Outline

• The oil from the pump flows to the transmission control valve through the oil filter. Oil flow is divided into the main relief
circuit and clutch actuation circuit.

• The pressure of the oil sent to the clutch actuation circuit is regulated by the main relief valve, and then used to actuate the
clutch and parking brake through the last chance filter. The oil relieved from the main relief valve is supplied to the torque
converter.

• When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to the command
current from the transmission controller in order to reduce the gear shifting shocks. The ECMV also keeps the clutch
pressure constant during travel.

• If the F, R, or 1st – 4th ECMV is selected, the regulated oil pressure is supplied to the selected clutch to set the
transmission in the desired gear speed.

• In the 2nd, 3rd, and 4th speed travel, the lockup clutch ECMV operates at a speed greater than the speed being specified
from the transmission controller.

10-78 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

MEMORANDUM

WA500-6 10-79 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

ECMV (Electronic Control Modulation Valve)

For F, R, 1st, 2nd, 3rd, and 4th clutch

★ Do not try to disassemble the ECMV since an adjustment for maintaining the performance is needed.

10-80 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

A. To clutch
P. From pump

T. Drain
Dr. Drain
P1. Clutch oil pressure pickup port

1. Fill switch connector

2. Proportional solenoid connector
3. Flow ate pickup valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)

*1
Clutch Used Letters Printed on Nameplate
F, R, 1st, 2nd, 3rd, and 4th D*******

Torque Values

Designation N•m lbf in

AA 11.27 ±1.47 99.75 ±13.01

BB 4.9 – 6.9 43.37 – 61.07

WA500-6 10-81 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Pressure Control Valve and Fill Switch

• The ECMV consists of one pressure control valve and one fill switch.

Pressure Control Valve

This valve receives the current sent from the transmission controller with a proportional solenoid and then converts it into oil
pressure.

Fill Switch

This switch detects that the clutch is filled with oil and has the following functions.

1. Outputs a signal (a fill signal) to the controller to indicate that filling is completed when the clutch is filled with oil.

2. Keeps outputting signals (fill signals) to the controller to indicate

whether or not oil pressure is applied while oil pressure is applied
to the clutch.
Range A: . . . . . . . . . . . . . . . . Before shifting gear (when draining)
Range B: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . During filling
Range C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure regulation
Range D: . . . . . . . . . . . . . . . . . . . . During filling (during triggering)
Point E: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of filling
Point F: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finish of filling
★ The logic is that the controller does not recognize completion
of filling even if the fill switch is turned ON during triggering
(Range D).

ECMV and Proportional Solenoid

• For each ECMV, one proportional solenoid is installed.

The proportional solenoid generates thrust according to the

command current from the controller, as shown in the figure.

★ Current – propulsion force characteristics of proportional

solenoid (figure to the right)

10-82 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
The thrust generated by the proportional solenoid is applied to the
pressure control valve spool to generate oil pressure as shown in
the figure. Accordingly, the thrust is changed by controlling the
command current to operate the pressure control valve to control
the flow and pressure of the oil.

★ Propulsion force - Hydraulic pressure characteristics of

proportional solenoid (figure to the right)

ECMV and Fill Switch

• For each ECMV, one fill switch is installed.

If the clutch is filled with oil, the fill switch is turned ON by the
pressure of the clutch. The oil pressure is built up according to this
signal.

Operation of ECMV
• ECMV is controlled with the command current sent from the
controller to the proportional solenoid and the fill switch output
signal.

The relationship between the proportional solenoid command

current of ECMV, clutch input pressure, and fill switch output
signal is shown below.
Range A: . . . . . . . . . . . . . . . . Before shifting gear (when draining)
Range B:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . During filling
Range C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure regulation
Range D: . . . . . . . . . . . . . . . . . . . . During filling (during triggering)
Point E: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of filling
Point F: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finish of filling
★ The logic is that the controller does not recognize completion
of filling even if the fill switch is turned ON during triggering
(Range D).

WA500-6 10-83 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Before Shifting Gear (when draining)

(Range A in chart)

• While no current is flowing in proportional solenoid (1), pressure

control valve (3) drains the oil from clutch port (A) through drain
port (T). At this time, since no oil pressure is applied to flow rate
pickup valve (4), fill switch (5) is turned OFF.

During Filling

(Range B in chart)

• If a current is given to proportional solenoid (1) while there is no

oil in the clutch, a hydraulic force, balanced with the solenoid
force, is applied to chamber (B) and pushes pressure control
valve (3) to the left. This conducts oil through pump port (P) and
orifice (a) of flow rate pickup valve (4) to start filling the oil to the
clutch chamber.

At this time, differential pressure is generated between the upper

stream and downstream of orifice (a) of flow rate pickup valve (4).
This differential pressure pushes flow rate pickup valve (4) to the
left.
As the clutch chamber is filled up with oil and the oil flow from
pump port (P) to clutch port (A) is stopped, differential pressure
before and after orifice (a) of flow rate pickup valve (4)
disappears. As the result, flow rate pickup valve (4) is pushed to
the right, turning ON fill switch (5).

10-84 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Pressure Regulation

(Range C in chart)

• If current flows in proportional solenoid (1), the solenoid generates

thrust in proportion to the current. This thrust of the solenoid is
balanced with the sum of the thrust generated by the oil pressure in
the clutch port and the repulsive force of pressure control valve
spring (2). In this manner, the pressure is settled.

WA500-6 10-85 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

For Lockup Clutch

★ Do not try to disassemble the ECMV since an adjustment for maintaining the performance is needed.

10-86 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

A. To clutch
P. From pump

T. Drain
Dr. Drain
P1. Clutch oil pressure pickup port

1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate (*1)

*1
Clutch Used Letters Printed on Nameplate
Lockup K*******

Torque Values

Designation N•m lbf in

AA 11.27 ±1.47 99.75 ±13.01

BB 4.9 – 6.9 43.37 – 61.07

WA500-6 10-87 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Outline

ECMV for Lockup Clutch

• This valve is used to switch the clutch in order to regulate the clutch oil pressure to the set pressure.

Since the modulation waveform is used for the pressure application characteristics to the clutch, ECMV is capable of
connecting the lockup clutch smoothly, thereby reducing shocks resulting from gear shift. This also prevents generation of
peak torque in the power train. These arrangements make the machine comfortable for the operator and enhance durability
of the power train.

★ When changing from torque converter travel to direct travel

★ At gear shift (in direct travel)

10-88 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Operation

When Clutch is Disengaged (released)

• While no current is flowing into proportional solenoid (1),

pressure control valve (3) drains the oil from clutch port (A)
through drain port (T).

When Clutch is Engaged (fixed)

• As current is conducted to proportional solenoid (1), the oil

pressure being balanced with the solenoid force is applied to
chamber (B), pushing pressure control valve (3) to the left. This
opens pump port (P) and clutch port (A) to start filling oil to the
clutch.

• As the clutch is filled with oil, the solenoid thrust is balanced with
the sum of the thrust generated from the oil pressure of the clutch
port and the tension of the pressure control valve spring (2). In this
manner, the pressure is settled.

WA500-6 10-89 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Main Relief Valve and Torque Converter Relief Valve

10-90 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

A. Drain (torque converter relief)

B. Drain

C. From pump
D. Drain
E. To torque converter
P1. Main relief oil pressure pickup port
P2. Torque converter relief pressure pickup port

Unit: mm (in)
No. Check Item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between Size Clearance Limit
Shaft Hole
1 main relief valve and
valve body -0.035 (-0.0014) +0.013 (-0.0005) 0.035 – 0.058 0.078
28 (1.10)
-0.045 (-0.0018) +0 (0).000 (0.0014 – 0.0023) (0.0031)
Clearance between
-0.035 (-0.0014) +0.013 (-0.0005) 0.035 – 0.058 0.078
2 torque converter relief 22 (0.87)
-0.045 (-0.0018) +0.(0).00 (0.0014 – 0.0023) (0.0031)
valve and valve body
Standard Size Repair Limit
Replace
Installed
Main relief valve spring Free Length Installed Length Installed Load Free Length
3 Load
(Outside)
479.1 N 456 N
128 (5.04) 78.3 (3.08) 124.2 (4.89)
(107.71 lbf) (102.51 lbf)
Main relief valve spring 365.5 N 347 N
4 108 (4.25) 78.3 (3.08) 104.8 (4.13)
(Inside) (82.17 lbf) (78.01 lbf)
Torque converter relief 134.3 N 127 N
5 50 (1.97) 43 (1.69) 48.5 (1.91)
valve spring (30.19 lbf) (28.55 lbf)

6. Body
7. Piston
8. Torque converter relief valve
9. Piston
10. Main relief valve

Torque Values

Designation N•m lbf ft Designation N•m lbf in

BB 44.1– 53.9 32.53 – 39.75 AA 9.8 – 12.74 86.74 – 112.76

WA500-6 10-91 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Outline
Torque Converter Relief Valve

• The torque converter relief valve regulates the torque converter inlet circuit pressure below the set pressure to protect the
torque converter from abnormally high pressure.

Set pressure: . . . . . . . . 0.84 MPa (121.83 psi) (cracking pressure)

Main Relief Valve

• The main relief valve regulates the pressure in the transmission and brake hydraulic circuits below the set pressure.

Set pressure: . . . . . 3.64 MPa (527.94 psi) (at rated engine speed)
Operation
Torque Converter Relief Valve

• The oil from the main relief valve is conducted to the torque
converter through port (E) and, at the same time, also conducted to
chamber (G) through orifice (b) of torque converter relief
valve (3).

• As the oil pressure to the torque converter goes beyond the set
pressure, the oil conducted to chamber (G) pushes piston (4). The
resulting resisting force pushes torque converter relief valve (3) to
the right, opening ports (E) and (A).

As the result, the oil in port (E) is drained through port (A).

Main Relief Valve

• The oil from the hydraulic pump flows to chamber (F) through the
filter, port (C) of the relief valve, and orifice (a) of main relief
valve (1).

• As the oil pressure in the circuit goes beyond the set pressure, the
oil conducted to chamber (F) pushes piston (2). The resulting
resisting force pushes spool (1) to the left, opening ports (C) and
(E).

This operation conducts the oil from port (E) to the torque
converter.

10-92 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

MEMORANDUM

WA500-6 10-93 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Lubrication Relief Valve

10-94 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

A. From oil cooler

B. Drain
C. Lubricant pressure pickup port

Unit: mm
No. Check Item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between Size Shaft Hole Clearance Limit
1
spool and valve body -0.035 (-0.0014) +0.013 (+0.0005) 0.035 – 0.058 0.078
22 (0.87)
-0.045 (-0.0018) 0 (0) (0.0014 – 0.0023) (0.0031)
Standard size Repair limit Replace
Free Installed
Installed Length Installed Load Free Length
2 Valve spring Length Load
59.7 97.4 N 92.6 N
37 (1.46) 57.9 (2.28)
(2.35) (21.9 lbf) (20.8 lbf)

3. Valve body
4. Spool

Torque Values

Designation N•m lbf ft Designation N•m lbf in

AA 58.5 – 78.4 43.15 – 57.82 BB 9.8 – 12.74 86.74 – 112.76

Function

• The lubrication relief valve is installed to the transmission valve and used for maintaining the pressure of the lubrication
circuit below the set pressure.

Set pressure: . . . . . . . . . 0.26 MPa (37.71 psi) (cracking pressure)

WA500-6 10-95 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Torque Converter Oil Cooler

1. Torque converter oil cooler

A. Inlet port
B. Outlet port
C. Coolant inlet
D. Coolant outlet

Outline

• Oil from the torque converter is heated by power transmitting energy. This oil enters the torque converter oil cooler
through inlet port (A) to be cooled by the engine coolant. It then flows into the transmission lubrication system through
outlet port (B).

10-96 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Torque Converter Oil Filter

A. Inlet port
B. Outlet port

1. Relief valve
2. Element
3. Drain plug

WA500-6 10-97 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Specifications
Filtering area: . . . . . . . . . . . . . . . . . 8,900 cm2 x 2 (1,379.5 in2 x 2)
Relief pressure: . . . . . . . . . . . . . . . . . . . . . . . 0.32 MPa (46.41 psi)

Operation

• Oil from the torque converter charge pump enters filter inlet
port (A). It passes from the outside to the inside of element (2) and
flows to outlet port (B).

• When element (2) is clogged with foreign matter or when low oil
temperature has caused pressure at inlet port (A) to increase, oil
from inlet port (A) opens relief valve (1) to flow to outlet port (B)
directly, preventing the pump and element (2) from being
damaged.

10-98 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Center Support

1. Front coupling
2. Case
3. Breather
4. Rear coupling

Outline

• The center support is installed between the center drive shaft and front drive shaft that are provided on the front frame.

• With the articulating frame, this part is constantly twisting from side to side. There is likely to be a large stress on the drive
shaft. The center support is used to transmit the power smoothly, to reduce the stress on the drive shafts, and, in this way,
to improve the durability of the drive shafts.

WA500-6 10-99 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

10-100 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm
No Check Item Criteria Remedy
Standard Tolerance Clearance
Standard Clearance
Clearance between Size Shaft Hole Limit
1
case and bearing – 0 (0).000 -0.036 (-0.0014) -0.018 to -0.061 -0.015
140 (5.51)
-0.018 (-0.0007) -0.061 (-0.0024) (-0.0007 to -0.0024) (-0.0006)
Clearance between
0.(0)00 -0.036 (-0.0014) -0.018 to - 0.061 -0.015
2 case and 130 (5.12)
-0.018 (-0.0007) -0.061 (-0.0024) (-0.0007 to - 0.0024) (-0.0006) Replace
bearing
Clearance between
+0.051 (+0.0020) –0 (0).000 0.032 – 0.066 0.029
3 coupling shaft and 80 (3.15)
+0.032 (+0.0013) -0.015 (-0.0006) (0.0013 – 0.0026 (0.0011)
bearing
Clearance between
+0.051 (+0.0020) –0.(0)000 0.032 – 0.066 0.029
4 coupling shaft and 75 (2.95)
+0.032 (+0.0013) -0.015 (-0.0006) (0.0013 – 0.0026 (0.0011)
bearing
Standard Size Tolerance Repair Limit
Wear of oil seal contact Repair by
5 –0 (0)000
surface 95 (3.74) –0.18 (–0.0071) chromium-
-0.087 (-0.0034)
plating or
Wear of oil seal contact –0.(0)000 replace
6 105 (4.13) –0.18 (–0.0071)
surface -0.087 (-0.0034)
End play of coupling
7 Preload 3.9 N•m (2.88 lbf ft) max. Replace
shaft

Torque Values

Designation N•m lbf ft

A 932 ±98 687.41 ±72.28

B 65.7 ±6.9 48.46 ±5.09

WA500-6 10-101 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Axle
Front Axle

10-102 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Oil filler plug

2. Front axle
3. Level plug
4. Front differential
5. Front brake
6. Final drive
7. Drain plug

Torque Values

Designation N•m lbf ft Designation N•m lbf in

AA 29.4 – 39.2 21.68 – 28.91 FF 3.9 – 6.9 34.52 – 61.07

BB 58.8 – 78.4 43.37 – 57.82

CC 343 – 441 252.98 – 325.26

DD 127 – 176 93.67 – 129.81

EE 490 – 608 361.40 – 448.44

GG 824 – 1030 607.75 – 759.69

WA500-6 10-103 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Rear Axle

10-104 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

1. Level plug
2. Oil filler plug
3. Rear axle
4. Rear differential
5. Rear brake
6. Final drive
7. Drain plug
8. Oil temperature sensor

Torque Values

Designation N•m lbf ft Designation N•m lbf in

AA 29.4 – 39.2 21.68 – 28.91 GG 3.9 – 6.9 34.52 – 61.07

BB 58.8 – 78.4 43.37 – 57.82

CC 127 – 176 93.67 – 129.81

DD 245 - 309 180.70 – 227.91

EE 343 – 441 252.98 – 325.26

FF 490 – 608 361.40 – 448.44

HH 59 – 74 43.52 – 54.58

JJ 29.4 – 49.0 21.68 – 36.14

WA500-6 10-105 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Differential
Front Differential

1. Pinion gear (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 38)

10-106 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Front Differential (with Limited Slip Differential)

1. Pinion gear (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 38)

WA500-6 10-107 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Rear Differential

1. Pinion gear (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 38)

10-108 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Rear Differential (with Limited Slip Differential)

1. Pinion gear (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 38)

WA500-6 10-109 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
★ This diagram shows the front differential mechanism.

10-110 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No Check Item Criteria Remedy

Standard Tolerance Clearance

Standard Clearance
Size Shaft Hole Limit
Clearance in side bearing
1 outer race of differential gear +0.012
0 (0)
assembly (+0.00047) -0.013 – 0.027
200 (7.87) -0.015 —
-0.013 (-0.0005 – 0.0011)
(-0.0006)
(-0.00051)
+0.090
Clearance in side bearing 0.(0)
(+0.0035) -0.065 to -0.115
2 inner race of differential gear 130 (5.12) -0.025 —
+0.065 (-0.0026 to -0.0045)
assembly (-0.0010
(+0.0026)
-0.050
Clearance in outer race of 0 (0)
(-0.0020) -0.020 to -0.079
3 bevel 215 (8.46) -0.030 —
-0.079 (-0.0008 to -0.0031)
pinion shaft bearing (-0.0012)
(-0.0031)
+0.045
Clearance in inner race of 0 (0)
(+0.0018) -0.023 to -0.065
4 bevel 100 (3.94) -0.020 —
+0.023 (-0.0009 to -0.0026)
pinion shaft bearing (-0.0008)
(+0.0009)
+0.21
Clearance in outer race of +0.063
(+0.0083) -0.037 to -0.21
5 bevel 165 (6.50) (+0.0025) —
+0.10 (-0.0015 to -0.0083)
pinion shaft bearing – 0 (0)
(+0.0039)
+0.039
–0.(0)
Clearance in inner race of (+0.0015) -0.020 to -0.054 Replace
6 75 (2.95) -0.015 —
bevel pinion shaft bearing +0.020 (-0.0008 to -0.0021)
(-0.0006)
(+0.0008)
-0.018
+0.057
Clearance between (-0.0007) 0.018 – 0.132
7 320 (12.60) (+0.0022) —
differential carrier and cage -0.075 (0.0007 – 0.0052)
–0.(0)
(-0.0030)
-0.13 +0.03
Clearance between spider
(-0.0051) (+0.0012) 0.021 to -0.11
8 and differential pinion 40 (1.57) —
-0.18 -0.02 (0.00083 to -0.00433)
bushing
-0.0071) -0.0008)
-0.025 +0.03
Clearance between pinion
(-0.0010 (+0.0012) 0.005 – 0.080
9 and differential pinion 46 (1.81)
-0.050 -0.02 (0.0002 – 0.0031)
bushing
(-0.0020) (-0.0008)
10 Backlash of bevel gear 0.30 – 0.45 (0.012 – 0.018)
11 Backlash of differential gear 0.36 – 0.51 (0.014 – 0.020)
12 End play of bevel pinion gear Max. 0.64 (0.025)
Free rotational torque of
13 Max. 8.34 N•m (6.15 lbf ft)
bevel gear
14 Rear runout of bevel gear 0.1 (0.004)
Clearance between bolt and
15 0.08 – 0.13 (0.003 – 0.005)
cap

WA500-6 10-111 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
★ This diagram shows the front differential mechanism.

10-112 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No Check Item Criteria Remedy
Standard Size Tolerance Repair Limit
1 Thickness of side gear washer
4 (0.16) ±0.05 (±0.0020) 3.8 (0.15)
2 Thickness of bevel pinion gear washer 3 (0.12) ±0.08 (±0.0031) 1.35 (0.05) Replace

0 (0)
3 Wear of oil seal contact surface 105 (4.13) —
-0.087 (-0.0034)

Torque Values

Designation N•m lbf ft

B 490 – 608 361.40 – 448.44

C 824 – 1030 607.75 – 759.69

D 27 – 34 19.91 – 25.08

E 245 – 309 180.70 – 227.91

F 1520 – 1910 1121.09 – 1408.74

G 107.8 – 147.0 79.51 – 108.42

WA500-6 10-113 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Outline

• The power from the engine is transmitted through the torque

converter, transmission, and drive shafts to the front and rear axles.

• In each axle, the direction of the power is changed by 90° and the
rotation speed is reduced by bevel pinion (1) and bevel gear (5).
The power is then transmitted through the differential mechanism
to axle shafts (2).

• The power of the axle shaft is further reduced in speed by the final
drive of the planetary gear type and then transmitted to the wheels.

While Machine is Traveling Straight

• While the machine is traveling straight, the right and left wheels
rotate at the same speed.

• Pinion gears (4) in the differential assembly do not rotate and the
power of carrier (6) is transmitted through pinion gears (4) and
side gears (3) to right and left axle shafts (2) evenly.

While Machine is Turning

• While the machine is turning, the right and left wheels rotate at
different speeds.

• Pinion gears (4) and side gears (3) in the differential assembly
rotate and transmit the power of carrier (6) to axle shafts (2),
depending on the difference in rotation speed between the right
and left wheels.

10-114 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Limited Slip Differential (if equipped)

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

WA500-6 10-115 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Operation of Limited Slip Differential

• The power from the transmission is transmitted through bevel gear (11), case (9), pressure rings (4), shaft (8), and pinion
(10) to side gears (7), and then distributed to the right and left shafts (6).

• The brake mechanism consisting of disc (2) and plate (3) is installed to the back side of each side gear (7). It generates
braking torque in proportion to the torque transmitted from pressure rings (4) to shaft (8).

• Since the brake torque restricts the rotation of side gears (7) and case (9), right and left side gears (7) cannot rotate freely;
thus the operation of the differential is restricted.

Generation of Braking Torque by Right and Left Side Gears (7)

Shaft (8) is supported on the cam surfaces made on the surfaces of

pressure rings (4) which are facing each other. The power (= torque)
transmitted from pressure rings (4) to shaft (8) is transmitted on the
cam surfaces. Force (Fa) to separate both pressure rings (4) is generated
by inclination of the cam surfaces in proportion to the transmitted
torque. Separating load (Fa) acts on the brake on the back side of each
side gear (7) to generate braking torque.

While Machine is Traveling Straight

1. When drive forces of right and left wheels are balanced.

[When the road conditions (coefficients of friction) under both
wheels and the wheel loads are even and the center of the load is at
the center of the bucket.]
The power from the transmission is distributed evenly by the
differential gears to the right and left. Under this condition, the slip
limits of the right and left wheels are the same. When the power
from the transmission exceeds the slip limits, both wheels slip and
the differential does not work. No load is applied to the brake on
the back side of each side gear.

10-116 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
2. When drive forces of right and left wheels are unbalanced.
[When the road conditions (coefficients of friction) under both
wheels and the wheel loads are uneven and either wheel slips more
easily.]
• Example 1: When either wheel is on soft ground in digging
work.
• Example 2: When either wheel is on snow and the other one is
on asphalt in snow removing work.
• Example 3: When the right and left wheel loads are
unbalanced in travel on a slope.
The power from the transmission is distributed evenly by the
differential gears to the right and left. If the distributed drive force
limits the wheel slip limit on the slipping side, the excess of the
drive force is transmitted through the brake on the back side of the
side gear and the case to the brake on the opposite side (locked
side) and given to the locked wheel.
Only when the excessive drive force exceeds the braking force, the
differential starts working.
On a road where either wheel slips easily, the drive force of the
limited slip differential is 1.82 times as great as that of the ordinary
differential.

The table shows the difference of wheel drive force in each type of differential when either wheel slips.

Wheel Drive Force

(Drive force of slipping wheel is 1)
Slipping Locked
Total (Ratio)
Wheel Wheel
Limited slip
differential 1 2.64 3.64 (1.82)
(if equipped)
Ordinary differential 1 1 2 (1)

While Machine is Turning

The differential gears in the limited slip differential operate similarly to

those in the ordinary differential. In this manner, a difference in
rotation speed between the outer and inner tires necessary for turning is
generated smoothly.

WA500-6 10-117 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
★ This diagram shows the front limited slip differential mechanism.

10-118 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No Check Item Criteria Remedy

Standard Tolerance Clearance

Standard Clearance
Size Shaft Hole Limit
Clearance in side bearing
1 outer race of differential gear +0.012
0 (0)
assembly (+0.00047) -0.013 – 0.027
200 (7.87) -0.015 —
-0.013 (-0.00051 – 0.00106)
(-0.0006)
(-0.00051)
+0.090
Clearance in side bearing –0 (0)
(+0.0035) -0.065 to -0.115
2 inner race of differential gear 130 (5.12) -0.025 —
+0.065 (-0.0026 to - 0.0045)
assembly (-0.0010)
(+0.0026)
-0.050
–0 (0)
Clearance in outer race of (-0.0020) -0.020 to -0.079
3 215 (8.46) -0.030 —
bevel pinion shaft bearing -0.079 (-0.0008 to -0.0031)
(-0.0012)
(-0.0031)
+0.045
–0 (0)
Clearance in inner race of (+0.0018) -0.023 to -0.065
4 100 (3.94) -0.020 —
bevel pinion shaft bearing 0.023 (-0.0009 to -0.0026)
(-0.0008)
(0.0009)
+0.21
+0.063
Clearance in outer race of (+0.0083) -0.037 to -0.21
5 165 (6.50) (+0.0025) —
bevel pinion shaft bearing +0.10 (-0.0015 to -0.0083)
–0 (0)
(+0.0039)
+0.039
–0 (0) Replace
Clearance in inner race of (+0.0015) -0.020 to -0.054
6 75 (2.95) -0.015 —
bevel pinion shaft bearing +0.020 (-0.0008 to -0.0021)
(-0.0006)
(+0.0008)
-0.018
+0.057
Clearance between (-0.0007) 0.018 – 0.132
7 320 (12.60) (+0.0022) —
differential carrier and cage -0.075 (0.0007 – 0.0052)
–0 (0)
(-0.0030)
8 Backlash of bevel gear 0.30 – 0.45 (0.012 – 0.018)
9 Backlash of differential gear 0.36 – 0.51 (0.014 – 0.020)
10 End play of bevel pinion gear Max. 0.64 (0.025)
Free rotational torque of
11 Max. 8.34 N•m {0.85 kgm} (6.15 lbf ft)
bevel gear
12 Rear runout of bevel gear 0.1 (0.0039)
Clearance between bolt and
13 0.08 – 0.13 (0.0031 – 0.0051)
cap
Standard Size Tolerance Repair Limit
14 Thickness of plate 3.4 (0.134)
±0.02 (±0.0008) 3.6 (0.1417)
3.5 (0.138)
15 Thickness of disc 3.2 (0.126) ±0.07 (±0.0028) 3.915 (0.154)
Clearance between disc and
16 0.2 – 0.8 (0.0079 – 0.0315)
plate (end play)

WA500-6 10-119 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No Check Item Criteria Remedy
Standard Size Tolerance Repair Limit
3.75 (0.1476)
17 Thickness of washer
4.0 (0.1575) ±0.05 (±0.0020) 3.8 (0.1496)
Replace
4.25 (0.1673)
Wear of coupling seal sliding 0 (0)
18 105 (4.134) —
surface -0.087 (-0.0034)

Torque Values

Designation N•m lbf ft

B 490 – 608 361.40 – 448.44

C 824 – 1030 607.75 – 759.69

D 27 – 34 19.91 – 25.08

E 245 – 309 180.70 – 227.91

F 1520 – 1910 1121.09 – 1408.74

G 107.8 – 147.0 79.51 – 108.42

10-120 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Final Drive

1. Axle shaft
2. Sun gear (Number of teeth: 17)
3. Ring gear (Number of teeth: 70)
4. Planetary carrier
5. Planetary gear (Number of teeth: 26)
6. Wheel

WA500-6 10-121 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

10-122 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

Unit: mm (in)
No Check Item Criteria Remedy
Standard Tolerance Clearance
Standard Clearance
Size Shaft Hole Limit
Clearance between planetary +0.029
1 +0.013
shaft and bearing (+0.0011) -0.003 to -0.029
50.8 (1.999) (+0.0005) —
+0.016 (-0.0001 to -0.0011)
+0 (0)
(+0.0006)
+0.063
+0.025
Clearance between ring gear hub 220.662 (+0.0025) –0.009 to -0.063
2 (+0.0010) —
and bearing (8.687) +0.034 (-0.0004 to -0.0025)
0 (0)
(+0.0013)
Thickness of ring gear mounting Standard Size Tolerance Repair Limit
3
retainer 22 (0.866) ±0.1 (±0.0039) 21.6 (0.850)
Backlash of planetary gear and
4 0.19 (0.0075)
sun gear
Backlash of planetary gear and
5 0.20 (0.0079)
ring gear Replace
Standard shim thickness of wheel
6 2.3 (0.0906)
hub
Standard Tolerance Clearance
Standard Clearance
Size Shaft Hole Limit
Clearance between wheel hub -0.036
7 +0.051
and bearing 314.325 (-0.0014) -0.036 to -0.119
(+0.0020) —
(12.375) -0.068 (-0.0014 to -0.0047)
+0 (0).000
(-0.0027)
-0.045
+0.072
Clearance between tube and (-0.0018) 0.045 – 0.146
8 190 (7.48) (+0.0028) —
bearing -0.074 (0.0018 – 0.0057)
+0 (0).000
(-0.0029)
-0.063
+0 (0)
Clearance between wheel hub (-0.0025) -0.059 to -0.095
9 260 (10.24) -0.004 —
and bearing -0.095 0.0023 to -0.0037)
(-0.00016)
(-0.0037)

Torque Values

Designation N•m lbf ft

B 44.1 – 53.9 32.53 – 39.75

C 245 – 309 180.70 – 227.91

D 98 – 123 72.28 – 90.72

E 157 – 196 115.80 – 144.56

F 27 – 34 19.91 – 25.08

G 58.8 – 78.4 43.37 – 57.82

H 59 – 74 43.52 – 54.58

WA500-6 10-123 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Outline

The final drive is reduced by the planetary gear unit in order to gain
increased force and then drive force is transmitted to the tires.

Operation

Power transmitted from the differential mechanism to sun gear (2)

through axle shaft (1) is transmitted to planetary gear (5). The planetary
gear rotates inside fixed ring gear (3) to transmit reduced rotation to
planetary carrier (4). The power is transmitted to wheel (6) mounted
onto the planetary carrier.

10-124 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

STEERING SYSTEM
Steering Piping Diagram

1. Steering cylinder (right) 6. Steering pump

2. Steering valve 7. EPC and brake pump
3. Stop valve (right) 8. Steering control valve
4. Work equipment pump 9. Stop valve (left)
5. Hydraulic tank 10. Steering cylinder (left)

WA500-6 10-125 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Steering Column

10-126 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

1. Steering wheel
2. Steering column
3. Joint
4. Steering valve

Unit: mm (in)
No Check Item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between Size Clearance Limit
Shaft Hole
5 steering shaft and column Replace
bearing –0 (0) +0.15 (+0.006) 0.05 – 0.23
19 (0.75) 0.4 (0.016)
-0.08 (-0.003) -0.05 (-0.002) (0.002 – 0.009)

Torque Values

Designation N•m lbf ft

C 49 – 62 36.14 – 45.73

D 12 – 25 8.85 - 18.44

E 29.4 ±2.9 21.68 ±2.14

F 30 – 39 22.13 – 28.76

WA500-6 10-127 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Steering Control Valve

1. Relief valve A. To steering cylinder

2. Relief valve B. To steering cylinder
3. Relief valve Pa. From steering valve
4. Unload spool Pb. From steering valve
5. Main spool P. From steering pump
PR. From steering pump (LS line)
T1. Return
T2. Drain

10-128 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Unit: mm (in)
No Check Item Criteria Remedy
Standard Size Repair Limit
Installed Installed Allowable
Free Length Free Length
1 Steering spool return spring Length Load Load
56.9 N 45.1 N
37.2 (1.46) 32.0 (1.26) —
(12.79 lbf) (10.14 lbf)
2.9 N 2.5 N Replace
2 Load check valve spring 20.9 (0.82) 18.3 (0.72) —
(0.65 lbf) (0.56 lbf)
147.1 N 120.6 N
3 Unload spool return spring 69.7 (2.74) 68.5 (2.70) —
(33.07 lbf) (27.11 lbf)
182.4 N 145.1 N
4 Relief valve spring 24.0 (0.94) 22.19 (0.87) —
(41.01 lbf) (32.62 lbf)

WA500-6 10-129 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
Operation of Steering Control Valve

When steering spool is at neutral position

• The oil from the steering pump is conducted to port (A).

• When the steering spool is at neutral, pressure-receiving chamber (II) is connected to the drain circuit through orifice (b)
and notch (c) is closed.

• Closed notch (c) increases pressure of oil in port (A). This increased pressure is then led through orifice (a) to
pressure-receiving chamber (I) to drive demand spool (1) to the left.

• As pressure of pressure-receiving chamber (I) reaches a specific level (this level is set from spring (3)), notch (f) opens to
conduct oil from the steering pump to the drain circuit. Notch (g) also opens at this time to lead oil from the steering pump
to low-pressure relief valve (4).

• The pressure generated at low-pressure relief valve (4) is input to the steering pump as the pilot pressure (LS pressure) to
be used for controlling the steering pump flow rate.

10-130 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
When steering spool is in operation

• Operating the steering conducts oil from the steering valve to steering spool (2), pushing steering spool (2) to the right.
Notch (c) opens as pressure- receiving chamber (II) and drain circuit are disconnected.

• This operation increases pressure in pressure-receiving chamber (II), thereby moving demand spool (1) to the right.

• The oil being conducted through notches (c) and (d) pushes load check valve (5) and then flows to the cylinder. Return oil
from the cylinder flows to the drain circuit through notch (e).

• At this time, the pressure of oil before passing through notch (c) is conducted to pressure-receiving chamber (I) and the
pressure after passing through notch (c) is led to pressure-receiving chamber (II). Demand spool (1) operates so that the
difference in pressures before and after passing through notch (c) may be maintained at constant level. The flow rate to the
cylinder port depends on the opening of notch (c). These differences in the pressure are set from spring (3).

WA500-6 10-131 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
Neutral

• Since the steering wheel is not operated, steering spool (2) does not move.

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

• Demand spool (1) moves to the left as the pressure in port (A) increases and part of the oil from the steering pump is
drained through port (B) of the spool and the other is conducted to the low-pressure relief valve through port (C).

10-132 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
Turning right

• Turning the steering wheel to the right activates the steering valve, moving steering (2) to the left.

• The oil from the steering pump enters port (A) and then enters steering spool (2) through demand spool (1). This flow
pushes open load check valve (6) of the spool. The oil is conducted to the bottom side of the left cylinder and the rod side
of the right cylinder to turn the machine to the right.

• The oil returned from the left and right cylinders is drained through the passage inside the steering spool.

WA500-6 10-133 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
Turning left

• Turning the steering wheel to the left activates the steering valve, moving steering (2) to the right. The oil from the
steering pump enters port (A) and then enters steering spool (2) through demand spool (1). This flow pushes open load
check valve (5) of the spool. The oil is conducted to the rod side of the left cylinder and the bottom side of the right
cylinder to turn the machine to the left.

• The oil returned from the left and right cylinders is drained through the passage inside the steering spool.

10-134 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Steering Relief Valve

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

Function

• The steering relief valve is contained in the steering valve. This valve is used to set the maximum pressure of the steering
circuit for the steering valve in operation.

• If the pressure of the steering circuit increases beyond the relief valve-specified level while the steering valve is in
operation, oil is relieved from the valve. The relief activates the spool of the demand valve, draining the oil to the steering
circuit.

WA500-6 10-135 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
Operation of Steering Relief Valve

• As the pressure of the circuit increases and reaches the level being set from adjustment screw (1) and spring (2), pilot
poppet (3) opens to drain the oil.

• This breaks down the balance between pressure-receiving chambers (I) and (II) and, as the result, demand spool (4) is
driven to the left.

• The movement of demand spool (4) drains oil in the steering pump, preventing the steering circuit pressure from
increasing beyond the set value.

10-136 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Safety Suction Valve

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

Function

The safety valve installed on the steering valve has two functions.

• The safety valve function protects the steering cylinder or hydraulic piping from damages when an abnormal pressure is
generated due to an impact applied to the steering cylinder while the steering valve is at neutral. In such a case, abnormal
pressure is relieved from this valve.

• The suction valve function prevents a vacuum state from occurring in the circuit when negative pressure is generated on
the steering cylinder side.

Operation of Safety Valve

• Port (A) and port (B) are connected to the cylinder circuit and
drain circuit, respectively. After being conducted through
poppet (1) hole, the oil works on the different areas of
diameters (d1) and (d2). Check valve poppet (3) and safety valve
poppet (2) are securely seated.

• As the pressure of port (A) reaches the level specified from the
safety valve, pilot poppet (4) opens. The oil flows around pilot
poppet (4) and then flows to port (B) through the hole.

WA500-6 10-137 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
• The opening of pilot poppet (4) decreases the pressure on the
backside of poppet (1), starting the movement of poppet (1). By
this movement, pilot poppet (4) is seated in its place.

• Since the inside pressure is lower than that of port (A), safety valve
poppet (2) opens. As the result, the oil is conducted from port (A)
to port (B) and abnormally high pressure is prevented from being
generated.

Operation of Suction Valve

• As negative pressure is generated on port (A), check valve poppet

(3) opens due to the difference in areas between diameters (d1) and
(d3).

• As the result, the oil is conducted from port (B) to port (A),
preventing a vacuum from occurring.

10-138 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Steering Valve

1. Needle bearing 7. Center pin

2. Centering spring 8. Sleeve
3. Drive shaft 9. Spool
4. Valve body 10. Stator
5. Rotor 11. Lower cover
6. Cover

WA500-6 10-139 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
Outline

• The steering valve is directly connected to the shaft of the steering

wheel.

• The steering wheel operation activates the steering valve using the
oil from the PPC pump as the pilot pressure. The oil from the
steering valve is conducted through the steering valve to either the
left or right steering cylinders to determine the machine direction.

• The steering valve is roughly divided into spool (9) and sleeve (8)
which has the rotary selecting function. This valve is configured
with the Gerotor set (combination of rotor (5) and stator (10)). In
the normal steering operation, this set functions as a hydraulic
motor. If the supply of oil is stopped due to a failure on the steering
pump or engine, it functions as a hand pump to supply pilot
pressure to the steering valve.

Structure

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

wheel. It is also connected to sleeve (8) through center pin (7) (it is
detached from the spool when the steering wheel is at Neutral) and
the centering spring.

• The top of drive shaft (3) is engaged with center pin (7) and thus
combined with sleeve (8). The bottom is engaged with the spline
of rotor (5) of the Gerotor set.

• Valve body (4) has four ports. These ports are respectively
connected to the pump circuit, tank circuit, steering cylinder head
side and bottom side. The ports on the pump side and tank side are
connected to the check valve in the body. If the pump or engine
fails, this check valve permits suction of oil directly from the tank.

10-140 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
Connection of Hand Pump and Sleeve

• The connections of suction and discharge openings of the Gerotor

and sleeve ports are shown in the figure to the right.

• If the steering wheel is turned to the right, ports (a), (c), (e), (g), (i),
and (k) are connected to the pump side by the vertical grooves of
the spool. Similarly, ports (b), (d), (f), (h), (j), and (l) are connected
to the steering cylinder head side.

• Under the condition in figure SBW00725, ports (1), (2), and (3)
are in the discharge state of the Gerotor set 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.

• Figure SBW00726 shows the state after turning the steering wheel
90° from the previous condition. Here, ports (1), (2), and (3) are
set to the suction state and connected to ports (i), (k), and (c). On
the other hand, ports (5), (6), and (7) are set to the discharge state
and connected to ports (d), (f), and (h).

WA500-6 10-141 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
• As shown previously, the ports in the discharge state of the Gerotor
are connected to the ports which are connected to the steering
cylinder. The ports in the suction state are connected to the pump
circuit.

• Delivery adjustment tailored to the steering angle of the steering

wheel
The internal gear of the Gerotor advances by one tooth as the
steering wheel rotates by 1/7 of a turn and discharges the oil from
the pump according to the steering angle of the steering wheel.
The discharge amount varies in proportion to the steering angle of
the steering wheel.

Role of Centering Spring

• Centering spring (2) is configured with three flat springs and four
plate springs being laminated. This spring is assembled between
spool (9) and sleeve (8) (see figure to the right). As the steering
wheel is turned, the spool compresses the spring, generating a
difference in rotation angle (angular displacement) between the
spool and sleeve.

• The spring connects the spool and the port of the sleeve and sends
oil to the cylinder. As rotation of the steering wheel is stopped,
rotation of the Gerotor is also stopped; the flow of oil to the
cylinder is also stopped. This results in an increase in the oil
pressure.

• The center spring is used to avoid trouble. As rotation of the

steering wheel is stopped, the center spring turns the sleeve by the
difference in rotation angle (angular displacement) between the sleeve and spool in order to return the steering wheel to
the Neutral position.

10-142 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Stop Valve

1. Boot A. From steering valve

2. Wiper B. To steering control (demand) valve
3. Seal DR: Drain
4. Poppet
5. Spring
6. Spool
7. Spring

WA500-6 10-143 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Joystick Steering Lever Linkage (if equipped)

Joystick Steering System

1. Joystick (steering lever)

2. HI/LOW selector switch
3. Console fore-aft adjustment lever
4. Joystick ON/OFF switch
5. Lock
6. Steering lock switch
7. Pad
8. Console tilt lever
9. Armrest adjustment lever
10. Lock cable

10-144 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Steering Cylinder

Unit: mm (in)
No Check Item Criteria Remedy
Clearance between Standard Tolerance Standard Clearance
steering cylinder rod, Size Shaft Hole Clearance Limit
1 bushing at frame
connection, and –0 (0).000 +0.174 (+0.0069) 0.100 – 0.248
65 (2.56) —
mounting pin -0.074 (-0.0029) +0.100 (+0.0039) (0.0039 – 0.0098)
Replace
Clearance between
steering cylinder bottom,
–0 (0).000 +0.174 (+0.0069) 0.100 – 0.248
2 bushing at frame 65 (2.56) —
-0.074 (-0.0029) +0.100 (+0.0039) (0.0039 – 0.0098)
connection, and
mounting pin
Standard Clearance
Boss Width Hinge Width (clearance between
Steering cylinder and a + b) After shim
3
front frame connection adjustment
75 ±1.2 79 ±1 1.8 – 6.2
Max. 0.5
(2.95 ±0.05) (3.11 ±0.04) (0.07 – 0.24)
(0.020)
Steering cylinder and 75 ±1.2 79 ±1 1.8 – 6.2
4
rear frame connection (2.95 ±0.05) (3.11 ±0.04) (0.07 – 0.24)

WA500-6 10-145 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Emergency Steering (if equipped)

Piping Diagram

10-146 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

1. Diverter valve
2. Steering pump
3. Hydraulic tank
4. Emergency steering pump
5. Transmission

WA500-6 10-147 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Diverter Valve (for emergency steering)

10-148 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

1. Check valve
2. Check valve
3. Check valve
4. Check valve
5. Spool
6. Valve body

A. From emergency steering pump

B. From emergency steering pump
D. To steering demand valve
L. Sensor mounting port
P. From steering pump
S. From hydraulic tank
T. To hydraulic tank

Function

Where steering is disabled because the engine stops or the steering pump seizes while the machine is traveling, this function
enables you to operate the steering wheel by utilizing the rotations of the transmission to operate the emergency steering
pump.

WA500-6 10-149 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

10-150 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Unit: mm (in)
No Check Item Criteria Remedy
Standard Tolerance Standard Clearance
Size Shaft Hole Clearance Limit
Clearance between body and -0.008 +0.015
1
spool (-0.0003) (+0.0006) 0.017 – 0.027
26 (1.02) —
-0.012 +0.009 (0.0007 – 0.0011)
(-0.0005) (0.0004)
Standard Size Repair Limit
Free Installed Installed Installed Replace
Free Length
2 Spool return spring Length Length Load Load
91.2 N 86.3 N
92 (3.62) 64 (2.52) 90.5 (3.56)
(20.50 lbf) (19.40 lbf)
4.0 N 3.8 N
3 Check valve spring 54.4 (2.14) 38 (1.50) 37.4 (1.47)
(0.90 lbf) (0.85 lbf)
1.96 N 1.84 N
4 Check valve spring 54.5 (2.15) 46.5 (1.83) 53.6 (2.11)
(0.44 lbf) (0.41 lbf)

Torque Values

Designation N•m lbf ft

B 30.5 ±3.5 22.50 ±2.58

C 66.5 ±7.5 49.04 ±5.53

D 58.8 43.37

WA500-6 10-151 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

Operation
★ If the pump and engine are normal.

• If the steering pump and engine are operating normally, the steering pump is operated by the engine and oil can be sent to
the steering valve to enable steering.

• The emergency steering pump is operated by the transmission and push-open check valve (2) from port (A) of diverter
valve (1) to direct the flow toward port (B).

Spool (3) is pressed to the left as pressure oil flows from the steering pump toward port (D).
For that reason, oil at port (B) flows to port (C) to be drained to the hydraulic tank.

10-152 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM

WA500-6 10-153 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING SYSTEM
★ If the machine is running and the pump or engine has failed.

• In a case where the machine is running and the pump or engine has
failed, rotations from the tires operate the emergency steering
pump through the transmission.

No pressure oil appears at port (D) because the steering pump is

not operating. For that reason, spool (3) is pressed by spring (4) to
the right.
The oil from the emergency steering pump goes through port (A)
and port (B) and then flows to the steering valve to enable steering.
★ The emergency steering pump is enabled for normal and reverse
rotations.

10-154 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

BRAKE SYSTEM
Piping Diagram

1. Accumulator charge valve 11. Front brake (right)

2. Brake valve 12. Front brake (left)
3. EPC and brake pump 13. Rear brake (right)
4. Slack adjuster (rear) 14. Rear brake (left)
5. Emergency parking brake cancel valve 15. Brake valve (right)
6. Slack adjuster (front) 16. Brake valve (left)
7. Transmission 17. Emergency brake switch (front)
8. Accumulator 18. Emergency brake switch (rear)
9. Accumulator (rear brake) 19. Hydraulic tank
10. Accumulator (front brake)

WA500-6 10-155 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

10-156 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

MEMORANDUM

WA500-6 10-157 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Brake Valve

10-158 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

A. To front brake
B. To rear brake

PA. From accumulator charge valve ACC1 port

PB. From accumulator charge valve ACC2 port
TA. Drain port
TB. Drain port

1. Rod
2. Piston
3. Spool (for rear)
4. Spool (for front)

Unit: mm (in)
Standard Size Repair Limit
No Check Item Free Installed Installed Free Installed Installed Remedy
Length Length Load Length Length Load
71.7 58.6 95.8 N 66.1
5 Return spring — —
(2.82) (2.31) (21.54 lbf) (2.60)
11 10 22.8 N
6 Control spring — — —
(0.43) (0.39) (5.13 lbf)
51.2 49.7 41.1 N
7 Control spring — — —
(2.02) (1.96) (9.24 lbf)
Replace
31
8 Control spring — — — — —
(1.22)
23.5
9 Control spring — — — — —
(0.93)
40.1 27.5 17.2 N
10 Return spring — — —
(1.58) (1.08) (3.87 lbf)

WA500-6 10-159 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
Outline

• 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, operating the brake.

• The left side and right side brake pedals are mechanically interlocked. Pressing one of the pedals operates the other pedal
at the same time.

• Working with the transmission cutoff switch, the brakes operate the transmission control valve electrically to set the
transmission to the neutral position.

Operation

When brake operated

• Pedal (1) pressing effort is transmitted to spool (4) through rod (2), piston (3), and spring (5).

• As spool (4) is pushed to the right, connection is cut off between port (A) and port (T). The oil from the pump and
accumulator is conducted to port (A) through port (PA) to operate the front brake cylinder.

• The pressing effort transmitted to spool (4) is further transmitted through plunger (7) to spool (6).

• As spool (6) is pushed to the right, connection is cut off between port (B) and port (T). The oil from the pump and
accumulator is conducted to port (B) through port (PB) to operate the rear brake cylinder.

10-160 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
When one side of brake alone is operated

(when the other brake failed)

• Even when only one of the brakes remains operable due to leakage of oil in the front or rear brake system, brake pedal (1)
pressing effort mechanically moves spool (4) and spool (6) to the right.

• The oil from the pump is normally supplied to the normal brake piston, enabling it to continue the operation. The brake,
therefore, is capable of stopping the machine as needed to ensure the intended safety level.

WA500-6 10-161 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
Balancing Operation

• If the front brake cylinder is filled with oil and oil pressure between port (PA) and port (A) increases, the oil is conducted
from orifice (e) of spool (4) to chamber (E).

• The oil pushes spool (4) resisting against spring (5), disconnecting ports (PA) and (A).

• Since port (A) is kept disconnected from port (T), the brake is kept operated by the oil pressure applied to the brake
cylinder.

• If ports (PA) and (A) of spool (4) are disconnected, the front brake cylinder is filled with the oil and the pressure in the line
between ports (PB) and (B) rises simultaneously. The oil then flows through orifice (f) of spool (6) to chamber (F).

• The oil pushes up spool (6) by the moving distance of spool (4) and disconnects port (PB) from port (B).

• Since port (B) is kept disconnected from port (T), the brake is kept operated by the oil pressure applied to the brake
cylinder.

• The operating force of the front brake circuit (port A side) is balanced against the pedal pressing effort and the operating
force of the rear brake circuit (port B side) is balanced against that of the front brake circuit (port A side).

• When spools (4) and (6) are moved to the stroke end, ports (PA) and (A) connect completely; ports (PB) and (B) also
connect completely. As a result, the oil pressure in the front and rear brake cylinders is equal to the oil pressure from the
pump.

• The braking force can be adjusted by adjusting the pedal pressing effort until spools (4) and (6) are moved to the stroke
end.

10-162 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
As brake is released

• If pedal (1) is released, the operating pressure being applied to spool (4) is reduced. Spool (4) is pushed back by the back
pressure on the brake cylinder and the tension of the spool return spring.

• Ports (A) and (T) are connected and the back pressure oil on the brake cylinder is drained through port (T); the front brake
is released.

• In the same manner as spool (4) was pushed back, spool (6) is also pushed back by the back pressure on the brake cylinder
and the spool return spring tension.

• Ports (B) and (T) are connected and the back pressure oil on the brake cylinder is drained through port (T); the rear brake
is released.

WA500-6 10-163 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Slack Adjuster

1. Cylinder A. Inlet port

2. Check valve B. Outlet port‘
3. Piston
4. Spring
5. Bleeder

Function

The slack adjuster is installed on the brake oil line leading to the brake piston from the brake valve, and functions to keep the
time lag during brake operation at a fixed level.

Specifications
Hydraulic oil pressure of piston:
. . . . . . . . . . . . . . . . . . . . . . . . 9.8 (+9.8/0) kPa (1.42 (+1.42/0) psi)
Check valve cracking pressure:
. . . . . . . . . . . . . . . . . . . . . . . . . 0.93 ±0.05 MPa (134.89 ±7.25 psi)
Check valve closing pressure:
. . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 ±0.05 MPa (85.57 ±7.25 psi)

10-164 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Unit: mm (in)
No Check Item Criteria Remedy
Standard Tolerance Clearance
Standard Clearance
Size Shaft Hole Limit
Clearance between body
6 +0.074
and piston -0.030 (-0.0012) 0.030 – 0.150 0.25
55 (2.17) (+0.0029)
-0.076 (-0.0030) (0.0012 – 0.0059) (0.010)
+0 (0).000
Standard size Repair limit
Replace
Free Allowable
Installed Length Installed Load Free Length
7 Slack adjuster spring Length Load
39.2 N
198 (7.80) 60 (2.36)
(8.81 lbf)
66.7 N
8 Spring 39.2 (1.54) 33 (1.30)
(14.99 lbf)

Torque Values

Designation N•m lbf ft Designation N•m lbf in

A 50 – 65 36.89 – 47.94 C 7–9 61.96 – 79.66

B 60 – 75 44.25 – 55.32

WA500-6 10-165 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
Operation

When the brake pedal is pressed down

• Before the brake is pressed down, piston (4) is restored equal to the
amount of stroke (S) (a full stroke). When the brake pedal is
pressed down, oil discharged from the brake valve branches into
right and left cylinders (2) from port (P) of the slack adjuster to
move piston (4) equal to the amount of stroke (S) to the right and
the left.

• This move causes brake piston (7) to move equal to stroke (S). At
this time, the relationship between brake piston (7) and the disc is
that the clearance is reduced to zero and no braking force is
generated.

• As the brake valve is kept pressed down further, oil pressure from
the brake valve exceeds the specified value to open check valve
(3). Port (C) is imposed pressure to function as the braking force.
The time lag when the brake is in operation is maintained at the
same value.

When the brake pedal is released

• When the brake is released, return spring (8) of the brake piston (7)
equal to the amount of oil of stroke (S) and the brake returns to its
released state. In other words, return stroke (T) of brake piston (7)
depends on the amount of oil of piston stroke (S). The braking time
lag stays the same regardless of the amount of wear of the brake
disc.

10-166 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Accumulator Charge Valve

A1. To work equipment valve

A2. To Orbitrol
ACC1. To brake valve PA
ACC2. To brake valve PB
PP. From pump
T. Drain

WA500-6 10-167 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

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

Function

• The accumulator charge valve keeps the oil pressure from the pump to the set pressure and stores it in the accumulator.

• If the oil pressure rises above the set pressure, the oil from the pump is led to the drain circuit to reduce the load on the
pump.

10-168 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
Operation

★ When oil is not supplied to accumulator (Cutout state)

• Since the pressure at port (B) is higher than the set pressure of
relief valve (R1), piston (2) is forced to move upward by the
hydraulic pressure of port (B). As this move opens poppet (1),
port (C) and port (T) are shorted.

• As the right-most spring chamber of spool (6) leads to port (C) of

relief valve (R1), tank pressure prevails.

• Oil from the pump enters port (P) and pushes spool (6) to the right
with a low pressure equivalent to the load of spring (5), and then
flows from port (A) to the steering valve and the work equipment
valve.

• At the same time, it flows to the tank through orifices (7), (4), and
(3).

★ When oil is supplied to accumulator

1. Cut-in state
• If the pressure at port (B) drops below the set pressure of relief
valve (R1), piston (2) is returned downward by the tension of
spring (8). This causes valve seat (9) to closely contact
poppet (1) to disconnect port (C) from port (T).
• The right-hand side spring chamber of spool (6) also gets
shuttered off from port (T) to increase pressure, leading
pressure at port (P) to rise as well.
• When pressure at port (P) exceeds the pressure at port (B)
(accumulator pressure), oil supply to the accumulator starts.
This timing is determined by the area size of orifice (7) and
the pressure differential before and after (equivalent to the
load of spring (5)). A fixed amount of oil is supplied
regardless of the engine speed; the remaining amount flows to
port (A).

WA500-6 10-169 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
2. When pressure reaches cut-out pressure.
• When pressure at port (B) (accumulator pressure) reaches the
set pressure for relief valve (R1), poppet (1) leaves valve
seat (9) to generate a flow of oil, creating the relief operation.
• The relief operation creates vertical pressure differential for
piston (2). Piston (2) moves upward to force poppet (1) to
open, shorting ports (C) and (T).
• As the right-most spring chamber of spool (6) leads to port (C)
of relief valve (R1), tank pressure prevails.
• Since the pressure at port (P) also drops to the level equivalent
to the load of spring (5), oil supply to port (B) is stopped as
well.

Safety Relief Valve (R3)

• If the pressure at port (P) (pump pressure) rises above the set
pressure for relief valve (R3), the oil from the pump resists
spring (10) and pushes ball (11) upward to cause oil to flow into
the tank circuit, thus protecting the circuit by defining the
maximum pressure for the brake circuit.

10-170 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

PPC Relief Valve

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

Function

The PPC relief valves are located between the EPC brake pump and the EPC valve and between work equipment units. When
the PPC valve is not operating or when any abnormal pressure has occurred in the EPC circuit, oil from the pump is relieved
from this valve in order to protect the pump and the circuit from damage.

WA500-6 10-171 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
Operation

• The relief valve is installed on the charge valve. Port (A) is

connected to the pump circuit and port (C) to the drain circuit.

• Oil runs through the orifice of main valve (1) and fills port (B).

• Pilot poppet (4) is seated on valve seat (3).

• When pressure at ports (A) and (B) reaches the set pressure, pilot
poppet (4) opens and oil pressure at port (B) is carried from
port (D) to port (C), causing pressure at port (B) to drop.

• When pressure at port (B) drops, the orifice of main valve (1)
functions to allow a pressure differential to occur at ports (A) and
(B), causing main valve (1) to open due to pressure from port (A).
Oil in port (A) is drained to port (C) for relief.

10-172 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Accumulator (for Brake)

Function

The accumulator is installed between the charge valve and brake valve.
The space between cylinder (3) and free piston (4) is filled with
nitrogen gas. The nitrogen gas absorbs the hydraulic pulses generated
by the hydraulic pump and secures the braking force and operability
when the engine stops by utilizing its compressibility.

Specifications
Gas used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nitrogen gas
Amount of gas . . . . . . . . . . . . . . . . . . . . . . . . 3,750 cc (228.84 in3)
Charging pressure . . . . . . . . . . . . . . . . . . . 3.4 ±0.1 MPa (at 20°C)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (493.13 ±14.50 psi) (at 68° F)

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

WA500-6 10-173 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Brake

1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear
6. Hub gear
7. Plate
8. Disc

10-174 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

WA500-6 10-175 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Unit: mm (in)
No Check Item Criteria Remedy
Standard Size Repair Limit
Free Installed Installed Free Allowable
9 Return spring Length Length Load Hole Length Load
104.8 452 N 102.7 338 N
96.5 (3.80)
(4.13) (101.61 lbf) (4.04) (75.99 lbf)
Standard Size Tolerance Repair Limit
10 Plate thickness
2.4 (0.094) — 2.15 (0.085)
11 Thickness of disc 5.1 (0.201) — 4.6 (0.181)
12 Assembled thickness of plate discs 84.9 (3.34) — 79.4 (3.13)
–0 (0).000
13 Wear of seal contact surface 430 (16.93) — Replace
-0.155 (-0.006)
+0.097 (+0.004)
14 Wear of piston seal contact surface 420 (16.54) —
+0 (0).000
+0.097 (+0.004)
15 Wear of piston seal contact surface 455 (17.91) —
+0 (0).000
Standard Strain Repair Limit
16 Strain of plate contact surface
0.5 (0.020) 0.7 (0.028)
17 Strain of disc contact surface 0.45 (0.018) 0.65 (0.026)
18 Backlash of outer gear and plate 0.24 – 0.72 (0.009 – 0.028)
19 Backlash of inner gear and disc 0.19 – 0.62 (0.007– 0.024)

Torque Values

Designation N•m lbf ft

AA 157 – 196 115.80 – 144.56

BB 98 – 123 72.28 – 90.72

10-176 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
Function

• All the four wheels are equipped with a main brake, which is a
wet-type multi-disc brake.

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

• When the brake pedal is released, back pressure on brake

piston (4) is released and the force of return spring (2) moves the
piston, in the direction shown by an arrow mark, to release the
brake.

WA500-6 10-177 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Parking Brake Control

10-178 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

1. Parking brake switch

2. Parking brake emergency release switch
3. Transmission control valve
4. Parking brake solenoid valve
5. Transmission (containing parking brake)

Outline

• The parking brake is installed at the output shaft with the wet-type, multi-disc brake being built in the transmission. Using
the pressing force of the spring, it mechanically operates to relieve the oil pressure.

• If parking brake switch (1) installed to the operator’s cab is turned ON, parking brake solenoid valve (4) installed to
transmission control valve (3) shuts off the oil pressure and the parking brake is applied. If parking brake switch (1) is
turned OFF, the hydraulic force in the cylinder releases the parking brake.

• The neutralizer relay cuts off current to the transmission solenoid valve as long as operation of the parking brake is
continued in order to maintain the transmission at the neutral position.

• Parking brake emergency release switch (2) is provided to permit movement of a machine currently stopped due to an
engine or drive system problem (parking brake of the machine is enabled).

WA500-6 10-179 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Parking Brake

Outline

• The parking brake is a wet-type, multi-disc brake operated mechanically with springs (2) and (3) to apply braking to
output shaft (1).

• The tension of springs (2) and (3) presses disc (7) against plate (6) with piston (4) to stop output shaft (1).

• When releasing, the oil pressure from parking brake oil port (5) operates piston (4) to release the pressing force being
applied to disc (7) and plate (6).

10-180 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

1. Output shaft
2. Spring (outside)
3. Spring (inside)
4. Piston
5. Parking brake oil port
6. Plate
7. Disc
8. Wave spring

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Repair Limit
Free Installed Installed Free Installed
9 Parking brake spring (outside) Length Length Load Length Load
1,266 N 1,203 N
94 (3.70) 72.6 (2.86) 91.2 (3.59)
(284.61 lbf) (270.45 lbf)
662 N 630 N
10 Parking brake spring (inside) 94 (3.70) 72.6 (2.86) 91.2 (3.59)
(148.82 lbf) (141.63 lbf)
Standard Size Tolerance Repair Limit Replace

4.0 (0.16) ±0.05 (0.002) 3.9 (0.15)

11 Plate Thickness
7.0 (0.28) ±0.05 (0.002) 6.9 (0.27)
Strain — 0.05 (0.002) 0.6 (0.024)
12 Disc Thickness 3.2 (0.13) ±0.08 (0.003) 2.97 (0.117)
Load of wave spring 626.4 N ±176.5 N 533 N
13
(testing height: 3.2 mm or 0.126 in) (140.82 lbf) (±39.68 lbf) (119.82 lbf)

Torque Values

Designation N•m lbf ft

AA 98 - 123 72.28 - 90.72

WA500-6 10-181 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Parking Brake Solenoid Valve

1. Coil (ON-OFF type)

2. Push pin
3. Spring
4. Spool
5. Block
6. Check valve

Torque Values

Designation N•m lbf ft Designation N•m lbf in

AA 47.0 – 53.9 34.6 – 39.7 BB 6.9 – 7.8 61.07 – 69.04

DD 44.1– 53.9 32.5 –- 39.7 CC 9.8 – 12.7 86.74 – 112.40

10-182 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM
Operation

★ When parking brake is applied (when solenoid is de-energized.)

• As the parking brake switch is turned ON, the solenoid is turned

OFF. As the result, spool (1) is pushed back in the left direction by
the tension of spring (2).

• Pump port (P) is disconnected from parking brake port (A),

stopping flow of the pressurized oil from the pump to the parking
brake. At the same time, the oil that was working as back pressure
of the parking brake is drained through port (A) and port (T).

• As the back pressure of the piston is drained, the piston being

pushed back by the spring contacts the plate and disc closely to
enable the parking brake.

★ When parking brake is released (when solenoid is energized.)

• If the parking brake switch is turned OFF, the solenoid is turned

ON and spool (1) is moved to the right.

• The pressurized oil from the pump flows to the parking brake
through port (P), inside of spool (1) and port (A). At the same time,
port (T) is closed and the oil is not drained.

• As oil pressure is applied to the back side of the piston, it

compresses the spring, separating the plate and disc from each
other. As the result, the parking brake is released.

WA500-6 10-183 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

Emergency Parking Brake Release Valve

1. Valve
2. Solenoid valve

A. To parking brake
B. From parking brake valve
C. From pilot circuit
T. Drain
P. From brake valve (accumulator circuit)

Function

The emergency release solenoid valve is installed between the

transmission and transmission control. It operates the solenoid of the
parking brake release switch installed at the operator’s seat when oil
pressure is not available from the power train pump due to engine
failure, etc. in order to supply accumulator charge pressure in the brake
circuit to the parking brake.

Operation

When parking brake emergency release switch (1) is turned to ON,

solenoid valve (2) starts operating and oil pressure from
accumulator (3) enters port (P). Pilot pressure then switches the circuit
and the pressure moves to the parking brake from port (A) to release
the parking brake.

10-184 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BRAKE SYSTEM

MEMORANDUM

WA500-6 10-185 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

UNDERCARRIAGE AND FRAME

Axle Mount

10-186 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

1. Front axle
2. Rear axle
3. Rear frame
4. Front frame
5. Axle mount bolt

Torque Values

Designation N•m lbf ft

A 2450 – 3038 1807.03 – 2240.71

Outline

• Front axle (1) is directly fixed to front frame (4) with axle mount bolt (5) as it is directly subjected to the working force.

• Rear axle (2) has a swaying structure at the center of the rear axle to enable each tire to make contact with the ground
during travel on soft ground.

WA500-6 10-187 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

10-188 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Tolerance Standard Clearance
Size Shaft Hole Clearance Limit
Clearance between hole and shaft
1 on front support side (after press- -0.056
+0.489
fitting of bushing) 310 (-0.002) 0.056 – 0.626 1.6
(+0.019)
(12.20) -0.137 (0.002 –0.025) (0.063)
0 (0)
(-0.005)
+2.300 Replace
Clearance between hole and shaft +0.089
320.2 (+0.091) (Bushing is
2 on front support side (before (+0.0035) — —
(12.61) +0.800 adhered to
press-fitting of bushing) 0 (0)
(+0.031) support on both
-0.056 +0.481 front and rear.)
Clearance between hole and shaft
260 (-0.002) (+0.0189) 0.048 –0.618 1.6
3 on rear support side (after press-
(10.24) -0.137 -0.008 (0.0019 – 0.0243) (0.063)
fitting of bushing)
(-0.005) (-0.0003)
+2.300
Clearance between hole and shaft +0.089
270.2 (+0.091)
4 on rear support side (before press- (+0.0035) — —
(10.64) +0.800
fitting of bushing) 0 (0)
(+0.031)
Standard Size Tolerance Repair Limit
5 Thickness of thrust plate -0.10 (-0.004)
22 (0.87) —
-0.25 (-0.010)
+0.1 (+0.004) Replace
6 Thickness of thrust washer 5 (0.20) —
-0.3 (-0.012)
7 Thickness of rear bushing 5 (0.20) ±0.1 (±0.004) —
8 Thickness of front bushing 5 (0.20) ±0.1 (±0.004) —

Torque Values

Designation N•m lbf ft

A 1519 – 1911 1120.3 – 1409.4

B 245 – 309 180.7 – 227.9

WA500-6 10-189 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

Center Hinge Pin

1. Front axle
2. Front frame
3. Rear frame
4. Rear axle
5. Upper hinge pin
6. Lower hinge pin

Outline

• Front frame (2) and rear frame (3) are coupled to each other through the bearings and center hinge pins (5) and (6).

• The right and left steering cylinders connect the front frame and rear frame and adjust the articulating angle of the frame,
or the turning radius of the machine.

10-190 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Tolerance Clearance
Standard Clearance
Size Shaft Hole Limit
Clearance between upper hinge -0.036
1 +0.054
pin and rear frame (-0.0014) 0.036 – 0.112
100 (3.94) (+0.0021) —
-0.058 (0.0014 – 0.0044)
0 (0)
(-0.0023)
-0.036
+0.054
Clearance between upper hinge (-0.0014) 0.036 – 0.112
2 100 (3.94) (+0.0021) —
pin and spacer (small) -0.058 (0.0014 – 0.0044)
0 (0)
(-0.0023)
-0.036 Replace
Clearance between upper hinge 0 (0)
(-0.0014) 0.016 – 0.058
3 pin and 100 (3.94) -0.020 —
-0.058 (0.0006 – 0.0228)
bearing (-0.0008)
(-0.0023)
-0.036
+0.054
Clearance between upper hinge (-0.0014) 0.036 – 0.112
4 100 (3.94) (+0.0021) —
pin and spacer (large) -0.058 (0.0014 – 0.0044)
0 (0)
(-0.0023)
-0.043
+0.063
Clearance between rear frame (-0.0017) 0.043 – 0.169
5 130 (5.12) (+0.0025) —
and spacer (large) -0.106 (0.0017 – 0.0067)
0 (0)
(-0.0041)

WA500-6 10-191 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

Unit: mm (in)
No. Check Item Criteria Remedy
-0.048
0 (0)
Clearance between front frame (-0.0019) -0.023 to -0.088
6 155 (6.10) -0.025 —
and lower hinge bearing -0.088 (-0.0009 to -0.0035)
(-0.0010)
(-0.0035)
-0.036
Clearance between lower hinge +0.054
(-0.0014) 0.036 – 0.112
7 pin and 100 (3.94) (0.0021) —
-0.058 (0.0014 – 0.0044)
bushing 0 (0)
(-0.0023)
-0.036
Clearance between lower hinge 0 (0)
(-0.0014) 0.016 – 0.058
8 pin and 100 (3.94) -0.020 —
-0.058 (0.0006 – 0.0023)
bearing (-0.0008)
(-0.0023)
-0.050
0 (0)
Clearance between front frame (-0.0020) -0.025 to -0.090
9 160 (6.30) -0.025 —
and upper hinge bearing -0.090 (-0.0010 to -0.0035)
(-0.0010)
(-0.0035)
-0.043
+0.063
Clearance between lower hinge (-0.0017) 0.043 – 0.146
10 125 (4.92) (+0.0025) —
rear frame and bushing -0.083 (0.0017 – 0.0057)
0 (0)
(-0.0033)
+0.280 Replace
+0.054
Clearance in seal fitting part of (+0.0110) -0.126 to -0.280
11 115 (4.53) (0.0021) —
lower hinge +0.180 (-0.0050 to -0.0110)
0 (0)
(+0.0071)
+0.310
+0.063
Clearance in seal fitting part of (+0.0122) -0.147 to -0.310
12 135 (5.31) (+0.0025) —
upper hinge pin +0.210 (-0.0058 to -0.0122)
0 (0)
(+0.0083)
Height of upper hinge pin Standard Size Tolerance Repair Limit
13
spacer (small) 35 (1.38) ±0.1 (±0.004) —
Height of upper hinge pin
14 101.5 (4.00) ±0.1 (±0.004) —
spacer (large)
Standard thickness of shim
15 between upper hinge and 2.3 (0.091)
retainer
Standard thickness of shim
16 between upper hinge and 1.6 (0.06)
retainer
Standard thickness of shim
17 between lower hinge and 1.6 (0.06)
retainer

10-192 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

MEMORANDUM

WA500-6 10-193 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

HYDRAULIC SYSTEM
Hydraulic Piping Diagram

10-194 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Hydraulic tank
2. Work equipment pump
3. Cooling fan pump
4. Hydraulic cooling pump
5. Steering pump
6. Tandem pump (power train + EPC and brake)
7. Steering demand valve
8. Steering cylinder
9. Bucket cylinder
10. Work equipment valve
11. Lift cylinder
12. Charge valve (built-in EPC relief valve)
13. Accumulator
14. Hydraulic oil cooler

WA500-6 10-195 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Work Equipment Control Lever Linkage

10-196 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Lift arm control lever

2. Bucket control lever
3. Hold switch
4. Subtotal switch (Load meter specifications)
5. Work equipment lock lever
6. RH console forward-reverse slide lever
7. Armrest adjustment lever
8. Kickdown switch
9. Cancel switch (Load meter specifications)
10. Armrest
11. Work equipment EPC valve

WA500-6 10-197 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Hydraulic Tank

10-198 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Hydraulic tank
2. Oil level sight gauge
3. Breather
4. Oil filler port
5. Filter bypass valve
6. Oil filter
7. Strainer
8. Drain valve

A. EPC return port

B. Main return port
C. Hydraulic oil cooler return port
D. Steering and loader pump suction port
E. Emergency steering suction port
F. Emergency steering return port
G. EPC pump suction port
H. Steering return port
J. Steering drain port
K. Brake valve return port
L. Cooling fan pump and hydraulic cooling pump suction port
M. Pump case drain port

WA500-6 10-199 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Operation of Oil Filter Bypass Valve

• In the case where the filter is clogged.

Bypass valve (1) opens and oil returns to the tank bypassing the
filter.
Bypass valve set pressure: . . . . . . . . . . . . . . 0.15 MPa (21.76 psi)

• In the case where the return circuit turns negative pressure.

Whole valve (2) is held up to serve as the check valve.

Check valve set pressure: . . . . . . . . . . . . . . . . .23.6 kPa (3.42 psi)

10-200 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Breather

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

Function

• Prevention of negative pressure in tank

Since the tank is pressurized and enclosed, if the oil level in it

lowers, negative pressure is generated. At this time, poppet (3) is
opened by the differential pressure between the tank pressure and
the atmospheric pressure to prevent generation of the negative
pressure.

• Prevention of pressure rise in tank

If the pressure rises to above a specified level while the circuit is in

operation due to an increase or decrease of oil level and the
temperature rise, sleeve (4) is operated to relieve pressure in the
hydraulic tank.

WA500-6 10-201 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Cooling Fan Motor LMF40

10-202 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

P. From fan pump

T. From parking brake valve
TC. To tank

Specifications
Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LMF40
Capacity:. . . . . . . . . . . . . . . . . . . . . . . . . . . 40 cc/rev (2.44 in3/rev)
Rated speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,190 rpm
Rated flow: . . . . . . . . . . . . . . . . . . . . . . . . . . . .47.6 l (12.6 gal)/min
Check valve cracking pressure: . . . . . . . . . . . . .44.1 kPa (6.40 psi)

Torque Values

Designation N•m lbf ft Designation N•m lbf in

1 98 – 123 72.28 – 90.72 2 9.8 – 12.74 86.74 – 112.76

WA500-6 10-203 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-204 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

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

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Repair Limit
Free Length x
Installed Installed Free Installed
Outside
13 Spool return spring Length Load Length Load If damaged or
Diameter
deformed,
44.8 x 12.0 58.8 N 47.1 N replace spring
33.0 (1.30) —
(1.76 x 0.47) (13.22 lbf) (10.59 lbf)
13.0 x 6.5 1.96 N 1.57 N
14 Check valve spring 9.5 (0.37) —
(0.51 x 0.26) (0.44 lbf) (0.35 lbf)

Torque Values

Designation N•m lbf in

D 9.8 – 12.7 86.74 – 112.40

WA500-6 10-205 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Hydraulic Motor
Function

• This is a swash plate-type axial piston motor. It converts the

energy of the pressurized oil sent from the pump into rotary
motion.

Principle of Operation

• The oil sent from the pump flows through valve plate (7) into
cylinder block (5).

• This oil can flow on only one side of the (Y–Y) line connecting the
top, dead center and bottom, dead center of the stroke of piston (4).

• The oil sent to one side of cylinder block (5) presses pistons (4)
(two or three pieces) and generates force (F1).

• A single piston force F1 [F1 (kg) = P (kg/cm2) x πD2/4 (cm2)]

• This force is applied to thrust plate (2).

• Since thrust plate (2) is fixed to a certain angle (a) to output shaft
(1), the force is divided into components (F2) and (F3).

• Radial component (F3) generates torque [T = F3 x ri] against the

(Y – Y) line connecting the top, dead center and bottom, dead
center.

• The result of this torque [T = Σ(F3 x ri)] rotates cylinder block (5)
through piston (4).

• Cylinder block (5) is coupled to output shaft (1) with the spline.

• Output shaft (1) rotates and torque is transmitted.

10-206 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Suction Valve
Function

• When the pump stops rotating, hydraulic oil does not flow into the
motor.

• Since the motor is revolved by the force of inertia, the pressure

rises on the outlet side of the motor.

• When the oil stops flowing in from inlet port (P), suction valve (1)
sucks in the oil on the outlet side and supplies it to port (MA)
where there is not sufficient oil. In this manner, cavitation is
prevented from being generated.

Operation

★ When pump is started

• When the hydraulic oil from the pump is supplied to port (P)
and the pressure on (MA) side rises.
• When starting torque is generated in the motor, the motor
starts to revolve.
• The oil on the outlet (MB) side of the motor returns through
port (T) to the tank.

★ When the pump is stopped

• When the engine stops, the pump input revolution becomes

0 rpm.
• Hydraulic oil from the pump is not supplied to port (P).
• As the hydraulic oil does not flow to the (MA) side of the
motor, the motor speed decreases gradually until it stops.
• If the motor shaft is revolved by the force of inertia while the
oil flow to port (P) decreases, the oil in port (T) on the outlet
side is sent by suction valve (1) to the (MA) side. In this
manner, cavitation is prevented from being generated.

WA500-6 10-207 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Reversible Valve
Operation

★ When ON/OFF solenoid is de-energized

• When ON/OFF solenoid (1) is de-energized, hydraulic oil

from the pump is cut off by valve (2).
• Port (C) is connected to the tank circuit.
• Spool (3) is pressed by spring (4) to the right.
• As a result, motor port (MA) opens and the hydraulic oil flows
into the motor to revolve it in the normal direction
(clockwise).

★ When ON/OFF solenoid is energized

• When ON/OFF solenoid (1) is energized, valve (2) switches.

• Hydraulic oil from the pump flows through port (C) into spool
chamber (D).
• Hydraulic oil in chamber (D) compresses spring (4).
• Spool (3) moves to the left.
• As a result, motor port (MB) opens and the hydraulic oil flows
into the motor to revolve it in reverse (counterclockwise).

10-208 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Safety Valve
Function

• When the engine is started, the pressure in port (P) of the motor is
increased in some cases.

• Safety valve (1) is installed to protect the fan system circuit.

Operation

• If the pressure in port (P) rises above the cracking pressure of

safety valve (1), valve (2) of safety valve (1) opens to release the
pressurized oil into port (T).

• In this manner, abnormally high pressure is prevented from being

generated in port (P).

WA500-6 10-209 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Cooling Fan Pump LPV45

10-210 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

P1. Pump discharge port

PAEPC. EPC output pressure pickup plug
PEPC. EPC valve basic pressure input port
PS. Pump suction port
TO. Drain port

1. Servo valve
2. Air bleeder

Torque Values

Designation N•m lbf ft Designation N•m lbf in

BB 107.8 – 142.2 79.51 – 104.88 AA 11.8 – 14.7 104.44 – 130.11

CC 98 – 123 72.28 – 90.72 DD 7.8 – 9.8 69.04 – 86.74

EE 27.4 – 34.3 20.21 – 25.20

FF 68.6 – 83.4 50.60 – 61.51

WA500-6 10-211 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-212 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

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

Torque Values

Designation N•m lbf ft

DD 34.3 – 44.1 25.30 – 32.53

EE 59 – 74 43.52 – 54.58

FF 19.6 – 24.5 14.46 – 18.07

WA500-6 10-213 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-214 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Function

• The pump converts the engine rotation torque transmitted to its shaft to oil pressure and delivers pressurized oil
corresponding to the load.

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

Structure

• Cylinder block (7) is supported to shaft (1) by spline (11).

• Shaft (1) is supported with front and rear bearings (12).

• The end of piston (6) has a spherical hollow and is combined with shoe (5).

• Piston (6) and shoe (5) form a spherical bearing.

• Shoe (5) is kept pressed against flat surface (A) of rocker cam (4) and slid circularly.

• Rocker cam (4) slides around ball (13).

• Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).

• Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation.

• This surface is designed so that the oil pressure balance is maintained at a suitable level.

• The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).

WA500-6 10-215 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Operation of Pump

• Cylinder block (7) rotates, together with shaft (1), and shoe (5)
slides on flat surface (A).

• Rocker cam (4) slants around ball (13). As a result, angle (a)
between center line (X) of rocker cam (4) and the axis of cylinder
block (7) changes.

• Angle (a) is called the swash plate angle.

• When the condition of center line (X) of rocker cam (4) has swash
plate angle (a) to axial direction of cylinder block (7), flat
surface (A) functions as a cam against shoe (5).

• Piston (6) slides on the inside of cylinder block (7); a difference

between volumes (E) and (F) is created inside cylinder block (7).

• A single piston (6) sucks and discharges the oil by the amount
(F) – (E).

• As cylinder block (7) rotates and the volume of chamber (E)

decreases, the pressurized oil is discharged.

• The volume of chamber (F) increases and, in this process, the oil is
suctioned.

• As center line (X) of rocker cam (4) matches the axial direction of
cylinder block (7) [swash plate angle (a) = 0], the difference
between volumes (E) and (F) inside cylinder block (7) becomes 0.

• Suction and discharge of pressurized oil is not carried out in this

state. Pumping action is not performed. (Actually, however, the
swash plate angle is not set to 0.)

• Swash plate angle (a) is in proportion to the pump delivery.

10-216 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Control of Delivery

• If the swash plate angle (a) increases, the difference between

volumes (E) and (F) increases and pump delivery (Q) increases.

• Swash plate angle (a) is changed with servo piston (10).

• Servo piston (10) reciprocates straight according to the signal

pressure of the servo valve.

• This straight motion is transmitted to rocker cam (4).

• Rocker cam (4), supported with ball (13), slides around ball (13).

WA500-6 10-217 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Servo Valve

10-218 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

P. EPC valve basic pressure

PE. Control piston pressure
PH. Pump discharge pressure
T. Drain port

1. Plug
2. Lever
3. Retainer
4. Seal
5. Spool
6. Piston
7. Sleeve
8. Spring

Torque Values

Designation N•m lbf in

DD 5.9 – 8.8 52.22 – 77.89

EE 9.8 – 12.7 86.74 – 112.40

WA500-6 10-219 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Torque Values

Designation N•m lbf ft Designation N•m lbf in

C 27.4 – 34.3 20.21 – 25.230 D 8.8 - ±1.0 77.89 ±8.85

E 59 – 74 43.52 – 54.58

10-220 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Function

• The servo valve controls the current input to the EPC valve and the
pump delivery (Q) so that they will be related as shown in the
diagram.

• The output pressure of the EPC valve flows in the piston chamber
to push piston (6).

• Piston (6) pushes spool (5) until it is balanced with the spring.

• The land of the servo piston pressure passage is connected to the

pump discharge passage by the notch of spool (5) and the
discharge pressure is led to the servo piston.

• When the rocker cam is pushed up by the servo piston, a position

feedback is applied and lever (2) moves to compress spring (8).

• When spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are cut off.

• Pressure in the servo piston chamber drops and the rocker cam returns in the direction of a maximum swash plate angle.

• These processes are repeated until the swash plate is fixed to a position where the EPC output pressure is balanced with
spring (8) force.

• The greater the EPC output pressure, the smaller the swash plate angle. Conversely, the smaller the EPC output pressure,
the greater the swash plate angle.

WA500-6 10-221 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Steering Pump

10-222 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

P1. Pump discharge port

P1L. Pump pressure input port
PD. Drain port
PD2. Drain plug
PD6. Drain port
PEN. Control pressure pickup plug
PL. Load pressure input port
POP. External pilot pressure input port
PS. Pump suction port

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

Torque Values

Designation N•m lbf ft Designation N•m lbf in

C 34.3 – 63.7 25.2– 46.9 A 11.8 – 14.7 104.44 – 130.11

E 19.6 – 24.5 14.4 – 18.0 B 9.8 – 12.7 86.74 – 112.40

F 68.6 – 83.4 50.5 – 61.5 D 7.8 – 9.8 69.04 – 86.74

WA500-6 10-223 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Pump Unit

PA. Control basic pressure output port

PD4. Drain port
PD5. Drain port
PE. Control pressure input port

Torque Values

Designation N•m lbf ft

1 153 – 190 112.85 – 140.14

10-224 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Bearing 6. Piston 11. Servo piston

2. Shaft 7. Cylinder block 12. Spring
3. Case 8. Valve plate 13. Oil seal
4. Rocker cam 9. End cover 14. Ball
5. Shoe 10. Shoe retainer

Torque Values

Designation N•m lbf ft

EE 34.3 – 44.1 25.30 – 32.53

WA500-6 10-225 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Function

• The pump converts the engine rotation torque, transmitted to its shaft, to oil pressure and delivers pressurized oil
corresponding to the load.

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

Structure

• Cylinder block (6) is supported on shaft (1) through spline (a). Shaft (1) is supported on the front and rear bearings.

• The end of piston (5) has a spherical hollow and is combined with shoe (4). Piston (5) and shoe (4) form a spherical
bearing.

• Rocker cam (3) is supported on case (2) and ball (9) and has flat surface (A). Shoe (4) is kept pressed against the plane of
rocker cam (3) and slid circularly. Shoe (4) leads high-pressure oil to form a static pressure bearing and slides.

• Piston (5) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (6).

• Cylinder block (6) seals the pressurized oil to valve plate (7) and carries out relative rotation.

• This surface is designed so that the oil pressure balance is maintained at a suitable level.

• The oil inside each cylinder chamber of cylinder block (6) is suctioned and discharged through valve plate (7).

10-226 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Operation of Pump

• Cylinder block (6) rotates, together with shaft (1), and shoe (4)
slides on flat surface (A).

• Rocker cam (3) slants around ball (9). As a result, angle (a)
between center line (X) of rocker cam (3) and the axis of cylinder
block (6) changes.

• Angle (a) is called the swash plate angle.

• When the condition of center line (X) of rocker cam (3) has swash
plate angle (a) to axial direction of cylinder block (6), flat
surface (A) functions as a cam against shoe (4).

• Piston (5) slides on the inside of cylinder block (6); a difference

between volumes (E) and (F) is created inside cylinder block (6).

• A single piston (5) sucks and discharges the oil by the amount
(F) – (E).

• As cylinder block (6) rotates and the volume of chamber (E)

decreases, the pressurized oil is discharged.

• The volume of chamber (F) increases and, in this process, the oil is
suctioned.

• As center line (X) of rocker cam (3) matches the axial direction of
cylinder block (6) [swash plate angle (a) = 0], the difference
between volumes (E) and (F) inside cylinder block (6) becomes 0.

• Suction and discharge of pressurized oil is not carried out in this

state. Pumping action is not performed. (Actually, however, the
swash plate angle is not set to 0.)

• Swash plate angle (a) is in proportion to the pump delivery.

WA500-6 10-227 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Control of Delivery

• If the swash plate angle (a) increases, the difference between

volumes (E) and (F) increases and pump delivery (Q) increases.

• Swash plate angle (a) is changed with servo piston (11).

• Servo piston (11) reciprocates straight according to the signal

pressure of the CO valve and LS valve.

• This straight motion is transmitted to rocker cam (3).

• Rocker cam (3), supported with ball (9), slides around ball (9).

10-228 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Servo Valve

P1. Pump discharge pressure port

PE. Control pressure output port
T. Drain port

WA500-6 10-229 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-230 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Nut
2. Plate
3. Plug
4. Spring
5. Seat
6. Plug
7. Spool
8. Plug
9. Piston
10. Seal
11. Piston
12. Sleeve
13. Spool
14. Seat
15. Retainer
16. Spring

LS Valve

PA. Pump pressure input

PE. Control piston pressure

PLS. LS pressure input

PPL. CO valve output pressure
PPLS. LS pump pressure input

CO Valve

PA. Pump pressure input

PPL. CO valve output pressure
T. Drain

Torque Values

Designation N•m lbf ft

DD 27.4 – 34.3 20.21 – 25.30

EE 29.4 – 39.2 21.68 – 28.91

WA500-6 10-231 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

LS Valve
Function

• The LS valve controls the pump delivery according to the stroke of the control lever, or the demand flow for the actuator.

• The LS valve detects the demand flow for the actuator from
differential pressure (ΔPLS) between control valve inlet pressure
(PPLS) and control valve outlet pressure (PLS) and controls main
pump delivery (Q). ((PPLS) is called the LS pump pressure, (PLS)
the LS pressure, and (ΔPLS) is the LS differential pressure.)

• The pressure loss caused by the flow of oil through the opening of
the control valve spool (= LS differential pressure ΔPLS) is
detected, and then pump delivery (Q) is controlled to keep that
pressure loss constant and supply the pump delivery according to
the demand flow for the actuator.

• Main pump discharge pressure (PA), LS pump pressure (PPLS),

and LS pressure (PLS) are led to the LS valve. The relationship
between LS differential pressure (ΔPLS) and pump delivery (Q)
changes as shown in the diagram.

CO Valve
Function

• When the pump pressure in the hydraulic circuit reaches the

maximum level, the CO (Cut-off) valve minimizes the pump
swash plate angle and protects the circuit by suppressing the rise of
pressure.

• The minimum pump swash plate angle given reduces the pump
suction torque to improve fuel economy.

Operation

1. Function of spring
• The spring load of spring (2) on the CO valve is determined
by the pump discharge pressure (PA).

2. When the load on the actuator is small and pump discharge pressure (PA) is low.
• The pressing force of spool (5) is decreased and spool (3) is a little to the right (Fig. 1 on next page). At this time,
ports (C) and (D) are connected to each other and the pressure in the LS valve is drain pressure (PT).
• At this time, ports (F) and (G) of the LS valve are connected to each other. As a result, the pressure in port (J)
becomes drain pressure (PT) and servo piston (6) moves to the left.
• Consequently, the pump delivery is increased.

3. When the load on the actuator is large and pump discharge pressure (PA) reaches the maximum pressure.
• The pressing force of spool (5) is increased and spool (3) is a little to the left (Fig. 2 on next page). At this time,
ports (C) and (B) are connected to each other and the pressure in the LS valve is pump pressure (PA).
• At this time, ports (F) and (G) of the LS valve are connected to each other. As a result, the pressure in port (J)
becomes pump pressure (PA) and servo piston (6) moves to the right.
• Consequently, the pump delivery is decreased.

10-232 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
★ When load is light
(Fig. 1)

★ When load is heavy

(Fig. 2)

WA500-6 10-233 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Work Equipment Hydraulic Pump HPV190

10-234 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Outline

The pump unit is composed of the variable capacity swash plate type piston pump, PC valve, LS valve, and EPC valve.

IM. PC mode selector current

PA. Pump discharge port

PB. Pump pressure input port

PD1. Case drain port

PD2. Drain plug
PEN. Control pressure pickup port
PEPC. EPC basic pressure port
PEPCC. EPC basic pressure pickup port
PLS. Load pressure input port
PLSC. Load pressure pickup port
PM. PC mode selector pressure pickup port
PS. Pump suction port

1. Main pump

2. LS valve

3. PC valve

4. PC-EPC valve

Torque Values

Designation N•m lbf ft Designation N•m lbf in

AA 19.6 – 27.4 14.46 – 20.21 BB 11.8 – 14.7 104.44 – 130.11

CC 98.1 – 122.6 72.35 – 90.42

WA500-6 10-235 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-236 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Shaft

2. Cradle

3. Front case

4. Rocker cam

5. Shoe

6. Piston

7. Cylinder block

8. Valve plate

9. End cover

10. Impeller

11. Servo piston

12. PC valve

Torque Values

Designation N•m lbf ft

DD 637 – 764.4 469.83 – 563.79

EE 246.3 – 308.7 181.66 – 227.69

FF 98 – 123 72.28 – 90.72

GG 27– 34 19.91 – 25.08

WA500-6 10-237 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-238 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Function

• The pump converts the engine rotation torque, transmitted to its shaft, to oil pressure and delivers pressurized oil
corresponding to the load.

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

Structure

• Cylinder block (7) is supported to shaft (1) by spline (14).

• Shaft (1) is supported by front and rear bearings (15).

• The end of piston (6) has a spherical hollow and is combined with shoe (5).

• Piston (6) and shoe (5) form a spherical bearing.

• Rocker cam (4) has flat surface (A). Shoe (5) is always pressed against this surface while sliding in a circular movement.

• Rocker cam (4) conducts high-pressure oil to cylinder surface (B) with cradle (2), which is secured to the case, and forms
a static pressure bearing when it slides.

• Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).

• Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation.

• This surface is designed so that the oil pressure balance is maintained at a suitable level.

• The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).

WA500-6 10-239 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Operation of Pump

• Cylinder block (7) rotates together with shaft (1) and shoe (5)
slides on flat surface (A).

• Rocker cam (4) moves along cylindrical surface (B). Angle (a)
between center line (X) of rocker cam (4) and the axial direction of
cylinder block (7) changes.

• Angle (a) is called the swash plate angle.

• When the condition of center line (X) of rocker cam (4) has swash
plate angle (a) to axial direction of cylinder block (7), flat
surface (A) functions as a cam against shoe (5).

• Piston (6) slides on the inside of cylinder block (7). A difference

between volumes (E) and (F) is created inside cylinder block (7).

• A single piston (6) sucks and discharges the oil by the amount
(F) – (E).

• As cylinder block (7) rotates and the volume of chamber (E)

decreases, the pressurized oil is discharged.

• The volume of chamber (F) increases and, in this process, the oil is
suctioned.

• As center line (X) of rocker cam (4) matches the axial direction of
cylinder block (7) [swash plate angle (a) = 0], the difference
between volumes (E) and (F) inside cylinder block (7) becomes 0.

• Suction and discharge of pressurized oil is not carried out in this

state. Pumping action is not performed. (Actually, however, the
swash plate angle is not set to 0.)

• Swash plate angle (a) is in proportion to the pump delivery.

10-240 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Control of Delivery

• If swash plate angle (a) increases, the difference between

volumes (E) and (F) increases and pump delivery (Q) increases.

• Servo piston (12) is used for changing swash plate angle (a).

• Servo piston (12) carries out linear reciprocal movement according

to the signal pressure from the PC and LS valves.

• This linear movement is transmitted to rocker cam (4) through

slider (13).

• Being supported by cradle (2) on the cylindrical surface, rocker

cam (4) slides on the surface while continuing revolving
movement.

• The space of the pressure receiving area of servo piston (12) is not
identical on the left side and right side. Main pump discharge
pressure (self-pressure) (PP) is always brought to the pressure
chamber of the small diameter piston side.

• Output pressure (PEN) of the LS valve is brought to the chamber

receiving the pressure at the large diameter piston end.

• The relationship in the size of pressure (PP) at the small diameter

piston end and pressure (PEN) at the large diameter piston end and
the ratio between the area receiving the pressure of the small
diameter piston and the large diameter piston controls the
movement of servo piston (12).

WA500-6 10-241 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

LS Valve

1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Locknut

PA. Pump port

PDP. Drain port

PLP. LS control pressure output port

PLS. LS pressure input port
PP. Pump port
PPL. Control pressure input port
PSIG. Drain port

10-242 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Function

• The LS (load sensing) valve detects the load of the actuator and
controls the delivery.

• This valve controls pump delivery (Q) according to differential

pressure (ΔPLS) [= (PP) – (PLS)] (called LS differential pressure)
between pump discharge pressure (PP) and control valve outlet
port pressure (PLS).

• Main pump pressure (PP), pressure (PLS) (called the LS pressure)

coming from the control valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional solenoid valve
enter this valve.

WA500-6 10-243 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Operation

★ When the control valve is situated at neutral

10-244 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
• The LS valve is a 3-way selector valve, with pressure (PLS) (LS
pressure) from the inlet port of the control valve brought to spring
chamber (B), and pump discharge pressure (PP) brought to
port (H) of sleeve (8).

• The magnitude of the force resulting from this LS pressure (PLS),

the force of spring (4), and the pump discharge pressure (self-
pressure) (PP) determine the position of spool (6).

• Before starting the engine, servo piston (12) is pressed to the left
(see the figure to the right).

• If the control lever is in neutral when the engine is started, LS

pressure (PLS) is set to 0 MPa {0 psi}. (It is connected with the
drain circuit through the control valve spool.)

• Spool (6) is pushed to the right. Port (C) and port (D) will be connected.

• Shuttle valve output pressure (PPH) enters the large diameter side of the piston from port (K).

• Pump pressure (PP) is present in port (J) on the small diameter side of the piston.

• Depending on the difference in the areas on servo piston (12), servo piston (12) moves in the direction to minimize the
swash plate angle.

WA500-6 10-245 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
★ Action for the direction of maximizing the pump delivery

• When the difference between pump discharge pressure (PP) and LS pressure (PLS) (LS differential pressure (ΔPLS))
decreases [for example, when the area of opening of the control valve increases and pump discharge pressure (PP) drops],
spool (6) is pushed to the left by the combined force of LS pressure (PLS) and the force of spring (4).

• When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve.

• The PC valve is connected to the drain port; the pressure across circuits (D) and (K) becomes drain pressure (PT). (The
operation of the PC valve is explained later.)

• The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT). Pump pressure (PP) enters
port (J) at the small diameter end; servo piston (12) is pushed to the left side. In this manner, servo piston (12) is moved in
the direction to make the delivery larger.

10-246 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
★ Action for the direction of minimizing the pump delivery

• If LS differential pressure (ΔPLS) increases (for example, when the area of the control valve opening decreases and the
pump pressure (PP) increases), spool (6) is pressed to the right by the force of pump pressure (PP).

• As a result of the movement of spool (6), shuttle valve output pressure (PPH) flows from port (C) to port (D), then from
port (K) to the large diameter side of the piston.

• While main pump pressure (PP) is present in port (J) of the smaller diameter side of the piston, servo piston (12) is pressed
to the right by its area difference between the larger and the smaller diameter sides. As the result, servo piston (12) moves
in the direction to minimize the swash plate angle.

WA500-6 10-247 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
★ When servo piston is balanced

• Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at
the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN).

• If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced,
and the relationship is (A0) x (PP) = (A1) x (PEN), servo piston (12) will stop in that position.

• The swash plate of the pump will be held in an intermediate position. [Spool (6) will be stopped at a position where the
distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.]

• The formula (A0): (A1) = 3: 5 represents the relation of pressure-receiving areas across the end of servo piston (12). And
(PP): (PEN) = 5:3 represents the pressure applied across the piston when balanced.

• The force of spring (4) is adjusted to determine the balanced stop position of this spool (6) at the center of the standard
when (PP) – (PLS) = 1.4 MPa (203.05 psi).

10-248 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

MEMORANDUM

WA500-6 10-249 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

PC Valve

1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring

PA. Pump port

PA2. Pump pressure pilot port

PDP. Drain port

PM. Mode selector pressure pilot port
PPL. Control pressure output port (to LS valve)

10-250 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Function

• The PC valve controls the flow to a certain rate corresponding to

the discharge pressure irrespective of how much the control valve
stroke is increased, when pump discharge pressure (PP1) (self-
pressure) and (PP2) (other pump pressure) are high.

• An uprise in the pump discharge pressure due to increased load

during work results in reducing the pump delivery.

• If the pump discharge pressure drops, it increases the delivery

from the pump.

• In this case, the relation between the mean discharge pressure of

the front and rear pumps [(PP1) + (PP2)]/2 and pump delivery (Q)
will be as shown in the figure if the relation is represented as the
parameter of the current value (X) to be given to the PC-EPC valve
solenoid.

• The controller continues counting the actual engine speed.

• During low speed, command current flows from the controller to the PC-EPC valve solenoid according to the engine
speed to reduce the pump delivery.

WA500-6 10-251 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
★ When the actuator load is small and pump pressures (PP1) and (PP2) are low

10-252 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Action of PC-EPC Valve Solenoid (1)

• Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller.

• This command current (X) works on the PC-EPC valve and outputs the signal pressure to change the force of pushing
piston (2).

• Spool (3) stops at a position where the combined force pressing spool (3) becomes balanced between a set force of
spring (4) and pump pressure (PP1) (self-pressure) and other pump pressure (PP2).

• The pressure [port (C) pressure] output from PC valve is changed depending on the above position.

• The size of command current (X) is determined by the nature of the operation (lever operation), the selected working
mode, and the set value and actual value of the engine speed.

★ Other pump pressure denotes the pressure of the pump situated on the opposite side. For the front pump pressure, the other
pump pressure is that of the rear pump. For the rear pump pressure, the other pump pressure is that of the front pump.

WA500-6 10-253 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-254 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Action of Spring

• The load of spring (4) at the PC valve is determined by the position of the swash plate.

• The spring load changes as servo piston (9) makes spring (4) elongate or contract.

• If the command current (X) to PC-EPC valve solenoid (1) changes, so does the force pushing piston (2).

• The load of spring (4) also changes according to the PC-EPC valve solenoid command current (X).

• Port (C) of the PC valve is connected to port (E) of the LS valve.

• Self-pressure (PP1) enters port (B) and the small diameter end of servo piston (9), and other pump pressure (PP2) enters
port (A).

• When pump pressures (PP1) and (PP2) are small, spool (3) will be positioned in the left side.

• Ports (C) and (D) are connected; the pressure entering the LS valve becomes drain pressure (PT).

• If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from
port (J) becomes drain pressure (PT), and servo piston (9) moves to the left side.

• The pump delivery will be set to the increasing trend.

• Spring (4) extends as servo piston (9) moves and weakens the spring force.

• As the spring force is weakened, spool (3) moves to the right; the connection between port (C) and port (D) is shut off; and
the pump discharge pressure ports (B) and (C) are connected.

• The pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the leftward move
of servo piston (9) is stopped.

• Stop position of servo piston (9) (= pump delivery) is determined by a position where the press force generated by
pressures (PP1) and (PP2) on spool (3) and the other press force by the PC-EPC valve solenoid are balanced with the force
of spring (4).

WA500-6 10-255 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
★ When the actuator load is large, and the pump discharge pressure is high

Outline

• When the load is large and pump discharge pressures (PP1) and (PP2) are high, the force pushing spool (3) to the right
increases and spool (3) is moved to the position shown in the above diagram.

• Part of the pressure to be conducted from port (C) to the LS valve flows from port (B) to ports (C) and (D) through the LS
valve. At the end of this flow, the level of this pressure becomes approximately half of main pump pressure (PP2).

10-256 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Operation

• When port (E) and port (G) of the LS valve are connected, the pressure from port (J) enters the large diameter end of servo
piston (9), stopping servo piston (9).

• If main pump pressure (PP2) increases further and spool (3) moves further to the right, main pump pressure (PP1) flows to
port (C) and acts to make the pump deliver the minimum.

• When servo piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3).

• When spool (3) moves to the left, the openings of port (C) and port (D) increase.

• The pressure on port (C) (= J) is decreased and the rightward move

of servo piston (9) is stopped.

• The position in which servo piston (9) stops at this time is further
to the right than the position when pump pressures (PP1) and
(PP2) are low.

• The relationship between the average pump pressure (PP1 + PP2)/

2 and average pump delivery (Q) is as shown in the diagram to the
right.

• If command voltage (X) sent to PC-EPC valve solenoid (1)

increases further, the relationship between average pump pressure
(PP1 + PP2)/ and pump delivery (Q) is proportional to the force of
the PC-EPC valve solenoid and moves in parallel.

• The force of PC-EPC valve solenoid (1) is added to the pushing

force to the right because of the pump pressure applied to
spool (3). The relationship between the average pump pressure
(PP1 + PP2)/2 and pump delivery (Q) moves from (A) to (B) as
command current (X) is increased.

WA500-6 10-257 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

PC-EPC Valve

10-258 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger

C. To PC valve
P. From pilot pump
T. To tank

Torque Values

Designation N•m lbf in

AA 0.1 – 0.3 0.89 – 2.66

BB 9.8 – 12.7 86.74 – 112.40

WA500-6 10-259 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Function

• The EPC valve consists of the proportional solenoid portion and

the hydraulic valve portion.

• On receiving signal current (i) from the controller, the EPC valve
generates EPC output pressure in proportion to the signal current
and outputs it to the PC valve.

Operation

1. When signal current is 0 (coil is de-energized).

• When there is no signal current flowing from the controller to
coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left by spring (4).
• Port (P) is closed and the oil from the pilot pump does not
flow to the PC valve.
• The oil from the PC valve is drained through ports (C) and (T)
to the tank.

10-260 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
2. When signal current is very small (coil is energized)
• When a very small signal current flows to coil (2), coil (2) is
energized and a propulsion force is generated on the right side
of plunger (7).
• Rod (6) pushes spool (5) to the right and pressurized oil flows
from port (P) to port (C).
• Pressure on port (C) increases and the force to act on spool (5)
surface and the spring load on spring (4) become greater than
the propulsion force of plunger (7).
• Spool (5) is pushed to the left and port (P) is shut off from
port (C).
• Port (C) and port (T) are connected.
• Spool (5) moves so that the propulsion force of plunger (7)
may be in balance with the pressure of port (C) + spring load
of spring (4).
• The circuit pressure between the EPC valve and PC valve is
controlled in proportion to the size of the signal current.

3. When signal current is maximum (coil is energized)

• As the signal current flows to coil (2), coil (2) is energized.
• When this happens, the signal current is at its maximum; the
propulsion force of plunger (7) is also at its maximum.
• Spool (5) is pushed toward the right side by rod (6).
• Hydraulic oil from port (P) flows to port (C) with maximum
flow rate. As the result, the circuit pressure between the EPC
and PC valves becomes maximum.
• Since port (T) is closed, pressurized oil does not flow to the
tank.

WA500-6 10-261 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Control Valve
For outside views and sectional views, only the 4-spool valve (with ECSS control valve) is shown.

Outside View

10-262 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

A1. To bucket cylinder head

A2. To lift arm cylinder bottom
A3. To lift arm cylinder bottom
ACC. To ECSS accumulator
B1. To bucket cylinder bottom
B2. To lift arm cylinder head
B3. To bucket cylinder bottom
CP. Pressure sensor installation port
CR. Pressure pickup port
P1. From front work equipment hydraulic pump
P2. From rear work equipment hydraulic pump
PA1. From bucket dump controller
PA2. From lift arm raise controller
PACC. From ECSS controller
PB1. From bucket tilt controller
PB2. From lift arm lower controller
PLS. To work equipment hydraulic pump LS port
PP. From pilot pump
PPS. To work equipment hydraulic pump
T. To tank
TS. To tank

1. Bucket valve
2. Lift arm valve
3. ECSS control valve
4. Lift arm Hi and bucket Hi valves
5. Cover 1
6. Cover 2
7. Lift arm suction valve
8. Accumulator charge valve

Torque Values

Designation N•m lbf ft Designation N•m lbf in

9A 156.8 – 196 115.65 – 144.56 12A 9.8 – 12.7 86.74 – 112.40

10A 27.5 – 34.3 20.28 – 25.30

11A 58.8 – 73.6 43.37 – 54.28

WA500-6 10-263 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Sectional View

(1/6)

10-264 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Load check valve (Bucket head)

2. Load check valve (Lift arm bottom)
3. Load check valve (Lift arm Hi) and (Lift arm bottom)
4. Load check valve (Bucket Hi) and (Bucket bottom)
5. Pressure compensation valve (Lift arm head)
6. Load check valve (Bucket bottom)

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Repair Limit
Free Length x
Installed Installed Free Installed If damaged or
Outside
7 Check valve spring Length Load Length Load deformed,
Diameter
replace spring
38.9 x 11.5 30.0 29.4 N 23.5 N
—
(1.53 x 0.45) (1.18) (6.61 lbf) (5.28 lbf)

Torque Values

Designation N•m lbf ft

BB 372.7 – 411.9 274.89 – 303.80

WA500-6 10-265 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
(2/6)

10-266 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Spool (Boom Hi)

2. Spool (Bucket Hi)
3. Spool (ECSS control)
4. Spool (Lift arm)
5. Spool (Bucket)

Unit: mm
No. Check Item Criteria Remedy
Standard Size Repair Limit
Free Length x
Installed Installed Free Installed
Outside
6 Spool return spring Length Load Length Load
Diameter
54.5 x 34.8 51.2 393 N 315 N
—
(2.15 x 1.37) (2.02) (88.35 lbf) (70.81 lbf)
54.2 x 34.8 51.2 417 N 333 N
7 Spool return spring —
(2.13 x 1.37) (2.02) (93.75 lbf) (74.86 lbf)
If damaged or
58.1 x 33.0 51.5 351 N 280 N
8 Spool return spring — deformed, replace
(2.29 x 1.30) (2.03) (78.91 lbf) (62.95 lbf)
spring
51.6 x 33.0 45.0 351 N 280 N
9 Spool return spring —
(2.03 x 1.30) (1.77) (78.91 lbf) (62.95 lbf)
54.9 x 24.2 52.0 251 N 201 N
10 Spool return spring —
(2.16 x 0.95) (2.05) (56.43 lbf) (45.19 lbf)
66.9 x 36.1 63.5 263 N 210 N
11 Spool return spring —
(2.63 x 1.42) (2.50) (59.12 lbf) (47.21 lbf)
53.2 x 22.3 33.0 274 N 219 N
12 Spool return spring —
(2.09 x 0.88) (1.30) (61.60 lbf) (49.23 lbf)

WA500-6 10-267 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
(3/6)

10-268 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Safety-suction valve (bucket head)

2. Suction valve (bucket Hi) and (bucket bottom)
3. Suction valve (lift arm head)
4. Safety-suction valve (bucket bottom)

Unit: mm
No. Check Item Criteria Remedy
Standard Size Repair Limit
Free Length x
Installed Installed Free Installed If damaged or
Outside
5 Suction valve spring Length Load Length Load deformed, replace
Diameter
spring
46.8 x 7.5 40.6 5.5 N 4.4 N
—
(1.84 x 0.30) (1.60) (1.24 lbf) (0.99 lbf)

Torque Values

Designation N•m lbf ft

AA 137.3 – 156.9 101.27 – 115.72

WA500-6 10-269 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
(4/6)

10-270 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Unload valve

Bucket Valve
2. EPC valve (Tilt)
3. Load check valve (Dump)
4. Load check valve (Tilt)
5. EPC valve (Dump)
6. Safety-suction valve (Tilt)
7. Spool
8. Safety-suction valve (Dump)

Torque Values

Designation N•m lbf ft

AA 34.3 – 44.1 25.30 – 32.53

BB 147.1 – 186.3 108.50 – 137.40

CC 19.6 – 24.5 14.46 – 18.07

WA500-6 10-271 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
(5/6)

10-272 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Lift Arm Valve

1. EPC valve (Lower and float)
2. Load check valve (Lift)
3. LS shuttle valve
4. Pressure compensation valve (Lower)
5. EPC valve (Raise)
6. Suction valve (Lower and float)
7. Suction valve (Lower and float)
8. Spool

ECS Valve
9. Spool
10. EPC valve
11. Accumulator charge valve

Unit: mm
No. Check Item Criteria Remedy
Standard Size Repair Limit
Free Length x Installed Installed Free Installed
12 Check valve spring Outside Diameter Length Load Length Load
41.5 x 8.5 31.5 5.9 N 4.72 N If damaged or
—
(1.63 x 0.33) (1.24) (1.33 lbf) (1.06 lbf) deformed, replace
19.2 x 7.2 16.1 19.6 N 15.7 N spring
13 Valve spring —
(0.76 x 0.28) (0.63) (4.41 lbf) (3.53 lbf)
62.5 x 20.0 39.0 3.04 N 2.43 N
14 Suction valve spring —
(2.46 x 0.79) (1.54) (0.68 lbf) (0.55 lbf)

Torque Values

Designation N•m lbf ft Designation N•m lbf in

BB 78.4 – 102.9 57.82 – 75.90 EE 9.8 – 12.7 86.74 – 112.40

CC 108 – 147 79.66 – 108.42

DD 323.6 – 402 238.67 – 296.50

FF 19.6 – 24.5 14.46 – 18.07

GG 24.5 – 34.3 18.07 – 25.30

HH 19.6 – 27.5 14.46 – 20.28

WA500-6 10-273 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
(6/6)

10-274 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Lift Arm Hi and Bucket Hi Valves

1. Load check valve (Lift arm Hi)
2. Spool (Lift arm Hi)
3. Load check valve (Bucket Hi)
4. Spool (Bucket Hi)
5. Suction valve (Bucket Hi)
6. Unload valve
7. Main relief valve
8. LS bypass valve

Torque Values

Designation N•m lbf ft

AA 19.6 – 24.5 14.45 – 18.07

BB 147.1 – 186.3 108.50 – 137.41

CC 65.7– 85.3 48.46 – 62.91

DD 49 – 58.5 36.14 – 43.15

EE 34.3 – 44.1 25.30 – 32.53

WA500-6 10-275 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

CLSS (Closed Center Load-Sensing System)

Outline of CLSS

Features

• Fine control not influenced by load

• Controllability enabling digging even with fine control

• Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations

• Energy saving using variable pump control

Structure

• CLSS is configured with a variable capacity piston pump, control valves, and respective actuators.

• The hydraulic pump is configured with pump body, PC valve, and LS valve.

10-276 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Basic Principle

Pump Swash Plate Angle Control

• The pump swash plate angle (pump delivery) is controlled so that

the LS differential pressure (ΔPLS), which is the differential
pressure between the pump discharge pressure (PPS) and LS
pressure (PLS) (the actuator load pressure) at the control valve
outlet, is constant.

• [LS differential pressure (ΔPLS) = Pump discharge pressure

(PPS) – LS pressure (PLS)]

• The pump swash plate angle shifts toward the maximum position if
LS differential pressure (ΔPLS) is lower than the set pressure of
the LS valve (when the actuator load pressure is high).

• If LS differential pressure becomes higher than the set pressure

(when the actuator load pressure is low), the pump swash plate
angle shifts toward the minimum position.

LS Differential Pressure (ΔPLS) and Pump Swash Plate Angle

★ For details about the functions, see Work Equipment Hydraulic

Pump HPV190 in this section.

WA500-6 10-277 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Pressure Compensation Control
.

10-278 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
• The valve (pressure compensation valve) to balance the load is installed to the lift arm head outlet side of the control
valve.

• When actuators are operated simultaneously, the pressure difference (ΔP) between the upstream (inlet port) and
downstream (outlet port) of the spool of each valve becomes the same regardless of the size of the load (pressure).

• The flow of oil from the pump is divided (compensated) in proportion to the area of openings (S1) and (S2) of each valve.

• This prevents the bucket from becoming inoperable because of excessive oil flow to the lift arm head due to the
lowering of the lift arm under its own weight and compound operation of the bucket.

WA500-6 10-279 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-280 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Bucket valve
2. Lift arm valve
3. ECSS valve
4. Lift arm Hi valve
5. Bucket Hi valve
6. Bucket spool
7. Lift arm spool
8. ECSS spool
9. Lift arm spool
10. Bucket spool
11. Pressure compensation valve
12. Suction valve
13. Load check valve
14. Accumulator charge valve
15. Main relief valve
Set pressure: 34.3 ±0.5 MPa (4974.79 ±72.52 psi)
16. Unload valve
Cracking pressure: 1.96 ±0.2 MPa (284.27 ±29.01psi)
17. Safety suction valve
Set pressure: 36.2 ±0.5 MPa (5250.37 ±72.52 psi)

WA500-6 10-281 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Function and Operation of Each Valve

Pressure Compensation Valve
(Installed on the cylinder head side of the lift arm valve)

★ When a high load is applied to the lift arm

10-282 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve

Function

• High load pressure is generated during independent operation of the lift arm and compound operation with the bucket.

• When the lift arm load pressure becomes higher than the bucket, the pressure compensation valve operates as a load check
valve to prevent reverse oil flow in the circuit.

Operation

• Actuator circuit pressure (B) becomes higher than pump discharge pressure (PPS) and LS pressure (PLS).

• Shuttle valve (3) of the pressure compensation valve moves to the right.

• Actuator circuit pressure (B) and spring chamber (C) are connected.

• Piston (4) is pressed by spring (5) to the left.

• Valve (2) is pressed by piston (4) to the left and pump outlet circuit (A) is closed. This prevents reverse flow of oil from
actuator circuit (B) to pump outlet circuit (A).

WA500-6 10-283 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
★ Compound operation (lift arm lower + bucket tilt)
.

10-284 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Function

• If the load pressure is lower than the bucket and the flow rate starts increasing during compound operation, the pressure
compensation valve compensates the pressure.

• On the bucket side, the load pressure is higher and the flow rate starts to decrease.

Operation

• If the load pressure on the bucket side rises during compound operation, the flow rate of actuator circuit pressure (B) starts
to increase.

• As LS pressure (PLS) rises on the bucket side, shuttle valve (3) of the pressure compensation valve is pressed to the left.

• Hydraulic oil flows through the internal passage of piston (4) to spring chamber (C).

• Piston (4) and valve (2) are pressed to the left and the outlet side of pump circuit (PPS) is cut off.

• Outlet pressure (A) (spool meter-in downstream pressure) becomes equal to the bucket outlet pressure.

• Pump pressure (PPS) (spool meter-in upstream pressure) becomes equal for all actuators.

• Pump pressure (PPS) and outlet pressure (A) become equal for all spools.

• Pump flow rate is distributed in proportion to the opening area of the respective spools.

WA500-6 10-285 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Shuttle Valve in the Pressure Compensation Valve

★ If holding pressure of port (B) > LS pressure in spring chamber (C)

1. Hydraulic pump
2. Valve
3. Shuttle valve
4. Piston

Function

• Shuttle valve (3) is pressed to the right by port (B) pressure and ports (B) and (D) are cut off.

• Holding pressure of port (B) is led to spring chamber (C) and piston (4) is pressed to the left to prevent it from being
separated from valve (2).

10-286 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Area Ratio of Pressure Compensation Valve

Function

• The state of division changes according to the area ratio of pressure compensation portions (A1) and (A2).

Area ratio = (A2)/(A1)

• Since the area ratio is less than 1, spool meter-in downstream pressure < maximum load pressure and the oil flow is
divided greater than by the area ratio of the opening.

WA500-6 10-287 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

LS Shuttle Valve
★ Supply of LS pressure

10-288 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve

Function

• The LS pressure (PLS) is the actuator load pressure on the outlet side of the control valve.

• Pressure compensation valve (3) upstream pressure (spool meter-in downstream pressure) is led through main spool (2) to
LS shuttle valve (7).

• Connected to actuator port (B) through valve (4), and makes LS pressure = actuator load pressure.

• Orifice (a) inside main spool (2) has a small diameter concurrently serving as a throttle.

Operation

• If main spool (2) is operated, pump discharge pressure (PPS) flows to actuator circuit (B).

• Pump discharge pressure (PPS) is led through orifice (a) of main spool (2) to LS circuit (PLS).

• When actuator circuit (B) rises to the necessary pressure level, pump discharge pressure (PPS) rises.

• Check valve (5) in main spool (2) opens and the high pressure in LS circuit (PLS) flows out to actuator circuit (B).

• Pressure in LS circuit (PLS) becomes approximately equal to that of actuator circuit pressure (B).

WA500-6 10-289 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

LS Bypass Valve

10-290 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass valve
6. LS circuit

Function

• Releases the residual pressure in LS pressure circuit (6) from orifices (a) and (b).

• Slows down the rising rate of the LS pressure to prevent a sudden change of hydraulic pressure.

• The bypass flow from LS bypass valve (5) causes a pressure loss to be generated due to the circuit resistance between
throttle (c) of main spool (2) and LS shuttle valve (4).

• Effective LS differential pressure drops to improve the dynamic stability of the actuator.

WA500-6 10-291 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

ECSS Control Valve

10-292 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Function

• The controller automatically turns on and off the accumulator charged with high-pressure gas according to the travel
condition.

• The ECSS control valve gives elasticity to the vertical movement of the work equipment and reduces rocking of the
machine body during high-speed travel in order to improve the comfort of the operator and prevent spillage of material,
resulting in higher working efficiency.

Operation

• If the travel speed exceeds 5 km/h (3 mph), the signal is sent to solenoid valve (2) and the pressure is applied to (a).

• Spool (1) moves to the right.

• As spool (1) moves, the line from (PR) to accumulator (ACC) is closed and the lines from (A2) to accumulator (ACC) and
from (B2) to (T) are opened. As a result, the ECSS is turned ON.

• While the travel speed is below 4 km/h (2.5 mph), the signal 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 accumulator (ACC) is charged.

• If accumulator (ACC) is charged up to the set pressure, check valve (5) is closed and the pressure in accumulator (ACC)
does not rise any further.

Accumulator Pressure Relief Valve

If the pressure in accumulator (ACC) needs to be relieved, loosen
plug (3) and nut (4) to open circuits (PR) and (TS).

WA500-6 10-293 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Accumulator Charge Valve

10-294 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Screw
2. Poppet (Safety valve)
3. Spring (Safety valve)
4. Spring (Main pressure reducing valve)
5. Pressure reducing valve spool
6. Poppet (Check valve)
7. Spring (Check valve)

CR. Pressure pickup port

P. From main pump
PR. To accumulator through ECSS spool
TS1. To tank
TS2. To tank
TS3. To tank

Torque Values

Designation N•m lbf ft

BB 98.1 – 122.5 72.35 – 90.35

CC 24.5 – 34.3 18.07 – 25.30

DD 19.6 – 27.5 14.46 – 20.28

WA500-6 10-295 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-296 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
★ When valve is in neutral and (P) is low

Function

Discharge pressure (P) of the hydraulic pump is reduced and the oil is supplied to the ECSS accumulator.

Operation

• Poppet (2) is pressed by spring (3) against the seat and the line from port (P1) to port (T) is closed.

• Poppet (6) is pressed to the left and the line from port (P1) to port (PR) is closed.

• Poppet (6) is moved to the right by pressure (P1) and the line from (P1) to (PR) is opened. If (P1) < (PR), poppet (6) is
pressed to the left by spring (7) and the line from (P1) to (PR) is closed.

WA500-6 10-297 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
★ When load pressure (P) is high

Operation

• If pressure (P) rises above the set pressure, poppet (3) opens and the hydraulic oil flows through port (P1), hole (a) in
spool (5), opening of poppet (2), and tank port (T).

• In this manner, differential pressure is made before and after hole (a) in spool (5). Spool (5) moves to close the opening
between ports (P) and (P1). Pressure (P) is reduced to a certain pressure (the set pressure) by the open area at this time and
supplied as pressure (P1).

10-298 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Accumulator (for PPC Circuit)

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port

Specifications
Type of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nitrogen gas
Amount of gas: . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 cc (30.51 in3)
Max. operating pressure: . . . . . . . . . . . . . . . 3.92 MPa (568.55 psi)
Min. operating pressure: . . . . . . . . . . . . . . . . . . . . . . . 0 MPa (0 psi)
Function

The accumulator is installed between the charge valve and work

equipment valve. If the engine is stopped with the lift arm raised,
compressed nitrogen gas pressure in the accumulator feeds the pilot oil
pressure to the work equipment valve for operation. In this manner, the
lift arm and bucket are enabled to descend under their own weight.

Operation

• After the engine is stopped, chamber (A) in the bladder is

compressed by oil pressure in chamber (B).

• When the work equipment EPC solenoid is tripped by operating

the work equipment EPC lever, pressure inside nitrogen gas
chamber (A) expands the bladder and the oil in chamber (B)
operates the work equipment valve as the pilot pressure.

WA500-6 10-299 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

MEMORANDUM

10-300 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Work Equipment Electric Lever

Torque Values

Designation N•m lbf in

1 6.9 – 9.8 61.07 – 86.74

2 11.8 – 14.7 104.44 – 130.11

3 3.4 – 4.4 30.09 – 38.94

WA500-6 10-301 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

10-302 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Lever
2. Rod
3. Centering spring
4. Metering spring
5. Nut
6. Rod
7. Detent spring
8. Retainer
9. Lever
10. Potentiometer
11. Seat
12. Ball
13. Detent spring
14. Rod
15. Body
16. Solenoid
17. Bushing
18. Body
19. Retainer
20. Rod

Torque Values

Designation N•m lbf in

CC 11.8 – 14.7 104.44 – 130.11

DD 1.0 – 2.0 8.85 – 17.70

WA500-6 10-303 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Function

• When lever (1) is operated, rod (20) moves up and down and
rotates potentiometer (10) according to the operating distance of
the lever.

• The operating angle (stroke) of the control lever is sensed with the
potentiometer and output as a signal voltage to the controller.

• A potentiometer is installed. It outputs two signal voltages which

are opposite to each other as shown in the diagram to the right.

10-304 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Operation

★ When work equipment control lever is operated

• Rod (20) is pushed up by spring (4) according to the operating distance of lever (1).
• Lever (9) and rod (14), installed to the rotary shaft of potentiometer (10), are connected to each other.
• Potentiometer (10) outputs signal voltage according to the vertical stroke of the rod.

★ When work equipment is operated to lift arm lower (or to lift arm raise or bucket tilt)
• If rod (2) on the lift arm lower side is pushed down by lever (1), ball (12) touches projection (a) of rod (14) in the
middle of the stroke (before electric detent operation starts).
• If rods (2) and (14) are pushed in further, ball (12) pushes up retainer (8), supported on detent spring (7), and escapes
out to go over projection (a) of rod (14).
• At this time, rod (20) on the opposite side is pushed up by spring (4).
• If rod (20) is pushed up while the current is flowing in solenoid (16), nut (5) is attracted by bushing (17).
• In this manner, rod (20) is kept pushed up and the lift arm lower state is kept even if the lever is released.

★ When lift arm lower operation of work equipment control lever is reset
• Lever (1) is returned from the lift arm lower position by pushing down rod (20) with a force larger than the attractive
force of the solenoid.
• The lift arm lower state also can be reset and lever (1) can be returned to the neutral position by turning off the current
in the solenoid.

WA500-6 10-305 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

WORK EQUIPMENT
Work Equipment Linkage

1. Bucket 6. Bucket link

2. Bell crank 7. Bucket hinge pin
3. Bucket cylinder 8. Bucket hinge pin
4. Lift cylinder 9. Bell crank pin
5. Lift arm 10. Cord ring

10-306 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

WA500-6 10-307 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

10-308 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

Unit: mm (in)
No. Check Item Criteria Remedy
Standard
Tolerance Standard Clearance
Size
Clearance Limit
Shaft Hole
Clearance between bushing and pin at each
1 -0.036 +0.307 0.256 –
end of bucket link
120 (-0.0014) (+0.0121) 0.397
1.0 (0.039)
(4.72) -0.090 +0.220 (0.010 –
(-0.0035) (+0.0087) 0.016)
-0.036 +0.307 0.256 –
Clearance between bushing and pin 120 (-0.0014) (+0.0121) 0.397
2 1.0 (0.039)
connecting lift arm and bucket (4.72) -0.090 +0.220 (0.010 –
(-0.0035) (+0.0087) 0.016)
-0.043 +0.395 0.338 –
Clearance between bushing and pin 140 (-0.0017) (+0.0156) 0.501
3 1.0 (0.039)
connecting lift arm and frame (5.51) -0.106 +0.295 (0.013 –
(-0.0042) (+0.0116) 0.020)
-0.043 +0.395 0.338 –
Clearance between bushing and pin 125 (-0.0017) (+0.0156) 0.501 Replace
4 1.0 (0.039) [Replace if pin
connecting bucket cylinder bottom and frame (4.92) -0.106 +0.295 (0.013 –
(-0.0042) (+0.0116) 0.020) has scuff mark]
-0.043 +0.395 0.338 –
Clearance between bushing and pin 125 (-0.0017) (+0.0156) 0.501
5 1.0 (0.039)
connecting bucket cylinder rod and bell crank (4.92) -0.106 +0.295 (0.013 –
(-0.0042) (+0.0116) 0.020)
-0.043 +0.395 0.338 –
Clearance between bushing and pin 160 (-0.0017) (+0.0156) 0.501
6 1.0 (0.039)
connecting bellcrank and lift arm (6.30) -0.106 +0.295 (0.013 –
(-0.0041) (+0.0116) 0.020)
-0.036 +0.307 0.256 –
Clearance between bushing and pin 120 (-0.0014) (+0.0121) 0.397
7 1.0 (0.039)
connecting lift cylinder bottom and frame (4.72) -0.090 +0.220 (0.010 –
(-0.0035) (+0.0087) 0.016)
-0.036 +0.307 0.256 –
Clearance between bushing and pin 120 (-0.0014) (+0.0121) 0.397
8 1.0 (0.039)
connecting lift cylinder rod and lift arm (4.72) -0.090 +0.220 (0.010 –
(-0.0035) (+0.0087) 0.016)
Standard
Boss-to-Boss
Width of Hinge Clearance
9 Connecting part of bucket cylinder and frame Width
(Clearance of a+b)
153 (6.02) 150 (5.91) 3.0 (0.118)
Adjust
10 Connecting part of lift arm and frame 183 (7.20) 180 (7.09) 3.0 (0.118) [Insert shims to
11 Connecting part of lift arm and bucket 183 (7.20) 180 (7.09) 3.0 (0.118) both sides so
12 Connection of bucket link and bucket 183 (7.20) 180 (7.09) 3.0 (0.118) that clearance
will be below
13 Connecting part of bellcrank and bucket link 183 (7.20) 180 (7.09) 3.0 (0.118) 1.5 mm
14 Connecting part of lift cylinder and frame 153 (6.02) 150 (5.91) 3.0 (0.118) (0.059 in) on
each side]
15 Connecting part of bellcrank and lift arm 316 (12.44) 313 (12.32) 3.0 (0.118)
Connecting part of bucket cylinder and
16 155 (6.10) 150 (5.91) 5.0 (0.197)
bellcrank
17 Connecting part of lift arm and lift cylinder 153 (6.02) 150 (5.91) 3.0 (0.118)

WA500-6 10-309 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

Bucket

Bucket 5.6 M3 (with Bolt-On Cutting Edge)

10-310 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

1. Bucket
2. Bolt-on cutting edge (BOC)

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Repair Limit
3 Wear on edge Turn over or replace
38 (1.50) 15 (0.59)

Torque Values

Designation N•m lbf ft

CC 800 – 1200 649.05 – 885.07

WA500-6 10-311 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

Bucket 5.2 M3 (with Teeth and Segment Edge)

Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Repair Limit
1 Wear on bucket teeth Replace
38 (1.50) 23 (0.91)
2 Clearance in bucket tooth mounting parts Max. 0.5 mm (0.02 in) (Clearance between edge) Adjust or replace
3 Wear on segment edge 38 (1.50) 15 (0.59) Turn over or replace

Torque Values

Designation N•m lbf ft

EE 880 – 1,200 649.05 – 885.07

FF 1878 ±279 1385.14 ±205.78

GG 1040 ±157 767.06 ±115.80

10-312 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

Bucket Positioner and Boom Kickout

Unit: mm (in)
No. Check Item Criteria Remedy
1 Clearance of bucket positioner switch 3 – 5 (0.1181 – 0.1968)
Adjust
2 Clearance of lift arm position detection switch 0.5 – 1 (0.0197 – 0.0394)

WA500-6 10-313 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

Work Equipment Lubrication

1. Steering cylinder A. Lift cylinder pin left

2. Bell crank B. Lift cylinder pin right
3. Lift arm C. Bucket cylinder (bottom side)
4. Bucket cylinder D. Lift cylinder (bottom side) right
5. Front frame E. Lift cylinder (bottom side) left
6. Lift cylinder F. Steering cylinder (rod side) right
7. Rear frame G. Steering cylinder (rod side) left
H. Center support

10-314 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT

J. Rear axle (thrust plate)

K. Rear axle mount (rear)
L. Rear axle mount (front)

WA500-6 10-315 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

CAB AND ITS ATTACHMENTS

ROPS Cab

1. Front glass
2. Front wiper
3. Door
4. Rear wiper

10-316 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

Torque Values

Designation N•m lbf ft

1 1177 – 1471 868.11 – 1084.95

WA500-6 10-317 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

Air Conditioner
Air Conditioner Piping Diagram

1. Air outlet duct

2. Air conditioner unit
3. Compressor
4. Receiver
5. Condenser
6. Hot water take-out port
7. Hot water return port

Specifications
Refrigerant used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R134a
Refrigerant refilling volume (g) . . . . . . . . . . . . . . . . . . . . . 1,250 ±50

10-318 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

Cooling Circuit Diagram

WA500-6 10-319 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

Air Conditioner Unit

A. Hot water outlet

B. Hot water inlet
C. Refrigerant inlet side
D. Refrigerant outlet side

10-320 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

Condenser

1. Fin
2. Tube
3. Refrigerant gas outlet port
4. Refrigerant gas inlet port

Function

• The condenser cools and liquefies the high-pressure and high-temperature refrigerant from the compressor.

• If the fins are crushed or are clogged with dust, heat exchange efficiency is degraded and complete liquefaction of the
refrigerant becomes unavailable.

As the result, pressure in the refrigerant circulation circuit is increased, applying extra load to the engine or degrading the
cooling effect. Be very careful when handling the condenser and during the daily inspection.

Specifications
Fin pitch (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Total heat dissipation surface (m2) . . . . . . . . . . . . . . . . . . . . . . 6.55
Max. pressure used MPa (psi) . . . . . . . . . . . . . . . . . . . 3.6 (522.14)

WA500-6 10-321 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
Compressor

1. Case
2. Clutch

A. Suction service valve

B. Discharge service valve

Function

• Other than circulating the refrigerant, the compressor compresses the refrigerant gas from the evaporator to high-pressure,
high-temperature refrigerant so that it may be easily regenerated (liquefied) at normal temperature.

• Its built-in magnet clutch turns on or off depending on the evaporator temperature and refrigerant pressure.

Specifications
Number of cylinders – Bore x Stroke (mm) . . . . . . . . 5 – 35 x 28.6
Piston capacity (cc/rev) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Allowable maximum speed (rpm) . . . . . . . . . . . . . . . . . . . . . 4,000
Refrigerant oil used: . . . . . . . . . . . . . . . . . . . . . . . . . Sanden SP-20
Refrigerant oil refilling volume (cc) . . . . . . . . . . . . . . . . . . . . . . 175

10-322 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

Receiver

A. From condenser
B. To air conditioner unit

1. SIght glass

Function

• The receiver is used to store liquefied high-pressure, high-temperature refrigerant from the condenser. It is capable of
completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in
heat dissipation.

• The receiver eliminates foreign substances in the circulation circuit and water content in the refrigerant by using the built-
in filter and desiccating agent.

• Sight glass (1) allows you to inspect the flow of the refrigerant.

Specifications
Effective cubic capacity (cm3) . . . . . . . . . . . . . . . . . . . . . . . . . . 578
Weight of desiccating agent (g) . . . . . . . . . . . . . . . . . . . . . . . . . 300

WA500-6 10-323 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

Air Conditioner Panel

Manual Air Conditioner Specification

Display Unit

Display Displayed Display

No. Display Range Display Method Remarks
Category Items Color

All segments below applicable level

1 Temperature
Gauges
2 Volume
See above figure
come on (8-step display)
All segments below applicable level
See above figure
come on (4-step display)

The display indicates which is

Circulation of When circulating currently taking place – internal air Liquid
internal air and internal air and circulation or external air introduction, Black
3 crystal
introduction of introducing responding to the operation of the
Pilot external air external air internal/external air changeover
switch.

When air
Turns ON air conditioner switch, this
4 Air conditioner conditioner switch
lamp lights up.
is turned ON

10-324 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

Switch Block

No. Type Function Operation

It is used for selecting the internal air circulation or external air Internal air circulation
Internal/external air introduction ↓ ↑
5
changeover switch (The pilot indication on the display unit varies depending on the External air
given setting.) introduction

Air conditioner It turns on or off the cooling and the dehumidifying heating
6 OFF ← → ON
switch function.

This switch turns on or off the main power of the air conditioner.
ON: Display unit indicates the setting being specified when power
7 Main power switch OFF ← → ON
was turned OFF.
OFF: Turns off the display unit and stops the fan.

It controls volume of air sent from the fan.

8 Fan switch LO ←→ HI
(Adjusted in four steps [LO, M1, M2, HI])

Low temperature
Temperature It is used to control spurting out temperature.
9 ↑ ↓
adjusting switch (8-step adjustment)
High temperature

Outline

• The 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.

• The self-diagnosis function of the CPU makes the troubleshooting easier.

Input and Output Signals

JAE IL-AG5-14P [CN-C48]

Pin No. Signal Name Input and Output Signals

1 GND —

2 Sensor ground —

3 Internal/external air changeover damper actuator limiter Input

4 External air temperature sensor Input

5 Evaporator temperature sensor Input

6 Internal air temperature sensor Input

7 Starting switch (ON) Input

8 Night lamp signal Input

9 NC —

10 NC —

11 NC —

12 NC —

13 Day light sensor 2 Input

14 Day light sensor 1 Output

WA500-6 10-325 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS

JAE IL-AG5-22P [CN-C47]

Pin No. Signal Name Input and Output Signals

1 NC —

2 NC —

3 Blower motor relay Input

4 Internal/external air changeover damper actuator output 1 Output

5 Internal/external air changeover damper actuator output 2 Output

6 Mode selector actuator output 2 Output

7 Mode selector actuator output 1 Output

8 Air mix damper actuator output 2 Output

9 Air mix damper actuator output 1 Output

10 Actuator potentiometer power supply (5 V) —

11 NC —

12 NC —

13 NC —

14 NC —

15 Magnet clutch Input

16 Air mix damper actuator limiter Input

17 Mode selector actuator limiter Input

18 Air mix damper actuator potentiometer Input

19 Mode selector actuator potentiometer Input

20 Blower gate Input

21 Blower feedback Input

22 Actuator potentiometer ground —

10-326 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
Machine Monitor System
Outline

• In the machine monitor system, each monitor on the network monitors and controls the machine condition with the
sensors installed to various parts of the machine, and then sends the result as network information to the machine monitor,
which displays the information to notify the operator of the machine condition.

• The machine monitor displays the information in the operator (normal) mode or service mode.

Operator Mode

• The operator mode is used to display the information to the operator normally. The major functions displayed in the
operator mode are described here.

1. Items always displayed:

• Meters (speedometer or engine tachometer)
• Gauges (engine coolant temperature gauge, torque converter oil temperature gauge, hydraulic oil temperature gauge,
and fuel level gauge)
• Pilot indicators
• Service meter

The following items are displayed according to the set state of the optional device selecting function:
• Load meter calculated weight
• Hours
• Display of travel speed/engine speed on the character display

2. Items displayed when abnormality is detected:

• Caution lamps
• Action code (if the monitor panel mode selector switch (>) is pressed and released while an action code is displayed,
the failure code (six digits) is displayed.)

3. At the replacement period of a filter or oil, the character display displays that filter or oil (maintenance monitoring
function).

4. In addition to the above, the following display, setting, and adjustment functions are provided using the character display
and the machine monitor mode selector switch, which is the operation switch of the character display.

A. Load meter (if equipped)

• Loaded/no loaded calibration
• Reset of calibration
• Display/non-display of load meter
• Printer output format (printer (if equipped))
B. Displaying odometer
C. Resetting filter oil replacement time
D. Inputting telephone number
E. Selecting a language
F. Adjusting brightness of the night lighting for the machine monitor
G. Adjusting time of clock (load meter (if equipped))
H. Selecting travel speed and engine speed display
I. Setting display/non-display of travel speed and engine speed on the character display

WA500-6 10-327 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Service Mode

• The service mode function is provided for the ease of troubleshooting the controllers on the network (including the
machine monitor itself). The major functions used in the service mode are described here.

1. Electrical system failure history display function

The electrical system failures for each controller are saved in the machine monitor and displayed. The information about
these failures is deleted with this function.

2. Mechanical system failure history display function

The mechanical system failures of each controller are saved in the machine monitor and displayed.

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 mode function

This function is used to stop fuel injection to each cylinder from the fuel injector in order to determine the cylinder with
defective combustion.

5. No injection cranking function

This function is used to lubricate the engine internally before starting the engine after long-term storage of the machine.

6. Adjustment function
Function provided to correct and adjust the installation errors and manufacturing dispersion of the sensors, solenoid
valves, etc. Function for changing the control characteristic data upon request of the user.

7. Maintenance monitoring function

Changes the filter and oil replacement time and allows 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.

10. Machine serial number input function

Enters the machine serial number to identify the machine.

11. Model selection function

Enters the information for the applicable model.

12. Initialize function

Sets the machine monitor to the state set when the machine was delivered.

10-328 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Machine Monitor Circuits

Starting and Lighting

WA500-6 10-329 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Load Meter

10-330 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Sensing

WA500-6 10-331 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Power Supply and Network

10-332 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Electrical Circuit Diagram

WA500-6 10-333 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

10-334 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

MEMORANDUM

WA500-6 10-335 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Machine Monitor

10-336 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

1. Torque converter oil temperature gauge 26. Maintenance caution lamp

2. Torque converter oil temperature caution lamp
3. Engine coolant temperature gauge
4. Engine coolant temperature caution lamp
5. Speedometer or engine tachometer
6. Display of the unit of speedometer or engine tachometer
7. Turn signal pilot lamp (left)
8. Head lamp high beam pilot lamp
9. Turn signal pilot lamp (right)
10. Hydraulic oil temperature gauge
11. Hydraulic oil temperature caution lamp
12. Fuel level gauge
13. Fuel level caution lamp
14. Central warning lamp
15. Brake oil pressure caution lamp
16. Engine oil pressure caution lamp
17. Water separator caution lamp (not used)
18. Engine oil level caution lamp
19. Radiator coolant level caution lamp
20. Parking brake pilot lamp
21. Air cleaner clogging caution lamp
22. Transmission oil filter clogging caution lamp
23. Axle oil temperature caution lamp
24. Modulation clutch temperature caution lamp (not used)
25. Cooling fan reverse rotation pilot lamp
27. Battery electrolyte level caution lamp (if equipped)
28. Battery charge circuit caution lamp
29. Steering oil pressure caution lamp
30. Emergency steering pilot lamp
31. Output mode pilot lamp (Power mode)
32. Preheater pilot lamp
33. Semi-auto digging pilot lamp
34. Auto-grease pilot lamp (if equipped)
35. Joystick pilot lamp (if equipped)
36. Directional selector pilot lamp (not used)
37. ECSS pilot lamp
38. Economy operation indicator lamp
39. Shift position pilot lamp (forward/reverse)
40. Shift position pilot lamp (gear speed)
41. Shift indicator
42. Auto-shift pilot lamp
43. Lockup pilot lamp
44. Shift hold pilot lamp
45. Display of bucket loading (if equipped)
46. Addition mode: Total loading display/Reduction mode:
Display of level (if equipped)
47. Working object display (if equipped)
48. Addition/reduction mode display (if equipped)
49. Character display

WA500-6 10-337 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Machine Monitor Operation Switches

1. Load meter display selector switch (if equipped)

• Total mass display

2. Load meter mode selector switch (if equipped)

• Material selection
• Addition/reduction selection

3. Character display mode selector switch

4. Character display item selector switch

10-338 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Items Displayed on Monitor

Condition for judging that the engine is running:

If two or more of the following three conditions are met, the engine is considered to be running when the abnormality in the
CAN communication occurs (DAQRKR) and the charge level exceeds the specified level (DB2RKR).

1. Turning ON 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.

● Lighting

❍ Flashing (1.6 sec., 50% duty)

✩ Intermittent (Period: 240 msec., ON: 80 msec., OFF: 160 msec.)

Δ As per separate setting condition

Operating condition: Engine

operating condition included,
Operating State
error detection time counted (As

Signal Detection Controller

indicated at right)
Detection
Engine: Engine:

Display Color
time
Category

Stopped Running
(sec)
No. Item Device Remarks
Display of Message

Display of Message
Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset

Lights when error

(E03, E02) occurs
Central warning lamp

on each controller
Red

When error is made Δ Δ Δ Δ Δ Δ Δ Δ Δ

and at the same
time displays
Central warning
14 LED message.
lamp
Other than above, see
“Operating condition –
Central warning lamp” — — — — — — — —
column of relevant
items.
Gauges and meters Back light

For night Back light:

White

Back light (various

— lighting When small lamp is — — — — — — Monitor
back lights)
of LED turned ON
Indicates “0” if error is Switchable to
made in speedometer
communication other The first digit is
Fixed
5 Engine speed than when engine — — — — — — — Engine fixed at 0.
LCD
speed is selected or Number of display
tilt positioner set digits (4-digits):
angle is displayed. 0 – 3990

WA500-6 10-339 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Operating condition: Engine

operating condition included,
Operating State
error detection time counted (As

Signal Detection Controller

indicated at right)
Detection
Engine: Engine:

Display Color
time
Category

Stopped Running
(sec)
No. Item Device Remarks

Display of Message

Display of Message
Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
Switchable to
Other than when
tachometer
engine speed is not
Fixed Number of display
Travel speed selected and tilt — — — — — — — TM
LCD digits (4-digits):
positioner set angle is
0 – 99 (middle 2 out
displayed
of 4 digits are used.)
Switching between
speedometer/
tachometer
Displayed just
3 seconds when
instruction is given
from work
equipment
When tilt positioner
controller.
set angle is displayed.
Number of display
Tilt positioner set Fixed digits is 1-digit (-5 to
Lamp does not light — — — — — — — BBC
position display LCD 5) (middle 2 out of
up when error is
4-digits are used,
made in
unit is not
communication.
displayed).
Operation
Gauges and meters

completion sound
(short beep) and
5 cancel sound (long
beep sound) are
given
simultaneously.
Alarm is issued when
information of
“Overrun prevention
Overrun prevention
(in lockup release →
Remarks

Remarks

(when lockup
Fixed torque converter
release → torque ❍ ● ❍ ● — TM
❍

LCD mode) alarm notice” is

converter mode)
obtained from
alarm notice
transmission
controller, and is kept
at least 3 minutes.
Alarm is issued when Note 1
information of
“Overrun prevention
(in lockup release →
Overrun prevention
Remarks

Remarks

torque converter
(in lockup release Fixed
mode) alarm ❍ ● ❍ ● — TM
❍

→ torque converter LCD

detecting” is obtained
mode) alarm
from transmission
controller, and is
continued at least 3
minutes.

10-340 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Operating condition: Engine

operating condition included,
Operating State
error detection time counted (As

Signal Detection Controller

indicated at right)
Detection
Engine: Engine:

Display Color
time
Category

Stopped Running
(sec)
No. Item Device Remarks

Display of Message

Display of Message
Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
When engine speed is
— — — r/min — — r/min — —
selected
When speed [km/H] is
— — — km/h — — km/h — — Monitor
selected
Unit

6 Unit display LCD

When speed [MPH] is
— — — MPH — — MPH — —
selected
When tilt positioner
— — — — — — — BBC
set angle is displayed

Note 1
Central Main Part
Buzzer Message
Warning Lamp (*1)
Overrun notice ● ❍ ❍ (flashing) —
Overrun ● ❍ ❍ (flashing) Overrun prevention
• When the engine speed is displayed on the center LCD, the display flashes.
(*1) • When the travel speed is displayed, it is switched to the engine speed and the display flashes.

WA500-6 10-341 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Operating condition: Engine

operating condition included,
Operating State
error detection time counted

Signal Detection Controller

(As indicated at right)
Detection
Engine: Engine:

Display Color
Time
Category

Stopped Running
(sec)
No. Item Device Remarks

Display of Message

Display of Message
Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
Torque MAX position:
Pointer:
1 converter oil ——— ————— 135°C (275°F)
Movement
temperature Red zone start point:
Alarm: 120°C (248°F)
Level: 110°C (230°F)

(b@CENS)

(b@CENS)
Min. 120°C (248°F)
and [No 1/4 of full scale:

Red
10 1 — ● — — ● — (See figures 80°C (176°F)
abnormality is
detected (DGT1KX at end of Min. position:
is not generated)] table.) 50°C (122°F)
Torque Monitor When sensor is
converter oil Indicator: Alarm: Min. grounded:
2 B@CENS

B@CENS
temperature LED 130°C (266°F) and Max. of gauge

Red
caution lamp [No abnormality is 10 1 ❍ ● ● ❍ ● ● When sensor is
detected (DGT1KX
Operation of gauges and meters

disconnected or hot
is not generated)] shorted: Min. of gauge
DGT1KX

DGT1KX
When abnormality Red b@CENS does not display
20 5 ——— ———
is detected character message.

Engine
Pointer:
3 coolant —————————
Movement
temperature
Alarm: Min.
102°C (216°F) and
[No abnormality is
Red

3 — ● ——— ● —— MAX position:

detected (CA144
135°C (275°F)
and CA145 are not
(See figures Level: 85°C (185°F)
generated)] Engine
Engine at end of 1/4 of full scale:
monitor
CA145 CA144 B@BCNS

CA145 CA144 B@BCNS

coolant Indicator: table.) 65°C (149°F)

4 Alarm:
Red

temperature LED ❍ ● ● ❍ ● ● Min. position:

Min. 105°C (221°F)
caution lamp 50°C (122°F)

When abnormality
——— ———
is detected

When abnormality
——— ———
is detected

10-342 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Operating condition: Engine

operating condition included,
Operating State
error detection time counted

Signal Detection Controller

(As indicated at right)
Detection
Engine: Engine:

Display Color
Time
Category

Stopped Running
(sec)
No. Item Device Remarks

Display of Message

Display of Message
Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
Hydraulic oil Pointer: Max. position:
10 —————————
temperature Movement 125°C (257°F)
Alarm: Red zone start point:
Min. 100°C (212°F) 100°C (212°F)

B@HANS

B@HANS
and [No Level: 85°C (185°F)

Red
10 1 ❍ ● ● ❍ ● ● (green graduations
abnormality is
detected (DGH2KX only)
is not generated)] 1/4 of full scale:
(See figures 65°C (149°F)
Hydraulic oil Monitor at end of (green graduations
Indicator: table.) only)
11 temperature
LED
caution lamp Min. position:
DGH2KX

DGH2KX
50°C (122°F)
When abnormality
Operation of gauges and meters

20 5 ——— ——— — When sensor is

is detected grounded: Max. of
gauge
When sensor is
disconnected or hot
shorted: Min. of gauge
Pointer: MAX position:
12 Fuel level ——— ——— —
Movement 100%: 10Ω
3/4 of full scale: 75%
Level: 50%: 32Ω
1/4 of full scale:
25%: 49.5Ω
Red zone start point:
See specified LED
(See figures
lighting percent or
Monitor at end of
Fuel level Indicator: resistance.
Red

13 Min. 61.3 Ω 10 1 — ● — — ● — table.)

caution lamp LED Min. position: 0%: 85Ω
When sensor is
disconnected or hot
shorted: Gauge
EMPTY
When sensor is
grounded: Gauge
FULL

WA500-6 10-343 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Operating condition: Engine operating

condition included, error detection time Operating State

Signal Detection Controller

counted (As indicated at right)
Detection
Engine: Engine:
Time

Display Color
Stopped Running
Category

(sec)
Device

Display of Message

Display of Message
No. Item Remarks

Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
[When F is selected] and
1 0 ✩ ● ● ——— Green
[Engine is stopped]
[When R is selected] and
1 0 ✩ ● ● ——— Green
[Engine is stopped]
When F is selected 0 0 — ● — — ● — Green
When N is selected 0 0 — ● — — ● — Green
When R is selected 0 0 — ● — — ● — Green
When 4th gear speed is
Shift 0 0 — ● — — ● — Green
39 selected Monitor
position LED
40 When 3rd gear speed is TM
pilot lamp 0 0 — ● — — ● — Green
selected
When 2nd gear speed is
0 0 — ● — — ● — Green
selected
When 1st gear speed is
0 0 — ● — — ● — Green
selected
If error is made in
communication, display is held ——— ——— —
until key is turned OFF.
Actual gear speed

Displayed on right of
[Gear speed display].
Interlocked with shift
Upper line: F, N, R
valve. In neutral,
Lower line: 1, 2, 3, 4
Shift 9-segment however, gear speed is
41 If error is made in 0 0 ——— ——— — TM
indicator LCD not displayed.
communication, display is held
Displayed on left of [FNR
until key is turned OFF.
display].
N when F or R solenoid
vale is OFF.
When auto-shift is selected 0 0 — ● — — ● — Green
Auto-shift If error is made in
42 LED
pilot lamp communication, display is held ——— ——— Green
until key is turned OFF.
When auto-shift and shift hold
0 0 — ● — — ● — Green
is selected
Shift hold
44 LED If error is made in
pilot lamp
communication, display is held ——— ——— —
until key is turned OFF.
When lockup functions 0 0 ——— — ● — Green
Lockup If error is made in
43 LED
pilot lamp communication, display is held ——— ——— —
until key is turned OFF.
Functions when key is
Turn When turn signal switch is
Others

7 OFF to provide hazard

signal LED input 0 0 — ● — — ● — Green Monitor
9 function interlocking with
pilot lamp (including when key is OFF)
turn signal switch.

10-344 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Operating condition: Engine operating

condition included, error detection time Operating State

Signal Detection Controller

counted (As indicated at right)
Detection
Engine: Engine:
Time

Display Color
Stopped Running
Category

(sec)

Device

Display of Message

Display of Message
No. Item Remarks

Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
Head
When high beam is
lamp high
8 LED functioning: Head lamp ON 0 0 — ● — — ● — Blue Monitor
beam
and High beam ON
pilot lamp
Normal oil pressure (CLOSED) ——— ——— —
Below specified value (F)

2G42ZG
(OPEN)
(detection time is continued) 5 1 — ● — ❍ ● ● Red Front
and in 45 seconds after engine
is started
Below specified value (R)
(OPEN)

2G43ZG
(detection time is continued)
5 1 — ● — ❍ ● ● Red Rear
and in 45 seconds after engine
is started
(No detection time)
Below specified pressure (F)
(OPEN)
Brake oil (detection time is continued)
pressure and 45 seconds after engine is
15 LED Monitor
caution started
lamp 1 1 — ● — ❍ ● ● Red Front
(No detection time)
* When engine is stopped,
Others

condition of “45 seconds after

engine is started” is not
applied.
Below specified pressure (R)
(OPEN)
(detection time is continued)
and 45 seconds after engine is
started
1 1 — ● — ❍ ● ● Red Rear
(No detection time)
* When engine is stopped,
condition of “45 seconds after
engine is started” is not
applied.
At normal operation ——————— —
Engine oil
B@BAZG

B@BAZG

pressure
16 LED Engine oil pressure reduction Engine
caution ❍ ● ● ❍ ● ● Red
error is received
lamp

Normal oil level (CLOSED) ——— ——— — If alarm is detected when

Engine oil Low oil level (OPEN) continues key is turned ON, first
B@BAZK

level 2 seconds. information is kept until

18 LED Monitor
caution For 300 seconds after engine 2 1 — ● — ——— Red engine oil reaches
lamp is stopped, however, no error normal oil level even if
is detected. engine is started.

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Operating condition: Engine operating

condition included, error detection time Operating State

Signal Detection Controller

counted (As indicated at right)
Detection
Engine: Engine:
Time

Display Color
Stopped Running
Category

(sec)

Device

Display of Message

Display of Message
No. Item Remarks

Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
Radiator Normal coolant level
——— ——— —
coolant (CLOSED)

B@BCZK

B@BCZK
19 level LED Monitor
caution Low coolant level (OPEN) 30 1 — ● — — ● — Red
lamp
When parking brake is applied
— ● — — ● — Red
(OPEN)
When parking brake is not
Parking ——— ——— —
applied (CLOSED)
20 brake LED Monitor
pilot lamp Other than when parking brake
is applied and gear shift lever
0 0 ✩ ● ● Red
is at “N” position, and during
starting engine
Air Normal (CLOSED) ——— ——— —
cleaner

AA1ANX
21 clogging LED Sensor detects clogging Monitor
2 1 ——— — ● — Red
caution (OPEN)
lamp
Normal (CLOSED) ——— ——— 15BONX —
Transmis- Clogging (OPEN) and torque
sion oil fil- converter oil temperature > 2 1 ——— — ● — Red If abnormality is detected
ter 50°C while engine is stopped,
22 LED Monitor
clogging alarm is continued even
DHT2L6
Others

OFF

caution When abnormality is detected 3 ——— ——— — after engine is started.

lamp
——— ——— Red
Other than below ———————— —
Temperature increase (Min.
5 5 — ● ——— ● —— Red
120°C) (notice alarm)
Temperature increase (1 or 2
below)
1. Oil temperature is above
130°C for 5 seconds.
2. When travel speed is above
B@C7NS

B@C7NS

35 km/h while brake oil

Axle oil temperature, 125°C and 5 5 ❍ ● ● ❍ ● ● Red
tempera- above, is detected
23 ture LED continuously for 5 seconds. It Monitor
caution is released when oil
lamp temperature, 125°C and below,
is detected continuously for 5
seconds.
DGR2KX DGR2KA

DGR2KX DGR2KA

When abnormality is detected ——— ——— —

When abnormality is detected ——— ——— —

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Operating condition: Engine operating

condition included, error detection time Operating State

Signal Detection Controller

counted (As indicated at right)
Detection
Engine: Engine:
Time

Display Color
Stopped Running
Category

(sec)

Device

Display of Message

Display of Message
No. Item Remarks

Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
Cooling fan forward drive 0 0 ————————

As indicated at right

As indicated at right
Cooling fan reverse
rotation state is
Cooling
displayed.
fan
Cooling fan reverse rotation 0 0 — ● — — ● — Orange Trans- While fan is reversed,
25 reverse LED
mission message is displayed on
rotation
character display.
pilot lamp
COOLING FAN
Fan switch and solenoid REVERSE ROTATION
0 0 — ❍ — — — ❍ — — Orange
disagree.
Simultaneously displays
Mainte- Ordinary ——— ——— — contents on message
nance display.
26 LED Monitor
caution 30 h or less before
lamp maintenance or maintenance — ● — Δ — ● — Δ Red
time
Normal ——— ——— —
Battery
B@GAZK

B@GAZK
electrolyte
27 level LED Sensors: Less than 2 V 10 1 — ● — — — Red Monitor
caution
lamp
Option is not applied ——— ——— If abnormality is detected
Normal voltage (hysteresis on while engine is stopped,
——— ——— —
the right figure)
Others

alarm is continued even

Insufficient alternator voltage after engine is started.
Battery
See figures on alternator
AB00MA

(Hysteresis on the right figure),

charge
no starting motor C signal 30 1 ——— ❍ ● ● Red terminal R voltage.
28 circuit LED Monitor
input, and during running of
caution
engine
lamp
AB00L6

When abnormality is detected 3 1 ❍ ● ● ——— Red

Steering Not in operation — ———————— — Implemented only when

oil In operation (CN3-3 = OPEN) — — ● — — ● — Red “Emergency steering
DDE5MA

DDE5MA

29 pressure LED Monitor enabled” is specified on

caution When abnormality is detected ——— ——— — optional setting on
lamp monitor panel.

Normal operation
Emer- [Operation of divider
gency (= Below S/T pressure CN3- 1 1 — ● — — ● — Green
30 LED Monitor
steering 3=OPEN)] and [Travel speed,
pilot lamp min. 1 km/h]
Holds in position ——— ———
Output Power mode = P 0 0 — ● — — ● — Green
mode
Trans- Selection of power mode
31 pilot lamp LED
Power mode = Other than P ———————— mission is displayed.
(power
mode)

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Operating condition: Engine operating

condition included, error detection time Operating State

Signal Detection Controller

counted (As indicated at right)
Detection
Engine: Engine:
Time

Display Color
Stopped Running
Category

(sec)

Device

Display of Message

Display of Message
No. Item Remarks

Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
Preheat- Other than below ——— ——— —
32 ing pilot LED Engine
lamp In preheating (with signal) 0 0 — ● — — ● — Red
When auto digging switch is
——— ——— —
OFF
Semi-auto
When auto digging switch is
33 digging LED 0 0 — ● — — ● — Green BBC
ON
pilot lamp
When error is made in
——— ——— —
communication
Not in operation and not Status:Port A:Port B:
——— ——— —
installed Panel display
Operation 1 1 — ● — — ● — Green Operation:0 V:24 V:
Lighting
❍ 1 Hz

❍ 1 Hz
Auto-
34 grease LED Empty tank 3 1 — — — — Green Monitor Abnormality:0 V:0 V:
Flashing, 2 Hz
pilot lamp
Empty tank:24 V:0 V:
❍ 2 Hz

❍ 2 Hz
Flashing, 1 Hz
Abnormal 3 1 — — — — Green
Abnormality:24 V:24 V:
OFF
Option is not applied ———————— —
Operation of steering wheel ———————— — Monitor
Others

Operation of joystick system

Trans- CAN input signal from
only when joystick optional 0 0 — ● — — — ● — — Green
mission transmission controller
setting is made.
Joystick lever neutral lock CAN input signal from
(Output from work equipment 0 0 ✩ ❍ ● — ✩ ❍ ● — Green BBC work equipment
controller) controller
Operation of FR prohibition
function during locking of
Trans- CAN input signal from
joystick steering only when 0 0 ✩ ❍ ● — ✩ ❍ ● — Green
mission transmission controller
Joystick joystick optional setting is
35 LED
pilot lamp made.
Key ON and transmission
CAN input signal from
controller in other than N
0 0 ✩ ❍ ● — ✩ ❍ ● — Green BBC work equipment
(joystick) only when joystick
controller
optional setting is made.
FNR lever priority caution (only
machine equipped with
Trans- CAN input signal from
steering wheel and joystick) 1 0 ✩ ❍ ● ✩ ❍ ● — Green
mission transmission controller
only when joystick optional
setting is made.
When error is made in
——— ——— —
communication

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Operating condition: Engine operating

condition included, error detection time Operating State

Signal Detection Controller

counted (As indicated at right)
Detection
Engine: Engine:
Time

Display Color
Stopped Running
Category

(sec)

Device

Display of Message

Display of Message
No. Item Remarks

Individual Display

Individual Display
Central Warning

Central Warning
Alarm Buzzer

Alarm Buzzer
Detection

Reset
If Option not equipped ——— ——— —
When column gear shift is
——— ——— —
used
When right FNR switch is used
(In seesaw switch mode)
0 0 — ● — — ● — Green
(Only when right FNR switch
Direc- optional setting is made)
tional FNR lever priority caution Trans-
36 LED
selector (Only when right FNR switch 0 0 ✩ ❍ ● — ✩ ❍ ● — Green mission
pilot lamp optional setting is made)
Right FNR switch neutral
Others

caution (DDK3KM)
0 0 ✩ ❍ ● — ✩ ❍ ● — Green
(Only when right FNR switch
optional setting is made)
Error is not made in
——— ——— —
communication.
Economy Economy mode 0 0 — ● — — ● — Green
operation Trans-
38 LED
indicator Other than above 0 0 ——— ——— — mission
lamp
Not operated ——— ——— —
ECSS Operating 0 0 — ● — — ● — Green Trans-
37 LED
pilot lamp When error is made in mission
——— ——— —
communication

• Priority of sounding of buzzer: Continual (w) > Intermittent (A) > Cancellation of operation > Check of acceptance of
operation.

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Character Display Function

You can change the display and settings on the machine monitor by using the character display function.

The operator can use the functions shown in the “Operator disclosure function” section in the following figure.

For instructions on how to use the operator mode, see the Operation & Maintenance Manual.
.

★ *1: When an ID entered from the ID Entry screen is approved, the display changes directly to the Select Function screen
without displaying the ID Entry screen until the starting switch is turned OFF.

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Operator Mode Functions

Self-Check Screen (0th layer)

• The self-check function operates three seconds after the key is

turned ON.

• After the key is ON, it automatically starts and ends the self-check
function operation.

• After three seconds, the 1st layer appears automatically.

• In self-check mode, the mode switch is disabled.

Normal Screen (1st layer)

• After the self-check, the screen shown in the figure to the right is
automatically displayed.

• Press the ◊ switch to move to the 2nd layer.

★ The clock is displayed only for the load meter.

• Select Displayed for the “10. Engine speed or travel speed display
on character display and normal screen” item in the optional
setting. When the travel speed is displayed on the LCD at the
center of the monitor, the engine speed is displayed on the
character display.

• When the engine speed is displayed on the LCD, the travel speed is
displayed on the character display.

• For machines with SI specification, the travel speed unit is km/h;

for ones with non-SI specification, the optional setting is
respected.

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Failure Code Screen (1st layer)

• Pressing the > switch when the Warning screen is on display changes the display to the Failure Code screen.

• If multiple failure codes are present, pressing 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: D191KA, B@BCZK, CA431)

*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 seconds 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 Failure Code screen or if
a new alarm is turned ON.

*3: Pressing the > switch on the normal screen before 10 seconds elapse changes the display to the initial Failure Code screen.

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Operator Disclosure Function

Functions available for the operator (2nd layer or lower)

• For the 2nd layer or lower, the screen automatically returns to the 1st layer if the switch is not pressed more than
60 seconds in the screen display of each menu.

• Optional items are not displayed if not selected.

• The language is displayed as set in the Language selection function.

• For operation after selecting each menu, see the corresponding menu item. (Press the ◊ switch to select each menu.)

Function opened to the operator (2nd layer and lower)

(*1) This display is not available when the load meter function is turned off through Optional Select option of the Service
mode.

(*2) This menu is not available when the function to display the travel speed/rpm on the character display is turned OFF
through the Optional Select option of the Service mode.

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Service Mode Functions

The Service mode function is used to troubleshoot the controllers on the network (including the machine monitor itself).

When making initial and optional settings for the sensors, use the Service mode of the machine monitor.

Procedure for Switching to Service Mode

1. Entering the Service mode.

A. Turn the starting switch of the machine ON to power the

machine monitor.

B. When the normal Service Meter screen or alarm screen is on

the character display of the machine monitor, press the
machine monitor mode selector switches 1 (■) and 2 (<)
simultaneously for five seconds.
• The INPUT ID screen is displayed.

2. Input the ID.

A. Press the < or > switch. The value at the cursor position
increases or decreases. Select a desired value using the
◊ switch.
• ID to enter the Service mode is 6491.

B. Completing operations equivalent to four digits (1) brings you

to the ELECTRIC FAULT screen.
★ If you input an incorrect value, press the ■ switch to
return the cursor to the highest-order digit and re-enter
values from there.
★ If you press the ■ switch while the cursor is at the
highest-order digit, the normal Service Meter screen or
alarm screen is returned.
★ If any switch operation is done at least 60 seconds during the ID input, the normal Service Meter screen or alarm
screen is returned.
.
REMARK
If the starting switch is turned OFF in the Service mode, the normal Service Meter screen or alarm screen is returned
the next time the starting switch is turned ON.

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Service Mode Menu

.

★ Pressing the < or > switch at the Service mode menu displays a different screen. Use the switch to select a target
operation menu screen.

★ If you press the ◊ switch when the selection screen is displayed, the menu screen/operation screen of each function
appears.

★ If you press the ■ switch when the selection screen is displayed, the normal Service Meter screen or alarm screen is
returned the next time the starting switch is turned ON.

Electrical System Failure History Display Function (ELECTRIC FAULT)

★ The ** field displays the total number of the failure history

currently recorded (maximum of 20 histories can be stored).

• This function is used to check the electrical system failure history

of each controller saved in the machine monitor.

• For the failure codes displayed in the electrical system failure

history, see the Troubleshooting section. After each failure is
repaired and the normal operation is confirmed, delete the failure
history.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

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Mechanical System Failure History Display Function
(MACHINE FAULT)

The ** field displays the total number of the failure history currently
recorded (maximum of 20 histories can be stored).

• This function is used to check the mechanical system failure

history of each controller saved in the machine monitor.

• For the failure codes displayed in the mechanical system failure

history, see the Troubleshooting section.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

Real-Time Monitoring Function (REAL-TIME MONITOR)

• This function is used to check the input and output signals, etc.
recognized by each controller on the network.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)

• This function is used to stop fuel injection to each cylinder from

the fuel injector in order to determine the cylinder with defective
combustion.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

No Injection Cranking Function (NO INJECTION)

• This function is used when lubricating the engine, with the engine
stopped, when restarting the engine after long-term storage of the
machine.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

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Adjustment Function (TUNING)

• This function is used if you have changed or added sensors, valves,

or controllers. The installation errors and manufacturing dispersion
of the sensors, solenoid valves, etc. are corrected and adjusted, and
control characteristic data is changed upon request of the user.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

Maintenance Monitoring Function

(MAINTENANCE MONITOR)

• This function is used for changing the filter and oil replacement
timing and making an ON/OFF selection of this function.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

• See also Filter, Oil Replacement Time Display in the Operation

section of the Operation and Maintenance Manual.

Operating Information Display Function (OPERATION INFO)

• This function is used for displaying fuel consumption per

operating hour.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

Optional Device Selecting Function (OPTIONAL SELECT)

• This function is used to display the installed state of an optional

device or change the setting of that device.

• Use this function after any optional device is installed or removed.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

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Machine Serial Number Input Function (MACHINE No. SET)

This function is used to display or set the machine serial number of the
machine.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

Model Selection Function (MACHINE)

★ The lower column displays the currently selected model.

• This function is used to display or select the machine model.

• For the operating procedure for this function, see Machine Monitor
System: Normal and Special Functions of Machine Monitor in the
Testing and Adjusting section.

Initialize Function (INITIALIZE)

• This function is used to set the machine monitor to the state set
when delivered.

• Since this function is specially handled by the factory, no

modification is allowed. Do not use it.

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Electrical System Failure History Display Function

1. Display of electrical system failure history and selection for clearing entirely the electrical system failure history
• The items are displayed in the sequential order by the latest occurrence time from the latest one.
• The items which have not been reset are displayed before the items which have been reset.
• Pressing the > switch scrolls the items from the newer ones to the older ones.
• Pressing the < switch scrolls the items from the older ones to the newer ones.
• After the oldest saved item, the “Electrical system failure history all clear selected” screen is displayed.
• Pressing the ■ switch changes the screen to the “Electrical system failure history selected” screen.
• Pressing the ◊ switch changes the screen to the “Electrical system failure history individual cleared” screen or the
“Electrical system failure history all cleared” screen.

2. Selection of electrical system failure history (1st layer)

• Pressing the < switch changes the screen to the Select
Initialization screen.
• Pressing the > switch changes the screen to the “Select display
of mechanical system failure history” screen.
• Pressing the ■ switch changes the screen to the normal screen
or alarm screen.
• Pressing the ◊ switch changes the screen to the “Display
electrical system failure history” screen.

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3. Display of electrical system failure history and the electrical system failure history all clear selected (2nd layer)
• The items are displayed in the sequential order by the latest occurrence time from the latest one.
• The items which have not been reset are displayed before the items which have been reset.
• Pressing the > switch scrolls the items from the newer ones to the older ones.
• Pressing the < switch scrolls the items from the older ones to the newer ones.
• Pressing the ■ switch changes the screen to the “Display electrical system failure history” screen.
• Pressing the ◊ switch changes the screen to the “Display electrical system failure history” screen.
★ If there is only one history, the current screen does not change to the “Electrical system failure history all clear”
screen (only the “Electrical system failure history individual clear” screen is displayed).

4. Electrical system failure history individual clear and Electrical system failure history all clear (3rd layer)
• Select YES or NO with the < or > switch. The cursor “_” blinks on the selected item.
★ If YES is selected and the ■ switch is pressed, clearing is executed.
★ If NO is selected and the ■ switch is pressed, clearing is cancelled and the display changes as described below.
• If clearing is cancelled (NO), the current screen returns to the “Display electrical system failure history” screen
of the corresponding failure. (Returns to the screen before the “Electrical system failure history individual clear”
(“Electrical system failure history all clear”) screen).)
• If clearing is executed (YES), the current screen returns to the “Display electrical system failure history” screen
of the corresponding next failure.
• After all the failure histories are cleared, the current screen returns to the “Select electrical system failure
history” screen.
• By default, the cursor is on NO (cancel) to prevent an accidental reset.
• You cannot delete a failure which has not been reset. At this time, the operation cancel peeps for 0.1 second.
• If any failure history is cleared, the operation acceptance peeps (ON for 0.1 sec., OFF for 0.1 sec., ON for 0.1 sec.).
• When the ALL CLEAR (clearing all histories) option is selected and there is a history to be cleared, clearing is
assumed to be completed.

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Mechanical System Failure History Display Function

1. Display of mechanical system failure history

The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the older ones to the newer ones.
Pressing the ■ switch changes the screen to the “Mechanical system failure history selected” screen.

2. Selection of mechanical system failure history (1st layer)

• Pressing the > switch changes the screen to the “Select real-
time monitor” screen.
• Pressing the < switch changes the screen to the “Select display
of electrical system failure history” screen.
• Pressing the ■ switch changes the screen to the normal screen
or alarm screen.
• Pressing the ◊ switch changes the screen to the “Mechanical
system failure history selected” screen.

3. Display of mechanical system failure history (2nd layer)

• The items are displayed in the sequential order by the latest
occurrence time from the latest one.
• The items which have not been reset are displayed before the
items which have been reset.
• Pressing the > switch scrolls the items from the older ones to the newer ones.
• Pressing the < switch scrolls the items from the newer ones to the older ones.
• Pressing the ■ switch changes the screen to the “Mechanical system failure history selected” screen.

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Real-Time Monitor Function

• The real-time monitor function displays the information saved in the controllers mounted on the machine in real time.

• This function is used for testing, adjusting, or troubleshooting the machine.

• This function classifies the items and data by the relevant controllers and then displays the results. It has two display
modes for the normal display mode and the 2-item display mode for displaying two data items simultaneously.

Operating Procedure

1. Hold the ■ switch and < switch simultaneously for at least five seconds to change the screen to the ID Input screen.

2. Use the < and > switches to input the ID and then press the
◊ switch to enter the screen for the service person.

3. Using the < and > switches, display the “Real-time monitor
selection” screen and then press the ◊ switch.

4. Press the ◊ switch to display the “Monitor information display/

selection” screen.
★ Pressing the < and > switches selects transmission controller
information, engine controller information, work equipment
controller information, and the 2-item display function in
order.

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5. Press the ◊ switch while each selection screen is displayed. The
Display 1-Item screen or “Select 2-items display information”
screen appears.
***: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Item name
%%%%%: . . . . . . . . . . . . . . . . . . . . . . Data and unit (Unit: SI unit)
$$$$: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ID number
• Items displayed on the Display 1-Item screen change in order
by pressing the < and > switches to display information held
by the controller.

6. Input the ID.

★ “00000” is displayed during screen transition.
• Input a value between 0 and 9 at the cursor (_) position.

★ First, the cursor appears at the highest-order digit. Each time

the > or < switch is pressed, the digit changes by 1 between 0
and 9.
• Select a desired digit and press the ◊ switch.

★ The cursor moves to the 2nd position.

• Select the digits for all the positions in the same manner.
• Input a value at the lowest-order digit and press the ◊ switch to
move to the screen to select the display of the 2nd item.

★ If you press the ■ switch during the processing, the screen returns to the “Select 2 items display information” screen.
• In the display of the 2-items mode, input the ID of information to display two items simultaneously.

★ The ID displayed is the same as the ID number displayed on the Display 1-Item screen.

7. Items displayed on the Display 1-Item screen change in order by pressing the < and > switches to display the information
held by the controller.

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Display Contents of the Real-Time Monitor

The state of the controller input and output signals can be checked using the real-time monitor function of the monitor.

The following table shows the display items and display contents in normal operation for the real-time monitor function on the
machine monitor.

Display of Contents of
No. Item ID No. Display Contents in Normal Operation Remarks
Item Display Data
Monitor
Part No. of software is
1 software part 20200 VERSION Depends on the software part number
displayed
No.
Application Application version
2 20221 VERSION (APP) Depends on application version number
version number is displayed
VERSION Data version number
3 Data version 20222 Depends on data version
(DATA) is displayed
Li: 800 ±25 rpm
Hi: 2000 ±50 rpm (P-mode)
Engine speed is
4 Engine Speed 01001 ENG SPEED 1900 ±50 rpm (E-mode)
displayed
T/C stall: 1800 ±100 rpm (P-mode)
1730 ±100 rpm (E-mode)
F1/R1: 6.7/7.3 km/h ±5% (P-mode, T/C)
Travel speed is F2/R2: 11.7/12.8 km/h ±5% (P-mode, T/C)
5 Travel speed 40000 SPEED
displayed F3/R3: 20.3/22.0 km/h ±5% (P-mode, T/C)
F4/R4: 33.8/37.0 km/h ±5%(P-mode, T/C)
6 Fuel level 04202 FUEL SENSOR Fuel level is displayed 0 – 100%
When sensor is
disconnected or hot
Gauge FULL (100%,10 Ω): 0.32 V
shorted:
Gauge 1/2 (50%, 32 Ω): 0.88 V
7 Fuel level 04207 FUEL SENSOR Fuel level is displayed gauge EMPTY
Caution (61.3 Ω): 1.45 V
When sensor is
Gauge EMPTY (0%, 85 Ω): 1.81 V
grounded:
gauge FULL
Coolant temperature,
Engine
COOLANT Coolant temperature max. 100°C (212°F)
8 coolant 04103 Depends on machine status (°C)
TEMP is displayed Data is obtained from
temperature
engine controller.
Torque Torque converter oil
Overheat:
9 converter oil 40100 TC OIL TEMP temperature is Depends on machine status (°C)
120°C (248°F)
temperature displayed
When sensor is
disconnected or hot
Torque Torque converter oil Gauge red zone start point:
shorted: Min. of gauge
10 converter oil 40101 TC OIL TEMP temperature is 120°C (248°F): 1.62 V
When sensor is
temperature displayed 80°C (176°F): 2.91 V
grounded:
Max. of gauge
Hydraulic oil Hydraulic tank oil
Hydraulic oil
11 04401 HYD TEMP temperature is Depends on machine status: °C temperature: Max.
temperature
displayed 100°C (212°F)
When sensor is
disconnected or hot
Hydraulic oil Gauge red zone start point:
Hydraulic oil shorted: Min. of gauge
12 04404 HYD TEMP temperature is (120°C): 1.62 V
temperature When sensor is
displayed (80°C): 2.91 V
grounded:
Max. of gauge
Brake oil Brake oil temperature
13 30202 R BRAKE OIL Depends on machine status (°C)
temperature is displayed
Brake oil Brake oil temperature (120°C): 1.62 V
14 30205 R BRAKE OIL
temperature is displayed (80°C): 2.91 V
Charge level is
15 Charge level 04302 ALTERNATOR R Depends on machine status (0.0 – 30 V)
displayed
Small lamp Small lamp voltage is
16 40200 SMALL LAMP Depends on machine status (0.0 – 30 V)
voltage displayed

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Display of Contents of
No. Item ID No. Display Contents in Normal Operation Remarks
Item Display Data
Battery
Battery electrolyte Only when optional
17 electrolyte 40300 BATTERY A Min. 2 V
level is displayed setting is made
level A
Battery
18 electrolyte 40301 BATTERY B — — Not used.
level B
Standard lift arm
Lift arm top: 46.8 ±2.0 deg.
Calculation results of
Lift arm bottom: -42.3 ±3.0 deg.
19 Lift arm angle 06001 BOOM ANG lift arm angle is
Hi lift arm
displayed
Lift arm top: 49.3 ±2.0 deg.
Lift arm bottom: -40.5 ±3.0 deg.
Standard lift arm
Input voltage value to Lift arm top: 3.80 ±0.3 V
lift arm angle sensor Lift arm bottom: 1.33 ±0.5 V
20 Lift arm angle 06003 BOOM ANG
potentiometer is Hi lift arm
displayed Lift arm top: 3.87 ±0.3 V
Lift arm bottom: 1.38 ±0.5 V
(When arm is placed
horizontally at rated
Lift arm
BOOM BTM Lift arm bottom loading and Hi lift arm
21 bottom 40400 Depends on status
PRESS pressure is displayed operation lever at
pressure
FULL): Approx.
18 MPa (2610.68 psi)
(0MPa): 0.5V
Lift arm
BOOM BTM Lift arm bottom (10MPa): 1.3V
22 bottom 40402
PRESS pressure is displayed (20MPa): 2.1V
pressure
(50MPa): 4.5V
Only when optional
setting is made in load
meter
(When arm is placed
Lift arm head BOOM HEAD Lift arm head
23 40500 Depends on status horizontally at rated
pressure PRESS pressure is displayed
loading and Hi lift arm
operation lever at
FULL): Approx.
0.5 MPa (72.52 psi)
(0MPa): 0.5V
Only when optional
Lift arm head BOOM HEAD Lift arm head (10MPa): 1.3V
24 40501 setting is made in load
pressure PRESS pressure is displayed (20MPa): 2.1V
meter
(50MPa): 4.5V
Lift arm differential
pressure
Calibration corresponding to no
25 40600 CAL PRESS — Not used.
pressure load around level
position at load meter
calibration
Only when optional
Classified Load meter calculated
26 40800 MES LOAD Load weight [t] setting is made in load
weight weight is displayed
meter
Position of
27 30802 SW1, SW2, SW3 — — Not used.
rotary switch
Position of
28 30904 SW5-1, SW5-2 — — Not used.
DIP switch
Position of
29 30905 SW5-3, SW5-4 — — Not used.
DIP switch
Position of
30 30906 SW6-1, SW6-2 — — Not used.
DIP switch
Position of
31 30907 SW6-3. SW6-4 — — Not used.
DIP switch

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Display of Contents of
No. Item ID No. Display Contents in Normal Operation Remarks
Item Display Data
D-IN-0: Head lamp
D-IN-1: Not used
D-IN-2: Starting motor
10000000 (Head lamp = on)
C
00000000 (Not used)
D-IN-3: Not used
00100000 (Starting motor C = on)
D-IN-4: Auto grease A
00000000 (Not used)
(Only when optional
Input signal The state of input 00001000 (Auto grease: Empty)
32 40900 D-IN--0------7 setting is made in auto
D_IN_0-7 signal is displayed 0000100 (Auto grease: Operation)
grease)
00000000 (Auto grease: Abnormal)
D-IN-5: Auto grease B
00001100 (Auto grease: Abnormal)
(Only when optional
00000000 (Not used)
setting is made in auto
00000000 (Not used)
grease)
D-IN-6: Not used
D-IN-7: Not used
D-IN-8: Not used
D-IN-9: Not used
D-IN-10: Load meter
material selector SW
input
00000000 (Not used) (Only when optional
00000000 (Not used) setting is made in load
0100000 (Load meter material selector meter)
SW = on) D-IN-11: Load meter
Input signal The state of input 00010000 (Load meter addition/reduction addition/reduction
33 40901 D-IN- 8-----15 selector SW = on) selector SW input
D_IN_8-15 signal is displayed
00001000 (Right winker on) (Only when optional
00000100 (Left winker on) setting is made in load
00000010 (Monitor mode SW (◊) = on) meter)
00000001 (Monitor mode SW (■) = on) D-IN-12: Winker right
D-IN-13: Winker left
D-IN-14: Monitor mode
SW (◊)
D-IN-15: Monitor mode
SW (■)
D-IN-16: Brake oil
pressure (Front)
10000000 (Front brake oil pressure D-IN-17: Brake oil
SW = on = low level) pressure (Rear)
01000000 (Rear brake oil pressure D-IN-18: Not used
SW = on = low level) D-IN-19: Not used
00000000 (Not used) D-IN-20: Air cleaner
Input signal The state of input 00000000 (Not used) clogging
34 40902 D-IN-16-----23
D_IN_16-23 signal is displayed 00001000 (Air cleaner clogging SW = on) D-IN-21: Not used
00000000 (Not used) D-IN-22: Parking brake
00000010 (Parking brake emergency release emergency release SW
SW = on) D-IN-23: Load meter
00000001 (Load meter total weight display total weight display SW
SW = on) (Only when optional
setting is made in load
meter)
D-IN-24: T/M filter
clogging
(Only when optional
10000000 (T/M filter clogging SW = on)
setting is made)
00000000 (Not used)
D-IN-25: Not used
00100000 (Parking brake = on)
D-IN-26: Parking brake
00010000 (Coolant level SW = on = low level)
Input signal The state of input D-IN-27: Coolant level
35 40903 D-IN-24-----31 00000000 (Not used)
D_IN_24-31 signal is displayed D-IN-28: Not used
00000100 (Engine oil level SW = on = low level)
D-IN-29: Engine oil
00000010 (Emergency steering operation
level
SW = on)
D-IN-30: Emergency
00000000 (Not used)
steering operation (Low
S/T pressure)
D-IN-31: Not used

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Display of Contents of
No. Item ID No. Display Contents in Normal Operation Remarks
Item Display Data
D-IN-32: Subtotal SW
(Only when optional
setting is made in auto
grease)
D-IN-33: Cancel SW
10000000 (Subtotal SW = on)
(Only when optional
01000000 (Cancel SW = on)
setting is made in auto
00100000 (High beam = on)
grease)
Input signal The state of input 00000000 (Not used)
36 40904 D-IN-32-----39 D-IN-34: High beam
D_IN_32-39 signal is displayed 00001000 (SW for servicing = on)
D-IN-35: Not used
00000100 (Monitor mode SW (>) = on)
D-IN-36: SW for
00000010 (Monitor mode SW (<) = on)
servicing
00000000 (Not used)
D-IN-37: Monitor mode
SW (>)
D-IN-38: Monitor mode
SW (<)
D-IN-39: Not used
1000 (Buzzer = on) D-OUT-0: Buzzer
Output signal The state of output 0000 (Not used) D-OUT-1: Not used
37 40952 D-OUT-0--3
D_OUT_0-3 signal is displayed 0000 (Not used) D-OUT-2: Not used
0000 (Not used) D-OUT-3: Not used

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Engine Reduced-Cylinder (Cylinder Cut-out) Function

1. Using the < and > switches, display the “Reduced cylinder mode
selection (CYLINDER CUTOUT)” screen and then press the
◊ switch.

2.Operating method of reduced-cylinder function

• Press the > switch to move the cursor to the right (select a
cylinder to issue the reduced-cylinder command).
• Press the < switch to move the cursor to the left (select a
cylinder to issue the reduced-cylinder command).
• Press the ◊ switch to issue the monitor reduced-cylinder
command. Pressing this switch repeats the output/release of
the command.
• Press the ■ switch to return to the “Reduced cylinder mode
selection” (CYLINDER CUT-OUT) screen. The reduced-
cylinder commands from the monitor are all released.
★ Operation example: When the 3rd cylinder stop command is issued.

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No Injection Cranking Function

For starting the engine using this function, see Machine Monitor System: Service Mode: No Injection Cranking Function (NO
INJECTION) in the Testing and Adjusting section.

This section describes only the operating method.

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Adjustment Function
For making adjustments using this function, see Machine Monitor
System: Service Mode: Adjustment Function (TUNING) in the Testing
and Adjusting section.

This section describes only the outline of the adjustment function. All
references can be found in the Machine Monitor System: Service Mode:
Adjustment Function (TUNING) section.

★ 01: Reset of transmission initial learning

See Setting Transmission Initial Learning in the Testing and
Adjusting section.
★ 02: ECMV compensation
See Adjustment of Transmission ECMV Current in the Testing and
Adjusting section.
★ 04: Transmission shift point adjustment function
See Adjustment of Transmission L Mode Shift Point Function in
the Testing and Adjusting section.
★ 05: Adjustment of lift arm angle sensor (Raise) (for EPC lever)
See Adjustment of Lift Arm Angle Sensor (Raise) (for EPC lever)
Function in the Testing and Adjusting section.
★ 06: Adjustment of lift arm raise lever and variations in the dead
zone of EPC
See Adjustment of Lift Arm Raise Lever and Variations in the Dead
Zone of EPC in the Testing and Adjusting section.
See Adjustment of Bucket Dump EPC Starting Current in the
Testing and Adjusting section.
★ 07: Adjustment of lift arm lower lever and variations in the dead
zone of EPC
See Adjustment of Lift Arm Lower (Float) Lever and Variations in
the Dead Zone of EPC in the Testing and Adjusting section.
See Adjustment of Bucket Dump EPC Starting Current in the
Testing and Adjusting section.
★ 08: Adjustment of bucket tilt lever and variations in the dead zone
of EPC
See Adjustment of Bucket Tilt Lever and Variations in the Dead
Zone of EPC in the Testing and Adjusting section.
See Adjustment of Bucket Dump EPC Starting Current in the
Testing and Adjusting section.
★ 09: Adjustment of bucket dump lever and variations in the dead
zone of EPC
See Adjustment of Bucket Dump EPC Starting Current in the
Testing and Adjusting section.
★ 10: Adjustment of 3rd EPC cylinder extraction lever and variations
in the dead zone of EPC

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12
★ 11: Adjustment of 3rd EPC cylinder retraction lever and variations
in the dead zone of EPC
★ 12: Adjustment of joystick right lever and variations in the starting
point of EPC
Do not operate it.
★ 13: Adjustment of joystick left lever and variations in the starting
point of EPC
Do not operate it.
★ 14: Modification of lift arm lever pattern
See Modification of Lift Arm Lever Pattern in the Testing and
Adjusting section.
★ 15: Modification of bucket lever pattern
See Modification of Bucket Lever Pattern in the Testing and
Adjusting section.
★ 16: Adjustment of lift arm lower stop modulation
See Adjustment of Lift Arm Lower Stop Modulation in the Testing
and Adjusting section.
★ 17: Adjustment of pump cutoff pressure in up move of lift arm
See Adjustment of Pump Cutoff Pressure in Lift Arm Raise in the
Testing and Adjusting section.
★ 18: Adjustment of lift arm angle sensor (raise) (for load meter)
See Adjustment of Lift Arm Angle Sensor (Raise) (Machine with
Load Meter) in the Testing and Adjusting section.
★ 19: Adjustment of lift arm angle sensor (lower) (for load meter)
See Adjustment of Lift Arm Angle Sensor (Lower) (Machine with
Load Meter) in the Testing and Adjusting section.
★ 21: Modification of AJSS oil pressure command table pattern
Do not operate it.
★ 22: Adjustment of speed limit
See Adjustment of Speed Limit (Lockup Clutch Specification) in
the Testing and Adjusting section.

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Maintenance Monitoring Function

1. Selection of display of maintenance monitor function (1st layer)

• You can go to the destination by using the <, >, and
■ switches. See the “Function 1 for the service person: 2nd
layer transition” diagram.
• Press the ◊ switch to change the screen to the “Item NO. 1 is
displayed” screen.

2. Select Maintenance Item screen.

• (1) Using the > switch, display items in ascending order of numbers.
★ When the last item is selected, the screen is changed to the “Default value is set” screen.

• (2) Using the < switch, display items in descending order of numbers.
★ When the last item is selected, the screen is changed to the “All item timer stop/all item valid selector” screen.

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A. Change maintenance interval time procedure.

i. Input a value between 0 and 9 at the cursor position.

ii. The cursor is positioned at the highest-order digit.

Pressing the > or < switch increases or decreases the
value between 0 and 9.

iii. Input a desired value and press the ◊ switch.

iv. The cursor moves to the 2nd position. Select the digits for
all the positions by repeating Steps Aii and Aiii.

v. After selecting the digit for the lowest position, press the
◊ switch.
★ If the input interval time is acceptable, the screen
changes to the check screen.
★ If the input interval time is not acceptable, the time
does not change.

vi. Return the cursor to the highest-order digit.

★ The lower limit of the set value is 50h.

vii. When you have entered an incorrect value to a position

succeeding to the highest-order digit, move to the
highest-order digit using the ■ switch and repeat the
procedure from the beginning.
★ In this case, values that had been entered remain as they are until modified.

viii. When the cursor is at the highest-order digit, move to the higher layer using the ■ switch.
• Select YES or NO with the < or > switch.
• The cursor (_) is blinking at the selected item. If you have selected YES, press the ■ switch to execute the
change. If you have selected NO, press it to return to the Select Maintenance Item screen without executing
the change.
★ By default, the cursor is set to NO (cancel) to prevent a resetting error.
• When an interval time is changed, the remaining timer time is changed as shown below.
(Interval time being set – Elapsed time from the last replacement)

B. Select enable or disable timer by item.

• When the Timer by Item option is enabled, ON ➡ OFF is
displayed at the lower column.
• When the Timer by Item option is disabled, OFF ➡ ON is
displayed at the lower column.
★ By default, the setting is ON and the timer function is
enabled.
• When you disable the Timer by Item option, OFF is
displayed at the upper column.
• When you enable the Timer by Item option, ON is
displayed at the upper column.
• Select YES or NO with the < or > switch.

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• The cursor (_) blinks on the selected item. If YES is selected, the change is executed. If NO is selected, the
change is cancelled and the Select Maintenance Item screen is returned.
★ By default, the cursor is set to NO (cancel) to prevent a resetting error.
• Specify disabling the timer or releasing the disabling by maintenance item.
• If you cancel the timer disabled, interval time before having been disabled is used as the set value.
• The timer remaining time is reset.
★ The reset frequency is not incremented and remains the same as before the resetting.

3. Setting a default value

• Select YES or NO with the < or > switch.
• The cursor (_) blinks on the selected item. If YES is selected,
the change is executed. If NO is selected, the change is
cancelled and the Select Maintenance Item screen returns.
★ By default, the cursor is set to NO (cancel) to prevent a
resetting error.
• If the default value is executed, all the currently changed
interval times are returned to the default values. The default
value is applied to every item independent of whether or not
the function is enabled for a specific item.
• Timer remaining time is Default value - Elapsed time since the
last replacement.
★ The reset frequency is not incremented and remains the
same as before the reset.
• Set enable or disable of individual items.

4. Selection between timer stop for all items and enable by item

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*1: Press the ◊ switch to go to the ALL ITEMS OFF screen.

*2: When ALL ITEMS OFF is selected.

*3: When ALL ITEMS OFF is executed:

The timer function for all items is stopped and the Select Maintenance Monitor screen is restored. Setting for individual
items is also disabled.

When ALL ITEMS OFF is canceled: The operation is cancelled and the MAINTENANCE MONITOR screen is restored.

*4: When ALL ITEMS ON is selected.

*5: Select YES or NO with the < or > switch.

The cursor (_) is blinking at the selected item.
★ By default, the cursor is set to NO (cancel) to prevent a resetting error.

*6: When ALL ITEMS ON is executed:

• Interval time being set for all items is disabled independent of whether or not it is enabled or disabled for a specific
item.
• The timer remaining time is reset.
• The reset frequency is not incremented and remains the same as before the reset.
• The Select Maintenance Monitor screen is restored. Setting for individual items is also enabled.
When ALL ITEMS OFF is canceled: The operation is canceled and the Select Maintenance Monitor screen is restored.

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Operating Information Display Function

Outline

• The value of fuel consumption is obtained by adding the target injection amount sent from the engine controller.

★ This is not a measured but a calculated fuel consumption. Use it as a rough standard.

*1: The upper column displays fuel consumption [L/km or L/mile] per 1 km (or 1 mile) from the last reset.
• It is calculated from the fuel consumption and travel distance above.
• The unit km or mile is selected depending on that used on the odometer.
• The counting is stopped at 99999.9, the upper limit.
The lower column displays the average fuel consumption [L/h] from the last reset.
• The counting is stopped at 99999.9, the upper limit.
*2: The upper column displays the cumulative fuel consumption [L] from the last reset.
• The counting is stopped at 9999999.9, the upper limit.
The lower column displays the travel distance [km or mile] from the last reset.
• The unit km or mile is selected depending on that used on the odometer.
• The counting is stopped at 9999999.9, the upper limit.
*3: The upper column displays the cumulative fuel consumption [L] from the last reset.
• The counting is stopped at 9999999.9, the upper limit.
The lower column displays the elapsed time [h] from the last reset.
• The counting is stopped at 9999999.9, the upper limit.

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*4: Calculation of (*4) is executed when the load meter is installed.
★ The screen is not available when the load meter is not installed.
The upper column displays the loaded volume [ton] from the last reset.
• The counting is stopped at 199999999.9, the upper limit.
• Short ton or metric ton depends on optional setting.
The lower column displays the loading frequency from the last resetting.
• The counting is stopped at 65000, the upper limit.

★ (*1 – *4) Calculation is done only for the duration in which the engine is run.

*5: Using the ◊ switch, clear data of (*1), (*2), (*3), and (*4) to return to the previous screen.
Using the ■ switch, return to the previous screen without resetting.

REMARK
Other than the reset operation above, you can reset data by initializing the monitor panel or selecting the optional
setting as OFF.

Acquisition of Fuel Consumption (L)

• The monitor panel calculates the cumulative fuel consumption (L) based on the momentary fuel consumption (L/h) from
the engine controller.

*6: Setting gain correction

A. When the screen appears, the current set value is displayed and the cursor is placed on the (+/–) sign.

B. When the cursor is placed on the sign, (+), (↔), and (–) are displayed in order every time the > or < switch is pressed.

C. Press the ◊ switch to confirm the sign; ➝ cursor moves to the highest-order digit.

D. The cursor appears at the highest-order digit. Each time the > or < switch is pressed, the value at the digit increases or
decreases between 0 and 9. (The highest-order digit is between 0 and 2.)

E. Input the desired value and press the ◊ switch to confirm the entry.

F. The cursor moves to the lowest-order digit. Select a value in the same manner as Step D.

G. Input a value at the lowest-order digit and press the ◊ switch. (The screen returns to the previous one when the entry
is confirmed.)

H. If the ■ switch is pressed before completing the entry, the cursor moves to the sign position. In this case, the value
remains unchanged. Using the ■ switch, return to the previous screen.

I. If the value confirmed for the lowest-order digit is outside the range of -50.0 to +50.0, the cursor moves to the sign
position with the value unchanged as when the ■ switch is pressed.

Processing on the Monitor Panel

• Default value: 0.0%

• This setting allows you to correct the cumulative fuel consumption (L) in the range of -50.0 to +50.0%.

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Optional Device Selecting Function

See Machine Monitor System: Service Mode: Optional Device
Selecting Function (OPTIONAL SELECT) in the Testing and Adjusting
section.

Machine Serial Number Input Function

See Machine Monitor System: Service Mode: Machine Serial Number
Input Function (MACHINE No. SET) in the Testing and Adjusting
section.

Model Selection Function

See Machine Monitor System: Service Mode: Model Selection
Function (MACHINE WA500) in the Testing and Adjusting section.

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Load Meter Function (if equipped)

Outline

• The load meter displays the remaining amount of the total or target-loaded volume by classifying working objects into
five types and measuring the bucket-loaded volume.

• Functions include the ability to switch between reduction mode and addition mode, between working objects, and to
display and clear total-loaded volume. To operate these functions, use the load meter mode selector switch and monitor
panel mode selector switch.

• The load meter is equipped with calibration mode, calibration clear mode, and load meter calculation stop mode. To
operate these modes, use the monitor panel mode selector switch.

• A printer (if equipped) allows you to print measured data.

Weight Calculation

The load meter calculates weight (W) by detecting the lift arm
operating pressure (P) using the pressure sensor (A) installed at the lift
arm cylinder bottom and pressure sensor (B) installed at its head, and
calculating the center of gravity by the lift arm angle sensor (C).

Weight calculation is done based on the differential pressure (C)

between the reference value (A), where the lift arm pressure with no
load is saved (corrected by calibration), and the calculated lift arm
pressure (B) with load. In addition, to improve its precision, the
detection function calculates weight during lift arm raise operation.

The operation of the tires and work equipment generates a spring effect
on the machine. However, the measured lift arm pressure (D) is
provided with the characteristic shown in the figure to the right.

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The value (D) measured by the lift arm raise operation is calculated
based on the value obtained as the calculated value (B) according to the
following calculation criteria.

• For 0.5 seconds after lift arm raise operation start (E), the lift arm
state changes from the static state to the operating state. The
pressure largely fluctuates and is not stable; therefore, it is not used
for calculation of the calculated value (B).

• The spring effect of the machine is generated at intervals of

approximately one second. The calculated value (B) is obtained
based on the mean every one second during the period between the
lift arm raise operation start and the operation end.

Determination of Lift Arm Raise Operation Start

The load meter determines that the lift arm starts moving and starts weight calculation when all the following conditions are
satisfied.

The lift arm angle is between -10 and -30°.

Condition 1
(The range between the horizontal position and position immediately before it contacts the ground)
The lift arm angle changes at least 0.1° for 0.1 second.
Condition 2
(The lift arm starts moving with minimum specified speed in raising direction.)

Determination of Lift Arm Raise Operation Stop

The load meter determines that the lift arm stops moving and ends weight calculation when one of the following conditions is
satisfied.

The lift arm angle changes to under 0.5° for 0.5 second.
Condition 1
(The lift arm speed in raise direction is reduced below the specified speed.)
The lift arm angle changes to lowering direction.
Condition 2
(When the lift arm is lowered, weight calculation finishes.)
The lift arm angle changes to above +20°.
Condition 3
(At a high position, weight calculation stops.)
The lift arm raise speed suddenly changed.
Condition 4
(The current angular velocity is decreased 70% or more of the previous one.)
Condition 5 Weight calculation was performed seven times.

Display of Calculated Weight

The average of calculated weight values are displayed.

Number of Calculation
Weight Calculation and Display Method
Calculations Time (sec.)
Displays weight based on a single calculation result.
Only 1 time 1.5 – 2.5 In this case, however, the weight display blinks to inform the operator that the precision
is unstable due to the short calculation time.
2 times 2.5 – 3.5 Displays weight based on the mean value of two calculation results.
Min. 3 times 3.5 – 0.0 Displays weight based on the mean value of latest three calculation results.

10-380 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Reduction/Addition Mode

★ Monitor display in addition mode

This is the mode to display the bucket-loaded volume. Use this mode for obtaining the work rate.
• When addition mode is selected, TOTAL LOADED is displayed at
the display of addition mode (1), which indicates the value
obtained by adding the value at the display of calculated bucket-
loaded volume (3) to the value at the total-loaded volume (2).

• Weight calculation can be displayed by cumulating up to any five

working objects independently. Working objects can be selected
from types A to E at the working object display (4) in mode
selection.

• The display of total-loaded volume (2) indicates up to 9,999 t

unless data is cleared by the load meter subtotal switch. The
display indicates a value to one decimal place (in 100 kg) in the
case of a maximum 999.9 t. When it exceeds 1000 t, the decimal
point display disappears and switches to the display in 1 t.

★ For details about the display of total-loaded volume, see Display of Total Loaded Volume and Display of Remaining
Volume on the next page.

★ Monitor display in reduction mode

This is the mode to display the bucket-loaded volume based on the preset target weight. Use this mode for constant
loading work.
• When reduction mode is selected, REMAINING TARGET is
displayed at the display of reduction mode (1), which indicates the
value obtained by reducing the value at the display of calculated
bucket-loaded volume (3) from the value specified at the display of
total-loaded volume (2).

• Weight calculation can be displayed by cumulating up to any five

working objects independently. Working objects can be selected
from types A to E at the working object display (4) in mode
selection.

• For the display and calculation method when the value at the
display of bucket-loaded volume (3) exceeds the value at the
display of remaining volume (2), use the subtraction mode. Refer
to the Operation Manual provided with your load meter.

★ For details about the display of remaining volume, see Display of Total Loaded Volume and Display of Remaining
Volume on the next page.

WA500-6 10-381 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Display of Total Loaded Volume and Display of Remaining Volume

Actual Total Loaded Weight (t) Display of Total Loaded Volume Remarks
-99.5 -99.9 Display of decimal point
Display of decimal point
-99.4 to -0.1 –**.*
(second decimal place is rounded off).
Display of decimal point
0 – 999.4 ***.*
(second decimal place is rounded off).
Display of integer
999.5 – 9999.4 ****
(second decimal place is rounded off).
9999.5 – 9999 Display of integer

Unit of Calculated Weight

• Calculated weight values are all displayed in SI (metric ton).

• If MPH has been selected for speed display in monitor setting, it can be switched to short ton (US ton) in Service mode
optional setting.

• If you switch it to short ton, weight display is also output in short ton (US ton) on the printer.

WARNING! In countries where the SI unit is adopted, the speed display unit and weight display unit must not be
changed to a non-SI unit.

Load Meter Cancel Switch

• When the switch (1) is pressed during the holding time of

calculated weight (15 seconds after completion of calculation), the
value at the display of bucket-loaded volume is canceled and the
calculated weight is abandoned.

• In this case, the display of total-loaded volume (display of

remaining volume) newly added (reduced) is also canceled and the
previous display value is returned.

Load Meter Subtotal Switch

• To clear the display of total-loaded volume (in addition mode) or

display of remaining volume (in reduction mode), continuously
press the switch (1) for at least two seconds.

Specifications Operation after operating switch

Printer not Clears the display of total loaded volume (display
installed of remaining volume).
Printer Outputs saved subtotal data on the printer. After
installed the output, the subtotal data is cleared.

10-382 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Subtotal Data

The following data is saved as a set when calculated weight is confirmed.

• Type of working object

• Weight of loading in one bucket

• Total number of loading

• Total loaded volume

Memory capacity: . . . . . . . . . . . . . . . . . . . Min. 500 times of loading

Auto Subtotal Function

★ When the printer (if equipped) is connected.

The 501st weight calculation is executed. After 15 minutes data is stored in RAM; up to the 500th data is printed out on
the printer at the same time. After the output on the printer, the subtotal data is cleared. The character display displays
LOAD DATA FULL and CLEAR DATA after saving the 500th data then continues measurement.

★ When the printer (if equipped) is not connected.

The 501st weigh calculation is executed. After 15 minutes data is stored in RAM; up to the 500th weight data by bucket is
abandoned to the secure store data area. The character display displays LOAD DATA FULL and CLEAR DATA after
saving the 500th data then continues measurement.

★ Display on character display after 500th data is stored.

Cumulative Data Display Function

★ Display of data

• Total loaded volume and total number of loading in addition

mode or reduction mode are displayed.
• Press the load meter mode selector switch to display TOTAL
DATA on the character display.

WA500-6 10-383 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
★ The lower column (❈❈❈❈❈-❈❈❈❈❈h) displays cumulative hours according to the hour meter criteria.

Example: In the case of the display of 12300-12450h, the

cumulative data of 150 hours between 12300 and 12450 hours is
displayed in the character display.
• Press the monitor panel mode selector switch 2 (>) or (<) to select
“By the item (A) to (E)” or “All ON” at working object display (1).

• In the former case, cumulative weight by type (2) and the number
of loading (3) are displayed.

• In the latter case, total loaded volume (2) of all objects from (A) to
(E) and the total number of loading (3) are displayed.

Resetting Data

• Cumulative data by the item (A) to (E) or of all objects are reset.

• Display TOTAL DATA on the character display.

• Press the load meter selector switch (A/B) to specify either “By the item (A) to (E) or “All ON” at the working object
display.

• Press the load meter mode selector switch (A/B) for at least four seconds.

Printer Output (if equipped)

★ This function works only when the printer specified in the optional setting is installed.

• The output format of the load meter can be selected from three types (A, B, C) of the output mode.
• The output format of each mode is listed in the following table.
★ For selection of output mode and output method, see your load meter User Guide.

A-mode B-mode C-mode

(Total printer output)
• Model, serial number
• Date and time of printing
• Subtotal loading data
(Type/number of loading/loaded
volume)
• Total loading data
(Total number of loading/Total
loaded volume)
(Subtotal printer output)
• Model, serial number
• Date and time of printing
• Loading data
(Loaded volume)
• Subtotal loading data
(Type/number of loading/loaded
volume)
• Total loading data
(Total number of loading/Total
loaded volume)
(Operation record printer output)
• Model, serial number
• Date and time of starting record,
service meter
• Date and time of ending record
(printing), service meter
• Subtotal loading data
(Type/number of loading/loaded
volume)
• Total loading data
(Total number of loading/Total
loaded volume)
• Maintenance time
(Maintenance item/remaining
time)

10-384 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Calibration

• No load calibration and load calibration are provided; the former measures the pressure with the bucket empty and the
latter measures the pressure with a known weight loaded.

• The lift arm is raised with the bucket at full tilt. In this condition, the lift arm working pressure with no load (0 kg) or a
known weight loaded is saved.

• If the center of gravity of the load is deviated from the factory-set position due to modification of the lift arm or bucket, no
load or load calibration must be executed to operate the machine with high precision.

★ The saved calibration data is not cleared even after the battery has been removed for a long time.

★ No load calibration

• This function cancels the individual difference of weight inherent

to the machine, for example, the weight of the working equipment.
It makes compensation (B) by offsetting the error between the
actual weight and the reference value (A) as shown in the figure to
the right.

★ Load calibration

• This function compensates the reference pressure with the bucket

loaded. It makes compensation (B) of the error between the actual
pressure and the reference value (A) in the vicinity of the position
where load calibration is executed (C) as shown in the figure to the
right.

★ For the calibration execution method, see the load meter User
Guide.

Calculation Stop

• The calculation function of the load meter is stopped.

• During the calculation stop, the display of the load meter

disappears and the speed display or engine speed display appears. No data is added to the total data in this mode.

• To restart calculation, select the addition mode or reduction mode.

★ For the calculation stop method, see the load meter User Guide.

Function of Troubleshooting

• The machine monitors the input and output signals constantly for troubleshooting the system.

• If any abnormality is detected by self-diagnosis, the information is transmitted through the network to the machine
monitor. When an abnormality occurs, it can be confirmed on the machine monitor (display of failure history).

WA500-6 10-385 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Rear Side of Machine Monitor

★ Do not change the settings of the spare rotary switches or spare DIP switches.

1. Spare rotary switch (SW1)

2. Spare rotary switch (SW1)
3. Spare rotary switch (SW3)
4. Spare DIP switch (SW5-1)
5. Spare DIP switch (SW5-2)
6. Spare DIP switch (SW5-3)
7. Spare DIP switch (SW5-4)
8. Spare DIP switch (SW6-1)
9. Spare DIP switch (SW6-2)
10. Spare DIP switch (SW6-3)
11. Spare DIP switch (SW6-4)

10-386 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

WA500-6 10-387 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Connector Signal Tables

CN1 (070-20-pole) [CN-L51]

Pin
Specifications I/O Group Form of Use Signal Name WA500-6 Remarks
No.
1 — — — — —
Power supply of small Power supply
2 I — — —
lamp (+24 V)
Power supply of small Power supply
3 I — — —
lamp (+24 V)
NSW power supply Power supply NSW power supply NSW power supply
4 I —
(+24 V) (+24 V) (+24 V) (+24 V)
NSW power supply Power supply NSW power supply NSW power supply
5 I —
(+24 V) (+24 V) (+24 V) (+24 V)
SW power supply Power supply SW power supply SW power supply
6 I —
(+24 V) (+24 V) (+24 V) (+24 V)
SW power supply Power supply SW power supply SW power supply
7 I —
(+24 V) (+24 V) (+24 V) (+24 V)
8 — — — — — —
9 GND I — GND GND GND
10 GND I — GND GND GND
D_OUT_3
11 O A D/O sink (Spare) —
(+24 V, sink 200 mA)
D_OUT_2 (Automatic Executed by engine
12 O A D/O sink —
(+24 V, sink 200 mA) preheater relay) controller.
For small models
D_OUT_1 (HST solenoid
13 O A D/O sink — (Spare for medium
(+24 V, sink 200 mA) cutout relay)
and large models)
D_OUT_0
14 O A D/O sink Buzzer (Monitor) Buzzer (Monitor)
(+24 V, sink 200 mA)
Lift arm pressure
Sensor power supply Sensor power
15 O — sensor power —
output (+24 V) supply
supply
Lift arm angle Lift arm pressure
Sensor power supply Sensor power
16 O — sensor power and angle sensor For load meter
output (+5 V) supply
supply power supply
17 GND I — GND GND GND
18 GND I — GND GND GND
19 GND I — GND GND GND
20 GND I — GND GND GND

10-388 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

CN12 (070-18-pole + 12-pole) [CN-L52, CN-L53]

Pin Form of
Specifications I/O Group Signal Name WA500-6 Remarks
No. Use
D_IN_26
1 I E D/IGND Parking brake Parking brake
(24 V/GND, 5 mA)
D_IN_28 Executed by engine
2 I E D/IGND Engine oil pressure —
(24 V/GND, 5 mA) controller.
D_IN_30 Normal emergency Normal emergency
3 I E D/IGND
(24 V/GND, 5 mA) steering steering
D_IN_32
4 I F D/IGND Subtotal switch Subtotal switch For load meter
(24 V/GND, 5 mA)
D_IN_34
5 I F D/IGND High beam switch High beam switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/IGND Service function 2 Service function 2
(24 V/GND, 5 mA)
D_IN_38 Monitor mode switch 2 Switch for monitor
7 I G D/IGND ◊ switch input
(24 V/GND, 5 mA) ◊ switch input operation
8 P_IN_0(0.5Vp-p) I M P/I (Spare) —
9 GND O — GND GND GND
D_IN_27
10 I E D/IGND Engine coolant level Engine coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/IGND Engine oil level Engine oil level
(24 V/GND, 5 mA)
12 N.C. I E D/IGND N.C. N.C.
D_IN_33
13 I F D/IGND Cancel switch Cancel switch For load meter
(24 V/GND, 5 mA)
D_IN_35
14 I F D/IGND (Spare) —
(24 V/GND, 5 mA)
D_IN_37 Monitor mode switch 2
15 I G D/IGND ■ switch input
(24 V/GND, 5 mA) ■ input
D_IN_39 Low steering oil
16 I G D/IGND Spare
(24 V/GND, 5 mA) pressure
17 P_IN_1(5Vp-p) I M P/I (Spare) —
18 N.C. — — N.C. N.C.
A_IN_2
19 (High-resistance I J A/I Fuel level sensor Fuel level sensor
input)
A_IN_4
Torque converter oil Torque converter oil
20 (High-resistance I J A/I
temperature sensor temperature sensor
input)
Engine coolant
A_IN_6
temperature sensor Executed by engine
21 (High-resistance I K A/I —
(For automatic controller.
input)
preheater)
Lift arm pressure Lift arm pressure
22 A_IN_8 (0 – 5 V) I L A/I sensor sensor For load meter
(Rod) (Head)

WA500-6 10-389 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Pin Form of
Specifications I/O Group Signal Name WA500-6 Remarks
No. Use
Battery electrolyte Battery electrolyte level
23 A_IN_10 (0 – 14 V) — — If equipped
level A (If equipped)
24 GND O — GND SIGNAL GND GND
A_IN_3
Hydraulic oil Hydraulic oil
25 (High-resistance I J A/I
temperature sensor temperature sensor
input)
A_IN_5
Engine coolant Brake oil temperature Executed by engine
26 (High-resistance I J A/I
temperature sensor sensor controller.
input)
Lift arm pressure Lift arm pressure
27 A_IN_7 (0 – 5 V) I L A/I sensor sensor For load meter
(Bottom) (Bottom)
For load meter
(Shared with work
28 A_IN_9 (0 – 5 V) I L A/I Lift arm angle sensor Lift arm angle sensor
equipment
controller)
29 GND O — GND SIGNAL GND GND
Battery electrolyte For WA800 later
30 A_IN_11 (0 – 14 V) — — —
level B (Spare for others)

10-390 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
CN3 (070-18-pole + 12-pole) [CN-L54, CN-L55]

Pin Form of
Specifications I/O Group Signal Name WA500-6 Remarks
No. Use
D_IN_26
1 I E D/IGND Parking brake Parking brake
(24 V/GND, 5 mA)
D_IN_28 Executed by
2 I E D/IGND Engine oil pressure —
(24 V/GND, 5 mA) engine controller.
D_IN_30 Normal emergency Normal emergency
3 I E D/IGND
(24 V/GND, 5 mA) steering steering
D_IN_32
4 I F D/IGND Subtotal switch Subtotal switch For load meter
(24 V/GND, 5 mA)
D_IN_34
5 I F D/IGND High beam switch High beam switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/IGND Service function 2 Service function 2
(24 V/GND, 5 mA)
D_IN_38 Monitor mode switch 2 Switch for monitor
7 I G D/IGND < switch input
(24 V/GND, 5 mA) < switch input operation
8 P_IN_0(0.5Vp-p) I M P/I (Spare) —
9 GND O — GND GND GND
D_IN_27
10 I E D/IGND Engine coolant level Engine coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/IGND Engine oil level Engine oil level
(24 V/GND, 5 mA)
12 N.C. I E D/IGND N.C. N.C.
D_IN_33
13 I F D/IGND Cancel switch Cancel switch For load meter
(24 V/GND, 5 mA)
D_IN_35
14 I F D/IGND (Spare) —
(24 V/GND, 5 mA)
D_IN_37 Monitor mode switch 2
15 I G D/IGND > switch input
(24 V/GND, 5 mA) > input
D_IN_39
16 I G D/IGND Low steering oil pressure Spare
(24 V/GND, 5 mA)
17 P_IN_1(5Vp-p) I M P/I (Spare) —
18 N.C. — — N.C. N.C.
A_IN_2
19 (High-resistance I J A/I Fuel level sensor Fuel level sensor
input)
A_IN_4
Torque converter oil Torque converter oil
20 (High-resistance I J A/I
temperature sensor temperature sensor
input)
Engine coolant
A_IN_6
temperature sensor Executed by
21 (High-resistance I K A/I —
(For automatic engine controller.
input)
preheater)
Lift arm pressure sensor Lift arm pressure
22 A_IN_8 (0 – 5 V) I L A/I For load meter
(Rod) sensor (Head)
Battery electrolyte level
23 A_IN_10 (0 – 14 V) — — Battery electrolyte level A If equipped
(If equipped)

WA500-6 10-391 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Pin Form of
Specifications I/O Group Signal Name WA500-6 Remarks
No. Use
24 GND O — GND SIGNAL GND GND
A_IN_3
Hydraulic oil temperature Hydraulic oil
25 (High-resistance I J A/I
sensor temperature sensor
input)
A_IN_5
Engine coolant Brake oil temperature Executed by
26 (High-resistance I J A/I
temperature sensor sensor engine controller.
input)
Lift arm pressure
Lift arm pressure sensor
27 A_IN_7 (0 – 5 V) I L A/I sensor For load meter
(Bottom)
(Bottom)
For load meter
(Shared with work
28 A_IN_9 (0 – 5 V) I L A/I Lift arm angle sensor Lift arm angle sensor
equipment
controller)
29 GND O — GND SIGNAL GND GND
For WA800 later
30 A_IN_11 (0 – 14 V) — — Battery electrolyte level B —
(Spare for others)

CN4 (070 12-pole) [CN-L56]

Pin Form of
Specifications I/O Group Signal Name WA500-6 Remarks
No. Use
Monitor – transmission
1 S_NET(+) I/O N S-NET —
work equipment controller
Monitor – transmission
2 S_NET(+) I/O N S-NET —
work equipment controller
Cummins engine
controller, VSM controller Communication
3 CAN+ I/O P
communication (CAN (+))
(CAN (+))
4 S_NET(–) O N S-NET S_NET GND —
5 S_NET(–) O N S-NET S_NET GND —
6 GND O — GND S_NET shield GND
7 GND O — GND CAN shield CAN: twisted only
Cummins engine
Communication
8 CAN- I/O P controller communication
(CAN (–))
(CAN (–))
9 (NC)
10 (NC)
11 (NC)
12 (NC)

10-392 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
CN5 (070-14-pole) [CN-L57]

Pin Form of
Specifications I/O Group Signal Name WA500-6 Remarks
No. Use
1 (NC) — — —
RS232C serial
2 RS232C_1_RTS I/O Q —
communication
RS232C serial
3 RS232C_1_RD I Q RD —
communication
4 (NC) I R RD N.C. N.C.
5 (NC) I/O R N.C. N.C.
For load meter
BUSY input for load Printer BUSY
6 — — (Spare for medium
meter printer (if equipped)
and large models)
7 (NC) — — —
RS232C serial
8 RS232C_1_CTS I/O Q —
communication
RS232C serial Printer and personal
9 RS232C_1_TX O Q TX
communication computer TX
RS232C serial
10 RS232C_1_SG O Q —
communication
11 (NC) O R N.C. N.C.
12 (NC) O R TX N.C. N.C.
13 (NC) I/O R N.C. N.C.
14 (NC) — — N.C. N.C.

CN6 (040 8-pole) [CN-L58]

Pin Form of
Specifications I/O Group Signal Name WA500-6 Remarks
No. Use
1 RS232C_0_TXD O S — —
2 (NC) — — N.C. N.C.
3 RS232C_0_TXD O S — —
4 (NC) — — N.C. N.C.
5 RS232C_0_RXD I S — —
6 (NC) — — N.C. N.C.
7 RS232C_0_RXD I S — —
8 GND O — GND —

WA500-6 10-393 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Setting Switches (on circuit board)

Switch Form of
Specifications I/O Group Signal Name WA500-6 Remarks
No. Use
16 Posi rotary
1 I — Selection of model (Spare)
switch 1
16 Posi rotary Selection of
2 I — (Spare)
switch 2 specification
16 Posi rotary Selection of
3 I — (Spare)
switch 3 specification
4 2 Posi DIP switch 1 I — Selection of options (Spare)
5 2 Posi DIP switch 2 I — Selection of options (Spare)
6 2 Posi DIP switch 3 I — Selection of options (Spare)
7 2 Posi DIP switch 4 I — Selection of options (Spare)
8 2 Posi DIP switch 5 I — Selection of options (Spare)
9 2 Posi DIP switch 6 I — Selection of options (Spare)
10 2 Posi DIP switch 7 I — Selection of options (Spare)
11 2 Posi DIP switch 8 I — Selection of options (Spare)

10-394 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Work Equipment Control System

Work Equipment Controller

WA500-6 10-395 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

10-396 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Work Equipment Controls

Work Equipment Control Input and Output

WA500-6 10-397 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Work Equipment Control Lever Operation

The work equipment controller operates the work equipment by detecting the operating stroke of raise/lower, tilt/dump from
the signals of the work equipment lever potentiometer, and operating the main spool by operating each EPC valve attached to
the main valve with current control.

10-398 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
The work equipment control lever is equipped with detent notches. It is adjusted so that it will operate at the maximum speed
before each detent. The range beyond lower detent is the lift arm float operation position, where the lift arm operates by
external forces.

WA500-6 10-399 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Work Equipment Neutral Lock

When the work equipment lock lever is operated to the lock position, the lock switch (baffle lever switch) becomes OPEN and
the controller stops the operation of the work equipment by turning ON the work equipment neutral lock valve, cutting the
EPC pilot basic pressure.

★ While the work equipment is locked, the detent does not operate and the lever is not held at the detent position.

• The safety function is incorporated in which the work equipment continues to be locked until the work equipment control
lever is temporarily returned to the neutral position, even if the work equipment is unlocked.

Operation Table

Operation of
Operation by Man Input of Controller Work Equipment Control Output of Controller
Machine
Work equipment lever Work equipment
Baffle lever Baffle lever switch Oil pressure
potentiometer neutral lock valve
Lower OFF ON
— Cut
(LOCK) (OPEN) (24V)
Lower to raise OFF Work equipment control lever ON
Cut
(unlocking) (OPEN) being operated (24V)
After releasing, lever neutral of
Lower to raise OFF OFF
all work equipment detected Operating
(unlocking) (OPEN) (OPEN)
once
Raise ON OFF
— Operating
(FREE) (CLOSE) (OPEN)

10-400 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Neutral Position and Work Equipment Speed

• The work equipment control lever has neutral play of 5% in the lever stroke. It is adjusted so that the work equipment
starts to work from the position beyond the play.

• It also has a function to change the work equipment speed for the lever stroke through setting the controllers.

• The lift arm has five changeable tables; the bucket has three.

★ For the adjustment method and the characteristics of each table, refer to MACHINE MONITOR SYSTEM: Service Mode:
Adjustment Function: Modification of Lift Arm Lever Pattern and Modification of Bucket Lever Pattern in the Testing and
Adjusting section.

Lift Arm Lever Stroke vs. Speed Table

Lever Stroke -100 -90 -90 -85 -80 -70 -60 -50 -40 -30 -20 -10 -7 7 10 20 30 40 50 60 70 80 85 90 100

No. 1 100 100 60 52 46 36 28 21 16 11 6 1 0 0 1 6 12 18 26 35 47 70 100 100 100

No. 2 100 100 72 64 57 45 37 28 21 15 9 3 0 0 3 11 19 27 37 48 62 85 100 100 100

No. 3 100 100 72 72 66 54 45 37 29 21 13 4 0 0 5 18 28 38 48 59 72 90 100 100 100

No. 4 100 100 72 72 72 64 55 46 38 28 18 7 0 0 7 23 37 50 62 74 87 100 100 100 100

No. 5 100 100 72 72 72 72 66 57 47 36 25 10 0 0 10 30 45 59 73 86 100 100 100 100 100

WA500-6 10-401 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Bucket Lever Stroke vs. Speed Table

Lever Stroke -100 -95 -90 -85 -80 -70 -60 -50 -40 -30 -20 -10 -7 7 10 20 30 40 50 60 70 80 85 90 100

No.1 100 100 80 70 60 45 35 26 18 12 7 1 0 0 1 6 12 18 26 35 47 70 100 100 100

No.2 100 100 100 90 82 70 58 47 38 28 18 5 0 0 5 18 28 38 48 58 70 90 100 100 100

No.3 100 100 100 100 100 95 87 75 60 45 30 10 0 0 10 30 45 59 73 85 95 100 100 100 100

Tilt Priority Control

• Although the bucket and the lift arm can be operated simultaneously, because the machine has CLSS, it has a function that
prevents the lift arm from rising when the tilt operating stroke is large in order to ensure more efficient digging.

• This is accomplished by limiting the maximum speed of the lift arm raise for the tilt speed (see the following table).

★ This function does not work in a dump operation, which enables the simultaneous operation.

Bucket tilt speed 0% 20% 40% 60% 70% 100%

Maximum speed of lift arm raise 100% 80% 30% 0% 0% 0%

10-402 ➁ WA500-6
STRUCTURE, FUNCTION AND
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Lift Arm Stop Modulation

• The work equipment controller uses modulation to ease the top shock of the lift arm raise/lower when the operator
performs the lift arm stop operation faster than a certain speed.

• The operation of this stop modulation function can be changed through a setting.

★ For information about changing the lift arm stop modulation and the necessary precautions, see Machine Monitor System:
Adjustment Function (TUNING): Adjustment of Lift Arm Lower Stop Modulation in the Testing and Adjusting section.

★ Case A:
When lever command flow rate < modulation command flow rate
• Outputs according to the lever command flow rate.

★ Case B:
When lever command flow rate > modulation command flow rate
• Outputs according to the modulation command flow rate.

★ a: Modulation command flow rate

Deceleration flow rate: 0.75%/mS
100% ➨ 0% 143 mS

★ b: Implements modulation from 30% flow rate command or under

WA500-6 10-403 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Speed Reduction Function in Raising Cargo Lift Arm

• It implements the equivalent function as the cutoff function, performed with the cutoff valve in the conventional machine.

• Lift arm above horizontal (Lift arm angle sensor signal)

• Bucket tilt end (Tilt end proximity switch signal)
• Lift arm bottom pressure minimum 20 MPa (2,900.76 psi) (Signal by network communication from the monitor)
Only when the above conditions are simultaneously satisfied will the lift arm raise maximum speed be limited
to 70%.

• When the lift arm raise maximum speed is changed between 70% and 100%, modulation is equipped for reducing shocks
to control the speed so that it does not change suddenly.

• This function can change the condition value of the lift arm bottom pressure through the controller setting. By changing
the set value of the lift arm bottom pressure, matching of the lift arm rising speed and travel speed can be changed.

★ For information about the procedure, see Machine Monitor System: Adjustment Function (TUNING): Adjustment of Pump
Cutoff Pressure in Lift Arm Raise in the Testing and Adjusting section.

Adjusting Lever Detent Position and Work Equipment Starting Current

• The work equipment controller has an adjusting function for correction dispersion.

• The detent position is adjusted so that the lever potentiometer voltage at the detent position will be saved, ensuring control
before and after the detent. When it is not adjusted, such phenomena as “the positioner does not operate normally before
and after the detent” or “the lever position of lift arm float is not normal” may occur.

• When the work equipment starting current is not adjusted, such phenomena as “the neutral dead zone is large” or
“dashing/stopping shock of the work equipment becomes large” may occur.

★ For information about the procedure, see the following topics in the Testing and Adjusting section:

• Machine Monitor System: Adjustment Function (TUNING): Adjustment of Lift Arm Raise Lever and Variations in the
Dead Zone of EPC
• Machine Monitor System: Adjustment Function (TUNING): Adjustment of Lift Arm Lower (Float) Lever and
Variations in the Dead Zone of EPC
• Machine Monitor System: Adjustment Function (TUNING): Adjustment of Bucket Dump EPC Starting Current

10-404 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Remote Positioner
Bucket Positioner

This function allows the bucket to gently stop at any set position when the tilt lever is set to the detent position with the bucket
level or lower.

1. Setting stop position

The stop position of the bucket will change when the positioner is operated using the bucket positioner position set switch.

Condition for
Bucket lever stroke: neutral and travel speed below 5 km/h (3 mph)
Availability
When setting it upward from the current stop position, press the bucket positioner + position set
(1)
switch position (upward). (Use the downward switch to change it downward.)
Saves +1 to the current set position (memory); sounds a setting complete buzzer (pip); and the
monitor displays the numerical value for three seconds.
(2) (Set position will be maintained when the key is turned off.)
Setting method
* When the switch is operated exceeding ±5 of the set range, the monitor displays the same
value and the setting cancel buzzer (pip) sounds.
For further change, release the switch once and then press it again.
(3) * When the switch is operated exceeding ±5 of the set range, the monitor displays the same
value and the setting cancel buzzer (pip) sounds.

WA500-6 10-405 ➁
STRUCTURE, FUNCTION AND
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2. Resetting tilt detent
• If the bucket horizontal proximity switch is operated when the bucket lever is at the tilt detent position, the detent will
be reset after the delay time and the bucket will stop gently.

• Delay time
• The bucket horizontal proximity switch is set at the position where the bucket is “downward (-5).”
• The flow rate to the tilt cylinder is calculated from the pump delivery. When the necessary oil level for the set
position is reached, the detent will be reset and it will stop gently.

3. Tilt stop (gentle)

• After resetting the detent, whether the bucket lever is maintained by the tilt detent will be checked for 0.05 seconds
and if it is, stop operation will not be performed gently.
• If the bucket lever is operated when stopping (gently), the faster of the target speed with the tilt lever operation and
the target speed with the stop (gentle) function will be selected and output.
• If the bucket lever is operated in the direction of dump for 60% or more during stop (gentle) control, the stop (gentle)
control will be stopped and dump will be output.

10-406 ➁ WA500-6
STRUCTURE, FUNCTION AND
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Lift Arm Positioner

Function

★ Raise kickout (when raise lamp is on)

• Set the lift arm lever to raise detent; reset the lift arm raise detent when the lift arm rises before the set position; and
perform stop (gentle) control.
• When the lift arm is at positions other than the raise detent, it is raised by the operator.
• When raise is not selected, only raise detent will operate.
• When the detent is turned on, the remote positioner will not operate and only the kickout function (stop at the top
position of the lift arm) will operate.

★ Lower lift arm stop (when lower lamp is on)

• Set the lift arm lever to the float detent; start decreasing the speed when the lift arm is 10° before the set position;
reset the float detent when it is 4° before the set position; and perform stop (gentle) control.
• If the lift arm lever is kept as it is, the lift arm starts lowering again.
• When lower is not selected, only float detent will operate.
• When the detent is turned on with the lift arm angle level or lower, the remote positioner will not operate and only the
float detent function (it will not stop automatically) will operate.

★ The remote positioner of lower will not function as positioner and will not stop when the detent is turned on with the lift
arm angle level or lower in order to distinguish it from float operation in grading operation.

WA500-6 10-407 ➁
STRUCTURE, FUNCTION AND
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1. Setting stop position
• The stop position of the bucket will change when the positioner is operated using the bucket positioner position set
switch.
★ Setting and resetting raise stop position

Condition for
Lift arm lever stroke: neutral
Availability
(1) Raise the lift arm to a desired set position.
(2) Press the remote positioner raise position set switch (less than a second).
If the position where the switch is pressed is within the set range, save the lift arm angle.
(3)
Method of The setting completion buzzer sounds (pip, pip) and the switch indicator lights up.
setting raise
If it is out of the range (lift arm angle less than 0°), and in sensor errors, it will not be set
stop
(4) again.
(The buzzer will not sound; the set position will not be changed.)
When the set switch is operated for less than a second, the set position is always changed.
(5)
(The set position is maintained when the key is turned off.)
(1) Press and hold the remote positioner raise position set switch for a second or longer.
If it is within the set range when the switch is pressed, the position is set temporarily.
Method of If it is proceed for a second or longer in (3) above, the setting cancel buzzer (pip) sounds
(2)
resetting raise when a second elapses; raise selection is reset; and the switch indicator goes off.
stop *After the setting is reset, the whole lift arm angle will be available.
Remote positioner raise stop control is not performed.
(3)
Only boom kickout control will be performed.

★ Setting and resetting lower stop position

Condition for
Lift arm lever stroke: neutral
Setting
(1) Lower the lift arm to a desired set position.
(2) Press the remote positioner lower position set switch (less than a second).
If the position where the switch is pressed is within the set range, save the lift arm angle. The
(3)
Method of setting completion buzzer sounds (pip, pip) and the switch indicator lights up.
setting lower
If it is out of the range (other than lift arm angle of -37° to 0°), and in sensor errors, it will not
stop
(4) be set again.
(The buzzer will not sound; the set position will not be changed.)
When the set switch is operated for less than a second, the set position is always changed.
(5)
(The set position is maintained when the key is turned off.)
(1) Press and hold the remote positioner lower position set switch for a second or longer.
If it is within the set range when the switch is pressed, the position is set temporarily.
Method of If it is proceed for a second or longer in (3) above, the setting cancel buzzer (pip) sounds
(2)
resetting lower when a second elapses; lower selection is reset; and the switch indicator goes off.
stop *After the setting is reset, the whole lift arm angle will be available.
Remote positioner lower stop control is not performed.
(3)
Only float detent control will be performed.

10-408 ➁ WA500-6
STRUCTURE, FUNCTION AND
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★ Settable range of remote positioner stop position

[Raise, lower stop position settable range]

Stop Position Raise Lower
Min. 0° 0 to -37°
0°: Lift arm is level.

2. Resetting lift arm raise detent

• Raise detent turns on when the lift arm lever stroke becomes 60% or more.
• When the remote positioner operates, the detent goes off from 2° before stop angle to 1° past.
• When the lift arm raise detent automatically goes off due to the operation of the stop (gentle) function, the lift arm
raise/lower detent stays off for a second after it is turned off.

3. Lift arm raise stop (gentle)

• In the lift arm raise stop (gentle), the speed is decreased in accordance with the stop angle from stop angle of 9° to 2°
before, through lift arm angle feedback.
• After resetting the lift arm detent, check whether the lift arm lever is maintained by the detent for 0.05 seconds and if
it is, (gentle) stop operation will not be performed. Accelerate the raising rate of the lift arm to reach maximum speed
when the lift arm angle is 10° above the stop position.
• Therefore, when an operation exceeding the target stop angle is performed while the detent is maintained with the lift
arm raise remote positioner operated, the speed of the lift arm raise temporarily decreases and then increases.

WA500-6 10-409 ➁
STRUCTURE, FUNCTION AND
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4. Boom kickout
• When the lift arm raise detent is set when the stop position of the remote positioner is not set or above the stop
position, the lift arm slowly stops before the stroke end as kickout operation, reducing stop shock due to stroke end.
• In kickout operation, the detent becomes off from 2° before stop angle to above.

5. Resetting lift arm lower detent

• Lower detent turns on when the lift arm lever stroke becomes 60% or more.
• When the remote positioner operates, the detent becomes off from 2° before stop angle to 1° past.
• When the lift arm angle is less than -37°, the detent turns on for grading operation, regardless of operation of the
remote positioner.
• When the lift arm lower detent automatically goes off due to the operation of the stop (gentle) function, the lift arm
raise/lower detent stays off for a second after it is turned off.

10-410 ➁ WA500-6
STRUCTURE, FUNCTION AND
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6. Lift arm lower stop (gentle)
• In the lift arm lower stop (gentle), the speed is decreased in accordance with the stop angle from stop angle of 9° to 2°
before, through lift arm angle feedback.
• After resetting the lift arm lower detent, it is checked whether the lift arm lever is maintained by the detent for
0.05 seconds and if it is, stop operation (gentle) will not be performed. The lift arm lower is accelerated so that the lift
arm will be floating when the lift arm angle is at 10° below the stop position.
• Therefore, when an operation exceeding the target stop angle is performed while the detent is maintained with the lift
arm lower remote positioner operated, the speed of the lift arm lower temporarily decreases and then increases.
• Even during acceleration, when the lift arm angle reaches -37°, acceleration ends and float operation is set.

7. Detent operation during engine stop

• While the engine stops, the detent is constantly turned OFF. The lever is not held at detent position during engine
stop.

8. Adjustment of lift arm angle

• The work equipment controller has an adjusting function for correcting the lift arm angle sensor installation errors.
• It saves the lift arm angle sensor voltage at the lift arm top position and operates the kickout remote positioner
function.
• When not implementing an adjustment, such phenomena as the kickout position is “too early” and “no kickout occurs
and a shock is generated at the stroke end” may occur.

WA500-6 10-411 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Semi-Automatic Digging
Control of Semi-Automatic Digging

• Semi-automatic digging is a function in which digging operations

can be performed only with the kickdown switch and lift arm raise
operation, improving the working efficiency of less experienced
operators.

• The two modes of LOOSE mode/ROCK mode are separately used

due to the characteristics of the work objects.

• Select the bucket automatic operation pattern appropriate for the

work cycle/load.

★ Mode Selection

No. Object Mode

1 Gravel/sand LOOSE mode
2 Quarry/blasted rock ROCK mode

10-412 ➁ WA500-6
STRUCTURE, FUNCTION AND
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Conditions for Starting Semi-Automatic Digging

Semi-automatic digging is ready with (1) to (4) below.

(1) The semi-automatic digging switch is either in ROCK or LOOSE mode.
(2) In forward (with F signal)
Condition 1
(3) Lift arm angle less than -30° (almost to the ground)
Operate the kick-down switch.
(4) * Even when working in 1st, semi-automatic digging will not start without
operating the kickdown switch.
Semi-automatic digging (automatic tilting) will start when
the following conditions (1) and (2) are satisfied.
Condition 2
(1) Perform lift arm raise operation after condition 1 is satisfied.
(2) Travel speed km/h <3.5 x ENG rpm/1,800>

Conditions for Finishing Semi-Automatic Digging

Automatic tilting is finished when any of the following conditions is satisfied.

(1) Forward finished (F signal: ON → OFF)
Conditions
(2) Lift arm angle level or higher
(3) Detect tilt end (becomes full tilt)

Tilt Operation of Digging Model

★ Operation of LOOSE mode

• Tilt operation will start 0.5 seconds after the conditions for starting semi-automatic digging are satisfied.
• The speed is increased so that it becomes 100% 10 seconds after starting tilt.
• The maximum speed depends on the engine speed.

WA500-6 10-413 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
★ Operation of ROCK mode
• Tilt operation will start 0.6 seconds after the conditions for starting semi-automatic digging are satisfied.
• Tilt repeats operation/stop with different tilt time/cycle for each cycle.
• The number of tilts changes until loading is finished in accordance with the loading object.
• The maximum speed depends on the engine speed.

10-414 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Pump Swash Plate Control

In pump swash plate control, “horsepower loss decrease function in pump relief” and “pickup auxiliary function when engine
speed is low” are included. Based on calculation results of each function, data with less pump delivery (larger pump EPC
current) will be selected.

★ Horsepower loss decrease function in pump relief

• Horsepower loss is decreased by controlling pump delivery in relief, changing the command value of the pump swash
plate, when the work equipment pump is relieved.
• Output to pump EPC is changed with input signal of the loader pump pressure sensor.

WA500-6 10-415 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
• The work equipment controller operates pump EPC in 200 mA until loader pump pressure reaches 32 MPa
(4641.21 psi). When it becomes 33 MPa (4786.25 psi) or higher, the controller operates pump EPC in 700 mA.
• In this control, the delivery (pump EPC current) is changed over a second from 700 mA to 200 mA in order to prevent
sudden operation due to a rapid increase of flow rate, when the delivery changes in increasing direction (current
decreasing direction).

Pump Pressure Current Value

Pump Flow Rate
MPa (psi) (A)
33.3 (4829.76) 0.2 100%
34.3 (4974.79) 0.7 ≈ 30%

10-416 ➁ WA500-6
STRUCTURE, FUNCTION AND
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★ Pickup auxiliary function when engine speed is low.
• When the engine speed and torque are low, acceleration of the engine in work equipment operation is aided by
limiting the pump delivery.

• Engine speed is < 1,400 rpm.

↓
Pump flow rate restriction

WA500-6 10-417 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
• The work equipment controller operates pump EPC in 0.9 mA until engine speed reaches 500 rpm. When it becomes
1,400 rpm or higher, the controller operates pump EPC in 0.2 A.
Engine Speed Current Value (A) Pump Flow Rate
500 rpm 0.9 MIN
1,000 rpm 0.569 ≈ 40%
1,400 rpm 0.2 100%

10-418 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Joystick Steering Control

★ Joystick Steering (J/S) system
• Joystick steering controls the turning speed according to the joystick lever operation angle.
• The standard steering system is augmented with a system for implementing Orbitrol operation using the joystick
solenoid valve.
• Even during a joystick steering operation, turning operation can be done using the steering wheel.
• The transmission controller controls validity/invalidity of the joystick steering system. When the machine monitor
joystick indicator is other than lit (turned out or flashing), turning operation can not be done using the joystick lever.

★ Joystick neutral safety

• When starting the engine with the joystick steering system being valid (J/S ON/OFF switch = ON and J/S unlocked),
if the joystick lever is set to other than neutral and the joystick knob FNR switch is set to other than neutral, the
engine start signal is cut off to inhibit engine start by turning the neutral safety relay ON to prevent the machine from
turning and starting immediately after the engine starts.

★ Joystick neutral interlock

• A safety function is incorporated in the system to disable turning operation using the joystick lever until it is returned
to the neutral position, even if the joystick is valid with the joystick lever in operation while the joystick steering is
invalid (J/S ON/OFF switch = OFF or J/S is locked).

WA500-6 10-419 ➁
STRUCTURE, FUNCTION AND
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★ Adjustment of starting current
• The work equipment controller has an adjusting function for correcting dispersion.
• The work equipment starting current usually does not require adjustment. However, if phenomena such as “the
neutral dead zone is large,” “dashing/stopping shock from J/S turning is large,” or “the time lag for turning operation
start is large” should occur, they can be improved by implementing an adjustment.
★ For the adjusting procedure, see Machine Monitor System: Service Mode: Adjustment Function (TUNING) in the
Testing and Adjusting section

★ Joystick setting
• Since the joystick is an optional equipment, control will not be performed unless the option setting for joystick is
made valid in the optional setting of the machine monitor. It cannot be simultaneously installed with the right FNR
switch.
★ For the setting procedure of options, see Machine Monitor System: Service Mode: Optional Device Setting Function
(OPTIONAL SELECT) in the Testing and Adjusting section.

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STRUCTURE, FUNCTION AND
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Real-Time Monitor
★ Display contents of the real-time monitor

In the WA500-6, the state of the controller input and output signals can be checked using the real-time monitor function of
the machine monitor. The following table lists the display items and display contents in normal operation of the real-time
monitor in relation to the work equipment controller.

Display of Item Contents of Display Display Contents in

No. Check Item ID No. Remarks
Name Data Normal Operation
Software part Part No. of software is Depends on the software
1 20202 VERSION
number displayed number
Application Application version Depends on application
2 20225 VERSION APP
Version number is displayed version number
Data version number is Depends on data version
3 Data Version 20226 VERSION DATA
displayed number
When work equipment is in
Converted value of the
Loader pump neutral: 2.0 ±2.0 MPa
4 94700 PUMP PRESS loader pump oil pressure
pressure Work equipment relief:
is displayed
34.0 ±2.0 MPa
When work equipment is in
Input voltage value of
Loader pump neutral: 0.70 ±0.2 V
5 94701 PUMP PRESS loader pump oil pressure
pressure Work equipment relief:
is displayed
3.22 ±0.2 V
Li (800 rpm): 421 ±30 mA
Hi (above 950 rpm):
Loader pump Loader pump EPC OUT 200 ±10 mA
6 EPC current 94500 PUMP EPC DIR command current value Work equipment relief:
(Command) is displayed 700 ±10 mA
Engine stop (below
500 rpm): 900 ±10 mA
When work equipment is in
Pump delivery Results of pump delivery neutral: 170 CC/R
7 94600 PUMP FLOW
flow rate calculation are displayed Work equipment in relief:
23 ±10 CC/R
Standard lift arm
Lift arm top: 47.0 ±2.0 deg.
Lift arm bottom:
Calculation results of lift -43.0 ±3.0 deg.
8 Lift arm angle 06002 BOOM ANG
arm angle is displayed Hi-lift lift arm
Lift arm top: **.*±2.0 deg.
Lift arm bottom:
-**.*±3.0 deg.
STD lift arm
Input voltage value to lift Lift arm top: 3.80 ±0.3 V
arm angle sensor Lift arm bottom: 1.31 ±0.5 V
9 Lift arm angle 06005 BOOM ANG
potentiometer is Hi-lift lift arm
displayed Lift arm top: **.*±0.3 V
Lift arm bottom: **.*±0.5 V
Operation angle
WA500-6 has no
converted value of AJSS
10 Frame angle 94400 FRAME ANGLE — corresponding
frame potentiometer is
functions.
displayed

WA500-6 10-421 ➁
STRUCTURE, FUNCTION AND
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Display of Item Contents of Display Display Contents in

No. Check Item ID No. Remarks
Name Data Normal Operation
Number of lift Number of lift arm lever Display in accordance with
11 arm lever 42100 BOOM LVR operations is displayed in the number of lever
operations the unit of thousand operations
Neutral: 2.50 V ±0.10 V
Raise (before detent):
3.89 V ±0.20 V
Lever Input voltage value to lift Raise (detent position):
12 potentiometer 42000 BOOM POT1 arm lever potentiometer 1 4.11 V ±0.20 V
voltage lift arm 1 is displayed Lower (before detent):
1.11 V ±0.20 V
Float (detent position):
0.89 V ±0.20 V
Neutral: 2.50 V ±0.10 V
Raise (before detent):
1.11 V ±0.20 V
Lever Input voltage value to lift Raise (detent position):
13 potentiometer 42001 BOOM POT2 arm lever potentiometer 2 0.89 V ±0.20 V
voltage lift arm 2 is displayed Lower (before detent):
3.89 V ±0.20 V
Float (detent position):
4.11 V ±0.20 V
Bucket lever Number of bucket lever Display in accordance with
14 operation 42101 BUCKET LVR operations is displayed in the number of lever
frequency the unit of thousand operations
Neutral: 2.50 V ±0.10 V
Input voltage value to Tilt (before detent):
Lever
bucket lever 3.89 V±0.20 V
15 potentiometer 42002 BUCKET POT1
potentiometer 1 is Tilt (detent position):
voltage bucket 1
displayed 4.11 V ±0.20 V
Full dump: 0.89 V ±0.20 V
Neutral: 2.50 V ±0.10 V
Input voltage value to Tilt (before detent):
Lever
bucket lever 1.11 V ±0.20 V
16 potentiometer 42003 BUCKET POT2
potentiometer 2 is Tilt (detent position):
voltage bucket 2
displayed 0.89 V ±0.20 V
Full dump: 4.11 V ±0.20 V
Lift arm raise EPC output command
Neutral: 0 ±10 mA
17 EPC current 41900 RAISE EPC DIR current value to lift arm
Max.: 896 ±10 mA
(Command) raise is displayed
Neutral: ±10 mA
Lift arm lower EPC output command
LOWER EPC Before detent: 640 ±10 mA
18 EPC current 41901 current value to lift arm
DIR Float position:
(Command) lower is displayed
1,000 ±10 mA
Bucket tilt EPC EPC output command
Neutral: 0 ±10 mA
19 current 41902 TILT EPC DIR current value to bucket tilt
Max.: 930 ±10 mA
(Command) is displayed
Bucket dump EPC output command
Neutral: 0 ±10 mA
20 EPC current 41903 DUMP EPC DIR current value to bucket
Max.: 848 ±10 mA
(Command) dump is displayed
EPC output command WA500-6 has no
J/S EPC current
21 41908 AJSS EPC DIR current value to AJSS is — corresponding
(command)
displayed functions.

10-422 ➁ WA500-6
STRUCTURE, FUNCTION AND
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Display of Item Contents of Display Display Contents in

No. Check Item ID No. Remarks
Name Data Normal Operation
J/S right EPC EPC output command
22 current 41904 J/S EPC DIR RH current value to J/S right
(command) is displayed Neutral: 0 ±10 mA
J/S left EPC EPC output command Max.: 850 ±10 mA
23 current 41905 J/S EPC DIR LH current value to J/S left is
(command) displayed
Neutral: 2.50 V ±0.10 V
Lever Input voltage value to J/S When fully turned right:
24 potentiometer 42004 J/S POTI1 lever potentiometer 1 is 1.34 V ±0.20 V
voltage J/S1 displayed When fully turned left:
3.66 V ±0.20 V
Neutral: 2.50 V ±0.10 V
Lever Input voltage value to J/S When fully turned right:
25 potentiometer 42005 J/S POTI2 lever potentiometer 2 is 1.34 V ±0.20 V
voltage J/S2 displayed When fully turned left:
3.66 V ±0.20 V
3-spool valve 1,
EPC output command
ECMV and Neutral: 0 ±10 mA
26 41906 3RD EPC1 DIR current value to 3-spool
current value Max.: 960 ±10 mA
valve 1 is displayed
(Command)
3-spool valve 2,
EPC output command
ECMV and Neutral: 0 ±10 mA
27 41907 3RD EPC2 DIR current value to 3-spool
current value Max.: 960 ±10 mA
valve 2 is displayed
(Command)
Number of 3-spool valve
3-spool valve Display in accordance with
lever operations is
28 lever operation 42102 3RD LVR the number of lever
displayed in the unit of
frequency operations
thousand
Lever Input voltage value to 3-
Neutral: 2.50 V ±0.10 V
potentiometer spool valve lever
29 42006 3RD POT1 Retract: 4.11 V ±0.20 V
voltage 3-spool potentiometer 1 is
Extract: 0.89 V ±0.20 V
valve 1 displayed
Lever Input voltage value to 3-
Neutral: 2.50 V ±0.10 V
potentiometer spool valve lever
30 42007 3RD POT2 Retract: 0.89 V ±0.20 V
voltage 3-spool potentiometer 2 is
Extract: 4.11 V ±0.20 V
valve 2 displayed
Operation angle
WA500-6 has no
AJSS lever converted value of AJSS
31 94300 AJSS LEVER — corresponding
operation angle lever potentiometer is
functions.
displayed
AJSS lever Input voltage value of WA500-6 has no
32 potentiometer 94301 AJSS LEVER AJSS lever potentiometer — corresponding
voltage is displayed functions.
Input voltage value of
AJSS frame WA500-6 has no
AJSS frame
33 potentiometer 94401 FRAME ANGLE — corresponding
potentiometer is
voltage functions.
displayed
Deviation angle value of WA500-6 has no
AJSS S/T S/T
34 94800 AJSS frame and lever is — corresponding
deviation angle DEFLECTION
displayed functions.

WA500-6 10-423 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Display of Item Contents of Display Display Contents in

No. Check Item ID No. Remarks
Name Data Normal Operation
During digging operation:
Digging-in- The state of digging flag
35 94900 WORK FLAG ON
progress flag is displayed
Other than above: OFF
00000000
(Semi-auto switch = OFF) D-IN-0: Semi-auto
10000000 LOCK mode switch
Input signal The state of input signal (Semi-auto switch = ON) D-IN-1: Semi-auto
36 40910 D-IN--0-----7
D_IN_0-7 is displayed 010000000 LOOSE mode switch
(Semi-auto switch = ON) D-IN-2: J/S Hi-Lo
0010000000 selector switch
(J/S Hi-Lo selector switch)
11000000
(State of dump) D-ON-8: Tilt end
10000000 proximity switch
(Bucket level) D-IN-9: Tilt level
00000000 proximity switch
Input signal The state of input signal (Full tilt) D-IN-10: Bucket
37 40911 D-IN--8-----15
D_IN_8-15 is displayed 10100000 positioner raise set
(Bucket raise set switch = switch
ON) D-IN-11: Bucket
10010000 positioner lower set
(Bucket lower set switch = switch
ON)
1000000
D-IN-16: Work
(Work position)
equipment N lock
Input signal The state of input signal 00000000
38 40912 D-IN-16-----23 switch
D_IN_16-23 is displayed (Lock position)
D-IN-17: Starter C
01000000
terminal signal
(While cranking)
0000000
D-IN-28: Lift arm
00001000
positioner raise set
(Lift arm raise set SW =
Input signal The state of input signal switch
39 40913 D-IN-24-----31 ON)
D_IN_24-31 is displayed D-IN-29: Lift arm
0000010
positioner lower set
(Lift arm lower set SW =
switch
ON)
Input signal
D_IN_32-39 There is no used items in
(No. 33-39 don't The state of input signal this data
40 40942 D-IN-32-----39
apply to work is displayed 00000000 is constantly
equipment displayed
controller.)
10000000
D-OUT-0: Work
(Lock position)
equipment N Lock
00000000
SOL
ON/OFF output state of (Unlock neutral)
D-OUT-1: Lift arm
ON/OFF output SOL_OUT0 to 7 01000000
41 40952 D-OUT--0------7 raise detent SOL
D_OUT_0--7 '0' is displayed when (Raise detent SOL = ON)
D-OUT-2: lift arm
setting current output 00100000
float detent SOL
(Float detent SOL = ON)
D-OUT-3: Bucket tilt
0001000
detent SOL
(Tilt detent SOL = ON)

10-424 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Display of Item Contents of Display Display Contents in

No. Check Item ID No. Remarks
Name Data Normal Operation
ON/OFF output state of
SOL_OUT8 to 13 and 00000000
ON/OFF output ON/OFF output state of (J/S cut relay: OFF) SOL-OUT-8: J/S cut
42 40953 D-OUT-8-----15
D_OUT_8--15 SIG_OUT0 and 1 10000000 relay
'0' is displayed when (J/S cut relay: ON)
setting current output
D-OUT-18: Lift arm
00001000
positioner raise set
(Operate safety relay)
SIG_OUT2 – 3 indicator ON
00010000
HSW_OUT0 – 1 D-OUT-19: Lift arm
ON/OFF output (Display lift arm positioner
43 40954 D-OUT-16----23 ON/OFF output state of positioner lower
D_OUT_16--23 lower = ON)
BATT_RY_OUT is indicator ON
00110000
displayed D-OUT-20:
(Display lift arm positioner
Operation safety
raise/lower = ON)
relay

* JS = Joystick steering

WA500-6 10-425 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Diagnosis
★ Troubleshooting function

• The work equipment controller monitors the input and output signals constantly for troubleshooting the system.
• If any abnormality is detected by self-diagnosis, the information is transmitted through the network to the machine
monitor. When an abnormality occurs, it can be confirmed on the machine monitor/ KOMTRAX.

10-426 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Input and Output Signals

Pin Assignment

DEUTSCH-24P [CN-L05]

Input and Input and

Pin Pin
Signal Name Output Signal Name Output
No. No.
Signals Signals
1 Bucket lever potentio B Input 13 Boom lever potentio B Input
2 Loader pump press. sensor Input 14 Third EPC lever B Input
3 J/S potentio B Input 15 NC Input
4 GND_SIG_D 16 NC Output
5 NC Input 17 Semi-auto loading loose mode SW Input
6 NC Input 18 NC Input
7 Bucket lever potentio A Input 19 Boom lever potentio A Input
8 Boom angle sensor Input 20 Third EPC lever A Input
9 J/S lever potentio A Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
11 J/S speed Hi/Lo select SW Input 23 Semi-auto loading lock mode SW Input
12 NC Input 24 NC Input

WA500-6 10-427 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
DEUTSCH-40P (1) [CN-L06]

Input and Input and

Pin Pin
Signal Name Output Signal Name Output
No. No.
Signals Signals
Input and
1 NC Output 21 NC
output
Input and
2 NC Input 22 COMM_CAN_L_O
output
Input and
3 Remote positioner leveling set SW Input 23 NC
output
4 NC Input 24 PWR_CTR_EXT Input
5 NC Input 25 Starting switch (IGN-C) Input
6 NC Input 26 NC Input
7 NC Input 27 NC Input
8 NC Output 28 NC Input
9 NC Output 29 NC
10 NC Input 30 NC Input
11 NC Output 31 NC
Input and
12 NC 32 COMM_CAN_H_O
output
Input and
13 Remote positioner lifting set SW Input 33 NC
output
14 NC Output 34 NC
15 NC Input 35 Lever prohibiting equipment SW Input
16 NC Input 36 NC Input
17 NC Input 37 NC Input
18 NC Output 38 NC Input
19 NC Output 39 NC
20 NC Input 40 NC Input

10-428 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

DEUTSCH-40P (2) [CN-L07]

Input and Input and

Pin Pin
Signal Name Output Signal Name Output
No. No.
Signals Signals
1 PWR_IN_BATT Input 21 GND_PWR
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 Safety relay Output 24 PWR_CTR_KEY Input
5 Bucket tilting EPC Output 25 Third EXT EPC Output
6 Boom lifting EPC Output 26 J/S solenoid cut relay Output
Magnetic detent of boom lever
7 Work neutral lock solenoid Output 27 Output
float
8 Remote positioner lifting indicator Output 28 J/S right EPC Output
9 NC Input 29 NC Input
10 Bucket cylinder tilt end SW. Input 30 Bucket positioner up set SW Input
11 PWR_IN_BATT Input 31 GND_PWR
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 NC Output
15 Bucket dumping EPC Output 35 Third RET EPC Output
16 Boom lowering EPC Output 36 Loader pump EPC Output
Magnetic detent of bucket lever
17 Magnetic detent of boom lever lift Output 37 Output
tilt
Remote positioner lowering
18 Output 38 J/S left EPC Output
indicator
19 NC Input 39 NC Input
20 Bucket cylinder horizon SW Input 40 Bucket positioner down set SW Input

WA500-6 10-429 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Transmission Controller System

Electrical Circuit Diagram
Steering wheel specifications with lockup (if equipped)

10-430 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

WA500-6 10-431 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Transmission Controller Gear Shifting Control

Electronic Modulation Function

To reduce the shocks made when the gear speed is changed (when the clutch is engaged), the modulation control is applied.
The clutch oil pressure is controlled properly for the condition of the hydraulic circuit, depending on the engine speed,
transmission oil temperature, travel speed, gear shifting pattern, and transmission modulation data table saved in the
transmission controller memory so that the transmission is set in any gear speed (including the lockup clutch) smoothly.

Modulation control is also performed for the clutch on the side to be turned off in order to reduce lowering the torque. If an
abnormal time lag is made in gear shifting, the learning function corrects the modulation automatically.

Display of Gearshift

The transmission controller displays the state of the input signal related to the gearshift, sending it to the machine monitor via
the network.

★ Directional indicators
• The directional indicators of the machine monitor display the signal input state of the directional lever, which is input
to the transmission controller.
• When the lever is in the neutral position and there is no input signal to the transmission controller, the directional
indicators go out completely. If two signals are input due to a problem, the two indicators may light up at the same
time.
• If the directional lever is in the R state, the backup lamp relay is operated; the back lamp and back buzzer are
operated. If the machine has the right FNR switch (if equipped) and joystick steering (if equipped) installed with two
systems of the FNR signal, see Machine Monitor System: Service Mode: Optional Device Setting Function
(OPTIONAL SELECT) in the Testing and Adjusting section.

★ Gear speed indicators

• The gear speed indicators of the machine monitor display the signal input state of the gear speed lever, which is input
to the transmission controller.
• When the lever is in the neutral position and there is no input signal to the transmission controller, the gear speed
indicators go out completely. If two signals are input due to a problem, an indicator different from the lever position
may light up because priority is given to the higher gear speed.

★ Display of actual gear speed

• The actual gear speed display of the machine monitor shows the state of the gear speed and travel direction, which is
output from the transmission controller. When the directional lever is in N, the monitor display is N. When the
directional lever is in F or R, the monitor display is F or R + gear speed. This display is always N since no gear speed
is output while the parking brake is ON.

Automatic Gear Shifting Function

Auto-shift (in which the gear speed is automatically determined depending on the travel speed) and manual shift (in which the
speed is determined as the gear speed of the gearshift lever) are included in this function.

• In auto-shift, the auto-shift indicator of the machine monitor lights up. Shifting up/down and ON/OFF of the lockup clutch
are changed with the engine power mode and selected shift mode.

• There are two modes (H/L) in auto-shift whose gearshift points are different depending on the engine power mode.

• In auto-shift, shifting up/down is controlled in accordance with the directional lever, gearshift lever, travel speed,
accelerator pedal opening ratio, and data saved in the memory of the transmission controller according to the engine
speed. For the gearshift point of each mode, see Transmission Controller System: Auto-Shift Points Table in this section.

10-432 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
★ Gearshift lever in the 1st to 4th (when steering option is selected)
• The maximum gear speed (gear shifting range) used in the automatic gear shifting operation is limited.
• In the automatic gear shifting operation, the vehicle usually starts in the 2nd gear speed. If the gearshift lever is in 4th,
the gear is shifted up and down between the 2nd gear speed and 4th gear speed. The vehicle starts in the 1st gear
speed only when the kickdown function is used.

★ Directional lever in N position

• The gear speed of the transmission gearshift in the neutral position is changed in accordance with the travel speed, but
the display will always be N.

Shift Hold Function

• The shift hold function holds the current gear speed when the hold switch is pressed if the auto-shift mode is selected; it
does not shift up even when the travel speed is increased. Even if the travel speed is decreased, the gear does not shift
down.

• While the shift hold function is operating, the shift hold indicator of the machine monitor lights up. When the shift hold
switch is pressed again, the hold is released and the indicator goes out.

• The hold is released automatically also by the directional lever, gearshift lever, and kickdown switch operation.

• ON/OFF state of lockup is not held.

Kickdown Function

★ Kickdown in manual shift operation

• The kickdown switch operates only in the forward 2nd gear speed (F2) and the transmission is set in the forward 1st
gear speed (F1). Operation of the kickdown switch is ignored in any gear speed other than (F2).
• After the actual gear speed becomes (F1) due to the kickdown switch operation, the kickdown function is released
and the transmission is set in the gear speed of the lever when the directional lever is operated to a position other than
forward or the gearshift lever is operated to a position other than the 2nd gear speed.

★ Kickdown in auto-shift operation

• The kickdown function works regardless of the lever position if the directional lever is in a position other than N and
the gearshift lever is in a position other than the 1st gear speed.
• After the transmission gear is shifted because of the kickdown switch operation, an ordinary gear shift will be
performed in accordance with the auto-shift points table, after the time for the no-shift time is passed or when the
directional lever is operated.

WA500-6 10-433 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
• The gear speed selected by the operation of the kickdown switch depends on the travel speed as shown in the
following table.

<Reference> Gear Speed

Gear Speed before Output Shaft Speed [rpm] No-shift
Travel Speed after
Shifting when Kickdown Switch = ON Time
Conversion Shifting
2nd All range 1st 5 sec.
Below 824 12.5 km/h (7.8 mph) 1st 5 sec.
3rd
Min. 824 12.5 km/h (7.8 mph) 2nd 4 sec.
Below 824 12.5 km/h (7.8 mph) 1st 5 sec.
4th
Min. 824 12.5 km/h (7.8 mph) 3rd 4 sec.
2nd (lockup) All range 2nd *1
3rd (lockup) All range 3rd *1
4th (lockup) All range 4th *1

*1: When lockup is released due to the kickdown switch operation, lockup will not be ON again until the following
conditions are satisfied:
★ Perform temporary operation to turn the torque converter lockup switch OFF → ON.
★ The travel speed changes from below to above lockup ON speed as listed in the Auto-Shift Points table.

Torque Converter Lockup Control Function (if equipped)

• ON/OFF operation of the lockup is performed automatically due to the ON operation of the torque converter lockup
switch.

• When the lockup clutch is ON, the lockup indicator of the machine monitor lights up.

• Even when the manual shift is selected, if the torque converter lockup switch is ON, ON/OFF of the lockup is performed
automatically by the transmission controller.

• The operation gear speed of the lockup is shown in the following table.

Lockup Operation Gear Speed (Lockup operates: ❍)

Travel Mode
F1 F2 F3 F4 R1 R2 R3 R4
MANUAL ❍ ❍ ❍ ❍ ❍ ❍
Auto H ❍ ❍ ❍ ❍ ❍ ❍
Auto L ❍ ❍ ❍ ❍ ❍ ❍

★ Lockup rotation
• For ON/OFF of lockup, see Transmission Controller System: Auto-Shift Points Table in this section.

★ Lockup protection function

• Lockup ON only operates when the moving direction of the machine and the position of the directional lever match.

Determination of moving direction of the machine:

• The machine is thought to be stopping when the transmission controller is started (key on) or the transmission
output shaft speed is below 260 rpm.
• While the machine is thought to be stopping and the transmission output shaft speed becomes 260 rpm or more,
if the directional lever is in the F position, it is thought to be moving forward; if it is in the R position, it is
thought to be moving backward.
★ The travel speed is approximately 4 km/h (2.5 mph) when the transmission output shaft speed is 260 rpm.

10-434 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Hunting Prevention Function

• The transmission controller prevents hunting by detecting hunting which occurs between 2nd and 3rd when auto-shift is
selected.

• If gearshifts 2nd to 3rd to 2nd to 3rd are performed within six seconds from the previous gearshift, hunting is thought to
have occurred and the gear speed is selected from 2nd or 3rd, whose operation time is longer. When the hunting
prevention function operates, the shift point in hunting prevention stated in the Auto-Shift Points table is selected for the
next automatic gear shifting operation.

• The operation of the hunting prevention function ends when the next gear shift operation (including FR, kickdown
operation, etc.) is performed. The gear is set to the ordinary shift point of the auto-shift.

• When ON/OFF of 2nd lockup occurs consecutively within five seconds, the lockup is turned off and the speed is changed
to lockup ON travel speed when the hunting prevention function operates.

• The hunting prevention function operates when hunting occurs even in the manual shift.

Changing Shift Points

• The transmission controller has a function to adjust the gearshift points of L mode in auto-shift.

• If hunting occurs due to the conditions at a job site, the travel speed when shifted up/down can be changed by adjusting
the gearshift points.

★ For the changing procedure, see Machine Monitor System: Service Mode: Adjustment Function (TUNING):
Adjustment of Transmission L Mode Shift Point Function in the Testing and Adjusting section.

4th Gear Speed Derating Function

• The transmission controller has a function to limit the operation of the 4th gear speed by changing the optional setting.

★ For the changing procedure, see the Prohibition of 4th Gear Speed option in Machine Monitor System: Service Mode:
Optional Device Selecting Function (OPTIONAL SELECT) in the Testing and Adjusting section.

Transmission Initial Learning and ECMV Current Adjustment

• The transmission controller has an adjusting function to correct dispersion between the transmission unit and ECMV
solenoid.

• If the adjustment is not performed, a gear shifting shock or a time lag may occur.

★ For the adjusting procedure, see Machine Monitor System: Service Mode: Adjustment Function (TUNING): Setting
Transmission Initial Learning and Machine Monitor System: Service Mode: Adjustment Function (TUNING):
Adjustment of Transmission ECMV Current in the Testing and Adjusting section.

WA500-6 10-435 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Auto-Shift Points Table

The relationship among transmission output shaft speed, engine mode, shift switch, and gear shifting operation are shown in
the following table.

Unit: rpm
Engine Mode and Shift Switch
Power Mode Economy Mode
Shift Switch Shift Switch Shift Switch Shift Switch
H L H L
F1 → F2 395 395 362 362
F2 → F2 (lockup) 560 – 660 560 – 660 540 – 632 540 – 632
F2 → F2 (lockup)
692 – 824 692 – 824 659 – 744 659 – 744
when hunting is prevented
F2 → F3 632 – 922 501 – 922 573 – 896 481 – 896
F2 → F3
698 – 903 698 – 903 639 – 876 639 – 876
Gear shifting operation

when hunting is prevented

F3 → F3 (lockup) 942 – 1120 942 – 1120 909 – 1054 909 – 1054
F3 → F4 1166 – 1502 1120 – 1502 1080 – 1430 1034 – 1430
F4 → F4 (lockup) 1614 1614 1548 1548
F4 (lockup) → F4 1436 1436 1370 1370
F4 → F3 1034 – 1436 988 – 1436 949 – 1370 903 – 1370
F3 (lockup) → F3 850 850 817 817
F3 → F2 501 – 850 329 – 850 441 – 817 270 – 817
F3 → F2
501 – 725 329 – 725 441 – 679 270 – 679
when hunting is prevented
F2 (lockup) → F2 514 514 494 494

★ The transmission output shaft speed of 1 rpm corresponds to 0.0145 km/h (0.009 mph).

★ The shifting down point of F4 → F2 and F3 → F2 will be 66 rpm when the accelerator is idle.

10-436 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Transmission Controller Protection Function

Protection Function when Changing FR

In order to protect the transmission, the controller limits changing F-R operation with the directional lever during high-speed
travel.

• All range of auto modes (speed position switch at a position other than 1st gear speed) and manual mode (2nd, 3rd, and
4th)

• In auto-shift mode:
• Range I: F-R is changed and transmission is set in 2nd gear speed. (Ordinary range)
• Range II: F-R is changed; transmission is set in 2nd gear speed; and the alarm is turned ON.
• Range III: F-R is changed and the alarm is turned ON. The gear speed of the transmission gearshift depends on the
travel speed.
• Then the transmission is shifted down to 2nd gear speed with reduction of the travel speed.

• In manual-shift mode:
• Range I: Only F-R is changed. (Ordinary range)
• Range II: F-R is changed and the alarm is turned ON.
• Range III: F-R is changed and the alarm is turned ON. The gear speed of the transmission gearshift depends on the
travel speed.
• Then the transmission is shifted down to the speed position with reduction of the travel speed.

★ Two seconds immediately after the F-R changing operation, shifting up/down and kickdown switch operation will not
be accepted. If the shifting up/down operation is performed with the lever operation, the gear shift will be performed
in two seconds.

★ In auto-shift, shifting up will not be performed until 2nd gear speed is obtained by speed reduction.

Transmission output shaft speed before gear shift (rpm)

A B C
856 922 1054
Remarks
13 km/h (8.08 mph) 14 km/h (8.70 mph) 16 km/h (9.94 mph)
(Travel speed conversion)

WA500-6 10-437 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Protection Function in Shift-Down Operation

• In order to protect the engine and pump, the transmission controller performs shift-down protection in which operations
are not accepted while shifting down and the alarm is turned ON while it is operating.

• The operation conditions of the shift-down protection are shown in the following table. The alarm goes ON until the gear
shift position of the shift lever and the actual output gear shift match. Even when the travel speed does not decrease,
performing the shift-up operation will stop the alarm.

Protection Condition Condition for Resetting Protect

Target Gear Speed Transmission Output Transmission Output
Engine Speed Engine Speed
to Shift Down Shaft Speed Shaft Speed
To 3rd gear speed Min. 1,721 rpm — Below 1,549 rpm —
Min. 1,102 rpm — Below 861 rpm —
To 2nd gear speed
Min. 895 rpm Min. 1,620 rpm Below 964 rpm Below 1,440 rpm
To 1st gear speed Min. 895 rpm — Below 861 rpm —

• The shift-down protection is valid also in the kickdown operation in auto-shift. If the machine is traveling at a travel speed
above the protect condition when the kickdown operation is performed, the kickdown operation is not accepted and the
alarm goes ON for three seconds.

Protection Function in Lockup

• When the transmission output shaft speed becomes equivalent to the engine speed of 2,525 rpm or above, the lockup is
released automatically to prevent engine overrun and the alarm goes off. For five seconds after it is released temporarily,
the lockup stays OFF.

• When five seconds have elapsed and the transmission output shaft speed is equivalent to the engine speed of below
2,375 rpm, lockup comes on again. (Function of engine overrun prevention)

Lockup OFF travel speed by function of engine overrun prevention (reference)

Lockup Operation OFF Value
(equivalent to engine speed of 2,525 rpm)
WA500-6
Actual Gear Speed Reference Travel Speed
Output Shaft Speed (rpm)
km/h (mph)
F2 1137 17.3 (10.75)
F3 1908 29.0 (18.02)
F4 3250 49.3 (30.63)
R2 1281 19.4 (12.05)
R3 2151 32.6 (20.26)
R4 3661 55.6 (34.55)

10-438 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Protection Function by Shift-Up

• When traveling in T/C, if the engine speed becomes 2,525 rpm or more, the transmission is shifted up and the alarm goes
ON. After shifting up, it will not be shifted down for three seconds.

• After three seconds have elapsed and the engine speed drops below 2,375 rpm, the alarm stops and the shift control
becomes the ordinary control.

• When traveling in 4th gear speed, shift-up is not performed; only the alarm goes ON.

Function to Warn Operation of Overrun Prevention Action Warning

• When the engine speed is 2,425 rpm or more, the function to warn operation of overrun prevention action warning
operates.

• The alarm is released when the engine speed goes below 2,325 rpm.

Neutralizer Function

• When the parking brake switch is ON (while the parking brake switch is operating), transmission output is maintained in
neutral regardless of the state of the gearshift lever, for parking brake dragging prevention function.

• The parking brake switch circuit is a safety circuit and is not open when the key switch is changed from OFF to ON.
While the key is on, the transmission is always in neutral regardless of the state of the lever.

Engine Control
Engine Torque Curve Switching Function

The transmission controller selects the engine power mode from the signal input of the engine power mode changing switch. It
sends torque curve information used in the engine controller and engine power mode information of power/economy to the
monitor panel.

Maximum Travel Speed Limit

For lower fuel consumption in load and carry operations, the maximum travel speed is limited by setting the maximum travel
speed (select from three levels) and setting the upper limit to a throttle value in the F4 lockup state.

Setting Information Throttle Value Upper Limit

(1) (Default) 90%
(2) 100%
(3) 80%

Throttle Lock

For improving the working efficiency, the engine speed is maintained at an arbitrary speed.

• The engine speed is set by pressing the accelerator pedal and the rpm set idle up/down switch.

• When the right brake is pressed, throttle lock is temporarily released.

• For lower fuel consumption in a setting with auto-deceleration function, if the transmission neutral continues for four
seconds or the work equipment neutral state lasts for four seconds or longer, if the throttle lock SET/ACCEL SW and
throttle lock RESUME/DECEL SW are not operated, and if the travel speed is 5 km/h (3 mph) or less, the throttle lock
function is temporarily released and the transmission follows the signal of the accelerator pedal.

WA500-6 10-439 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
• In the state where the throttle lock is temporarily released, if the transmission is set to a position other than neutral or the
work equipment is in a state other than N, the throttle control state will resume automatically.

Right Brake Pedal

Throttle lock Operation
Component Throttle Lock Throttle Lock SET/ Throttle Lock
RESUME/DECEL (released) Switch
List Function Switch ACCEL Switch Indicator Lamp
Switch (Left brake
switch = OFF)
Switch Alternate 3-position Momentary proximity
Momentary seesaw switch Lamp
composition switch switch
Brake operated
ON
ON (GND) ON (GND) (GND)
Switch theory Performed through
OFF (OPEN) OFF (OPEN) Brake not operated
electrical circuit
(OPEN)
Resume function
When this switch is While the throttle
pressed upward, Function to set lock function is
“throttle lock auto throttle stroke released with the
deceleration function Save the throttle right brake pedal
is disabled.” stroke when it is ON operation (release),
When this switch is (lock accelerator press this switch
pressed downward, opening ratio) and the throttle lock When the right brake
“throttle lock auto Controls with input function is pedal is pressed for
deceleration function signal edge resumed. 0.5 sec. continually, Output is ON when
Function is enabled.” Controls with input the throttle lock throttle lock ON/
signal edge function is OFF switch is ON.
temporarily
When deceleration released.
When acceleration
function switch is
function switch is
When this switch is pressed for 0.5 sec.
pressed for 0.5 sec.
pressed in the continually, set
continually, set
middle, the throttle throttle stroke
throttle stroke rises
lock function is OFF. lowers by the time
by the time the
the switch is
switch is pressed.
pressed.

10-440 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
★ For a description of the throttle lock function, a sample time chart is shown below.

WA500-6 10-441 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Transmission Cutoff Control

• The transmission cutoff control sets the transmission in neutral by detecting the brake pilot oil pressure with the pressure
sensor when the left and right brake pedals are pressed.

• This function enables cutoff at an optional position by saving the brake pedal pressing position where the transmission
becomes neutral as the brake pilot oil pressure.

Contents of Transmission Cutoff Control

When transmission cutoff switch is ON and if pressure of left brake pressure

sensor signal exceeds set pressure, this switch sets the transmission in neutral.
(When the transmission cutoff operation condition is met)
Outline
Gear changes by cutoff return modulation provided the pressure drops below the
return pressure during cutoff or the condition for resetting transmission cutoff is
met and the left brake operation switch becomes OFF.
Operating condition at 1st and 2nd speed:
Transmission When transmission cutoff switch is ON and brake pilot pressure becomes > cutoff
cutoff control IN pressure
Operating condition Operating condition at 3rd and 4th speed:
When transmission cutoff switch is ON and accelerator opening is less than 30%
(including 2nd speed low idle operating state) and the brake pilot pressure
becomes > cutoff IN pressure
{When transmission cutoff switch is OFF}
Condition for resetting or
{Transmission cutoff pressure is < cutoff OUT pressure}
Settable condition Transmission cutoff switch is “ON”.
(1) Press left brake pedal to the set position. (Setting is enabled without stepping
on the brake.)
(2) Press the transmission cutoff switch.
(3) Transmission controller temporarily saves the pressure at the time the switch
is pressed if it is within the setting-enabled range.

Setting method If outside the range, the transmission controller temporarily saves the upper and
lower limit pressure and transmits information for sounding the setting complete
buzzer twice (pip, pip) over the network to the monitor.
Setting of (4) At this time, the built-in indicator in the transmission cutoff switch blinks for
transmission 2.5 seconds.
cutoff point
(5) After the indicator blinks for 2.5 seconds, the setting is saved (end of setting
mode). (Set condition is still held after the key is turned off.)
(1) During the 2.5 seconds in Step 4 of the above setting method (while the
transmission cutoff switch built-in indicator is blinking), press the transmission
cutoff switch again.
(2) Indicator stops blinking and cutoff point is set to default left brake pressure.
Resetting method
Transmit to the monitor information for sounding the setting cancel buzzer over
the network.
(3) Set (default) value is saved (end of setting mode). (Set condition is still held
after the key is turned off.)

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STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Outputting Conditions for Buzzer, Indicator (main monitor), and Indicator in Transmission Cutoff Switch

Indicator in Buzzer Command

Output Conditions Transmission (Communication Cutoff point
Cutoff Switch Output)
Controlled with value
When transmission cutoff switch is ON ON Not displayed
saved last.
2.5 seconds when transmission cutoff switch is When set switch is Controls with previously
Blinking
ON and transmission cutoff set switch is ON or pressed, set saved value.
(2.6 sec. or until
resetting (while sensor being normal) and completion buzzer Saves the pressure that
reset)
setting method being (2) to (5). sounds. pressed the set switch.
No control is made.
When transmission cutoff switch is ON and Remains turned Not displayed
Saved value is not
pressure sensor is abnormal (see FMEA). out (error buzzer sounds).
changed.
Controlled with value
Not displayed
When transmission cutoff switch is ON and set saved previous time.
ON (monitor displays
switch is abnormal (see FMEA). Saved value is not
error).
changed.
When transmission cutoff switch is ON and
Set cancel buzzer Controls with previously
transmission cutoff set switch is ON.
ON sounds when set saved value.
switch is pressed. Saves the default.
Reset within 2.5 sec.
When transmission cutoff switch is OFF. OFF Not displayed Not controlled

★ During cutoff, actual transmission gear speed will be indicated as N (neutral); FNR output number will be N.

★ During lockup, lockup will be cancelled to implement cutoff.

★ If cutoff is made after reaching 1st speed with kickdown switch, gear should return to 1st gear speed for both auto/manual
shift.

Setting Enabled Range of Transmission Cutoff Point

★ Setting enabled range: 0.49 – 4.41 MPa (71.07 – 639.62 psi)

• Add hysteresis of 0.2 MPa (29.01 psi) to the cutoff IN (for neutral) pressure and OUT (reset) pressure.
Example:
When cutoff point is set to position of 0.98 MPa (142.14 psi) of pressure sensor:
Cutoff IN pressure: . . . . . . . . . . . . . . . . . . . . 0.98 MPa (142.14 psi)
Cutoff OUT pressure: . . . . . . . . . . . . . . . . . . 0.78 MPa (113.13 psi)

★ If the pressure sensor is set for under 0.49 MPa (71.07 psi), the set value is 0.49 MPa (71.07 psi).

★ If the pressure sensor is set for over 4.41 MPa (639.62 psi), the set value is 4.41 MPa (639.62 psi).

★ The default value is 1.47 MPa (213.21 psi).

WA500-6 10-443 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

ECSS Function
The ECSS is a system in which the controller automatically turns on and off the accumulator charged with high-pressure gas
according to the travel condition and the lift arm operation condition, improving operator comfort and working efficiency by
preventing spillage of material by absorbing the vertical movement of the work equipment, when the vehicle travels at high
speed.

ECSS System Circuit

Operation of ECSS

Since the ECSS is optional equipment, control will not be performed unless the ECSS option is enabled in the optional setting
of the machine monitor.

★ For the procedure to set the option, see Machine Monitor System: Service Mode: Optional Device Setting Function
(OPTIONAL SELECT) in the Testing and Adjusting section.

ECSS Switch Gear Speed Output Shaft Speed ECSS Output

OFF All 0 to MAX OFF
1st 0 to MAX OFF
ON Condition A OFF
2nd to 4th
Condition B ON

• The transmission output shaft speed of 198 rpm corresponds to

approximately 3 km/h (2 mph).

• The transmission output shaft speed of 329 rpm corresponds to

approximately 5 km/h (3 mph).

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STRUCTURE, FUNCTION AND
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Operation of Solenoid in ECSS ON/OFF

• Modulation control is performed for the ECSS solenoid with EPC output in switching ON/ OFF, reducing the lowering of
the lift arm and occurrence of switching shocks.

• The constant current when the ECSS solenoid is ON is 800 mA.

Economy Lamp
Control of Economy Lamp

The transmission controller lights up the economy lamp indicator on the machine monitor when operating in low fuel
consumption, in order to prompt low fuel consumption operation to the operator.

Lighting Condition of Economy Lamp

When the engine power mode is the economy mode and the accelerator pedal opening ratio is 80% or less, the economy lamp
is illuminated.

Accelerator Opening Ratio Power Mode Economy Mode

Min. 80% OFF OFF
Max. 80% OFF Lighting

Turning Off Economy Lamp

The economy lamp can be constantly kept off by using the optional setting of the monitor.

★ For the setting procedure, see Machine Monitor System: Service Mode: Optional Device Setting Function (OPTIONAL
SELECT) in the Testing and Adjusting section.

WA500-6 10-445 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Cooling Fan Control

Control of Fan

• Employment of the hydraulically driven cooling fan, as well as controlling its speed through control of the hydraulic
pump swash plate, allows for reduction of horsepower loss and noises in a low temperature environment.

• Engine speed and coolant temperature received by the engine controller and hydraulic oil temperature and torque
converter oil temperature received by the machine monitor are sent to the transmission controller via the network.

• Based on the received information, the transmission controller sends the signal current to the swash plate angle control
EPC valve on the cooling fan pump so that the valve can control the swash plate angle in order to set the fan speed to a
level suitable for the given temperature level and the engine speed.

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STRUCTURE, FUNCTION AND
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Fan Speed in Accordance with Temperature

• The target fan speed is determined based on the data with the highest temperature among coolant temperature, hydraulic
oil temperature, and torque converter oil temperature.

★ Fan speed

Protection Function

• In order to prevent overrun of the cooling fan motor, this function minimizes the swash plate angle of the cooling fan
pump as the engine speed reached 2,300 rpm or above.

• If the transmission controller fails to recognize the engine speed and respective temperature data due to a failure on the
network communication, this function sends a specific command current (677 mA) to the swash plate angle control EPC
valve on the pump so that the pump may work functionally – equivalent to a fixed pump.

WA500-6 10-447 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Control for Starting Engine

In fan control, it is a different control from the ordinary temperature control when starting the engine.

• When stopping the engine (key switch 1-stage on)

When the engine is stopped, the cooling fan pump EPC current of 677 mA is output; it is the same as a state where the
engine speed cannot be recognized.

• While cranking
While cranking to start the engine and in order to improve engine start, the minimum swash plate is used for the cooling
fan pump by setting the fan EPC current to 850 mA, reducing the torque necessary for starting the engine.

10-448 ➁ WA500-6
STRUCTURE, FUNCTION AND
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Fan Reverse Rotation Function

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

Standard Specification Fan Manual Reverse Rotation Function

• This function is used by the operator to reverse the fan rotation. By pressing the fan manual reverse switch, the turning
direction of the fan is changed.

• Changing from forward to reverse and reverse to forward is performed when the following conditions are satisfied.
• The fan manual reverse switch is pressed.
• The engine speed is 500 rpm or lower.

• The fan reverse indicator flashes when the state of the fan manual reverse switch and the rotation direction of the fan do
not match. While the fan is rotating in the reverse direction, the fan reverse indicator illuminates.

Reverse SOL Output Forward/Reverse

Engine Reverse SOL Fan Pump Monitor Indicator
before Switch Selector Switch
Speed Output EPC Output Lighting Logic
Operation Operation
OFF From OFF to ON ON MIN speed From OFF to ON
OFF From ON to OFF Below OFF Ordinary From flashing to OFF
ON From OFF to ON 500 rpm ON MIN speed From flashing to ON
ON From ON to OFF OFF Ordinary From ON to OFF
OFF From OFF to ON OFF Ordinary From OFF to flashing
OFF From ON to OFF OFF Ordinary From flashing to OFF
Min. 500 rpm
ON From OFF to ON ON MAX speed From flashing to ON
ON From ON to OFF ON MAX speed From ON to flashing

Fan Reverse Rotation Function

★ Not used.

Fan Speed in Reverse

While it is operating in reverse, cleaning the radiator core is facilitated by increasing air flow by turning the fan at the
maximum speed without outputting fan pump EPC current (output 0 mA).

WA500-6 10-449 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Right FNR Switch Control (if equipped)

This is optional equipment installed to the side of the work equipment lever separately from the standard FNR lever. It enables
the operator to change travel direction with the right hand by arranging the directional selector switch.

Change of Right FNR

• When using only the standard FNR lever, FNR lever input signal equals FNR recognition.
When multiple switches are installed for the identical purpose of switching the travel direction, the selector switch is
provided to select operation.

★ Switching of operation to the right FNR switch is made when the right FNR validity switch is turned ON. The
operational priority will be given to the FNR lever (standard FNR lever).

• Switching condition to the right FNR switch turns the right FNR validity switch ON when the standard FNR lever is at N
(neutral) and the right FNR switch is at N (neutral). Only at that time is the switching of travel direction enabled with the
right FNR switch.

★ When the travel direction is selectable with the right FNR switch, the right FNR indicator on the machine monitor is
lit.

★ If either one of the switches is at other than N (neutral) and the right FNR validity switch ON-OFF is operated, the
buzzer is actuated and the right FNR indicator flashes on the machine monitor.

• Even if the right FNR switch is enabled, if the standard FNR lever is operated to other than N (F or R), the standard FNR
lever has priority. As the result, the standard FNR lever controls the travel direction. Since the switching has not been
made normally, the warning is actuated and the right FNR indicator on the machine monitor starts flashing.

★ The alarm is actuated and the right FNR indicator starts flashing. The alarm will not stop unless and until both the
standard and the right FNR switches are set to N (neutral) and the right FNR switch will not function to effect
forward-reverse travel.

★ The following table outlines the above information.

Right FNR
Monitor Operation
Mode Condition FNR Recognition Valid/Invalid
(Reference)
State
Lever: [F or N or R]
<a> lever Follows the FNR OFF Pilot lamp turns OFF.
Right SW: [N]
(Normal) lever (Invalid) Buzzer stops.
Right FNR validity SW: [OFF]
<b> seesaw SW Lever: [N]
Follow the right ON Pilot lamp turns ON.
(Normally [right Right SW: [F or N or R]
FNR seasaw SW (Valid) Buzzer stops.
switch]) Right FNR validity SW: [ON]
<c> lever has
Lever: [F or R] Pilot lamp is
priority Follows the FNR OFF
Right SW: [F or N or R] FLASHING.
(Emergency lever (Invalid)
Right FNR validity SW: [ON] Buzzer sounding.
operation)
Follows the FNR
Lever: [F or N or R] Pilot lamp is
<d> lever SW error lever OFF
Right SW: [F or R FLASHING.
(Operation error) (Right SW is (Invalid)
Right FNR validity SW: [OFF] Buzzer sounding.
disregarded)
Lever: [other than N]
Pilot lamp is
<e> switching error Right SW: [other than N] Follows the FNR OFF
FLASHING.
(Operation error) Right FNR validity SW: lever (Invalid)
Buzzer sounding.
[OFF ⇔ ON operation

★ *SW = Switch

10-450 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Interlocking at Starting Engine (engine start inhibited)

To prevent the machine from starting travel suddenly immediately upon engine start, the starting motor C terminal signal is cut
by actuating the neutral safety through the work equipment controller in case the right FNR validity switch is at the ON
position and the right FNR switch is at other than N (neutral) position.

Setting of the Right FNR Switch

Since the right FNR switch is an optional device, it does not perform control unless the right FNR optional setting is enabled
with the option setting on the machine monitor. Also no simultaneous installation with the joystick steering is enabled.

★ For the setting procedure, see Machine Monitor System: Service Mode: Optional Device Setting Function (OPTIONAL
SELECT) in the Testing and Adjusting section.

Joystick Control
Control of Joystick Steering

This is an optional device that enables turning of the machine (steering operation) and forward-reverse travel, shift-up/-down
by using the joystick lever provided in the left console.

Since turning the machine is performed by the work equipment controller, see Electrical System: Work Equipment Control
System: Joystick Steering Control in this manual.

Switching to the Joystick

• When using only the standard FNR lever, the FNR lever input signal equals FNR recognition.
When multiple switches are installed for the identical purpose of switching the travel direction, the selector switch is
provided to select operation.

★ Switching of operation to the FNR switch on the joystick knob is made only when the joystick validity switch is ON
and the joystick lock lever is cancelled. The FNR lever (standard FNR lever) will have complete priority for
operation.

• Switching conditions of the joystick to the FNR switch (hereinafter referred to as the joystick switch) are as follows:

★ Selection of the travel direction becomes enabled with the joystick switch by turning the joystick validity switch ON
and canceling the joystick lock lever while the standard FNR lever is at N (neutral) and the joystick switch is at N
(neutral).

★ When the travel direction is selectable with the joystick switch, the joystick indicator on the machine monitor is lit. If
either one of the switches is at other than N (neutral) and the joystick validity switch ON/OFF is operated, the alarm
is actuated and the joystick indicator flashes on the machine monitor.

• Even if the joystick switch is enabled, if the standard FNR lever is operated to other than N (F or R), the standard FNR
lever has priority. As the result, the standard FNR lever controls the forward-reverse travel. Since the switching has not
been made normally, the alarm is actuated and the joystick indicator on the machine monitor starts flashing.

★ Once the alarm is actuated and the joystick indicator starts flashing, the alarm will not stop unless and until both the
standard FNR lever and the joystick switches are set to N (neutral) and the joystick switch will not function to effect
forward-reverse travel.

• In the case where the joystick indicator is not lit, forward and reverse operation are disabled; simultaneously the
turning operation by the joystick is also disabled.

WA500-6 10-451 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
★ The following table outlines the above information.

JS
Monitor Operation
Mode Condition FNR Recognition Valid/Invalid
(Reference)
State
Lever: [F or N or R]
<a> lever Follows the FNR OFF Pilot lamp turns OUT.
JS SW: [N]
(Normal) lever (Invalid) Buzzer stop
JS validity SW: [OFF]
Lever: [N]
<b> JS SW Follow the JS ON Pilot lamp turns ON.
JS SW: [F or N or R]
(Normal [JS]) FNR SW (Valid) Buzzer stop
JS validity SW: [ON]
<c> lever has
Lever: [F or R] Pilot lamp is
priority Follows the FNR OFF
JS SW: [F or N or R] FLASHING.
(Emergency lever (Invalid)
JS validity SW: [ON] Buzzer sounding
operation)
Lever: [F or N or R] Follows the FNR Pilot lamp is
<d> lever SW error OFF
JS SW: [F or R] lever (JS SW FLASHING.
(Operation error) (Invalid)
JS validity SW: [OFF] disregarded) Buzzer sounding
Lever: [other than N]
Pilot lamp is
<e> switching error Right SW: [other than N] Follows the FNR OFF
FLASHING.
(Operation error) Right FNR JS validity SW: lever (Invalid)
Buzzer sounding
[OFF ⇔ ON operation]

★ JS validity switch [ON] in the table indicates the state where JS validity switch [ON] and JS lock lever is cancelled.
[OFF] indicate the state where J/S validity switch [OFF] or JS lock lever locked.

★ *JS = Joystick steering system

★ * SW = Switch

Joystick Shift-Up and Shift-Down Switch

• The joystick shift-up and shift-down switch performs shift-up and shift-down in the manual shift mode in the gear speed
below the gear speed of the gearshift lever (not set to a gear speed above the gear speed lever position). If the current gear
speed should exceed the gear speed lever position, the switch performs shift-down to the gear speed of the gear speed
lever position same as the normal shift-down.

★ When shifting down during high-speed travel, the shift-down protection function operates and shifting down will be
performed after the travel speed has decreased.

• In the case where the shift mode is in auto-shift mode (both H and L), the shift-up and shift-down switch of the joystick
lever does not function and the range switch only by the gear speed lever.

• When the shift-up and shift-down switch is operated at the same time, shift-down is effective.

• After pressing the switch once, the next shift-up and shift-down switch operation is not accepted for 0.2 seconds.

10-452 ➁ WA500-6
STRUCTURE, FUNCTION AND
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Interlocking at Starting Engine (engine start inhibited)

• To prevent the machine from starting travel suddenly upon engine start, the starting motor C terminal signal is cut by
actuating the neutral safety relay through the work equipment controller in case the joystick validity switch is at the ON
position, the joystick lock lever is in the open state, and the joystick FNR switch is at other than the N (neutral) position.
The starting motor signal is cut if the joystick indicator is in the flashing state.

• In case the joystick lever is operated when the joystick is in a valid state, the work equipment controller sends engine start
inhibit information to actuate the neutral safety relay and cut the starting motor C terminal signal.

Joystick Setting

• Since the joystick is optional equipment, it has no control unless the joystick option setting is made valid in the optional
setting on the machine monitor.

• It cannot be simultaneously installed with the right FNR switch.

★ For the setting procedure, see Machine Monitor System: Service Mode: Optional Device Setting Function (OPTIONAL
SELECT) in the Testing and Adjusting section.

WA500-6 10-453 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Real-Time Monitor
★ Display contents of the real-time monitor

In the WA500-6, the state of the controller input and output signals can be checked using the real-time monitor function of
the monitor. The following table lists the display items and display contents in normal operation of the real-time monitor
in relation to the transmission controller.

Display of Contents of
No. Check Item ID No. Data Unit (and Range) Remarks
Item Name Display Data

Output mass
Software part Depends on the software part
1 20201 VERSION production software
number number
part number

Software Output software

VERSION Depends on the software
2 application 20223 version (software
(APP) version
version logic part version)

Software Output software

VERSION Depends on the software
3 application data 20224 version (software data
(DATA) version
version part version)

Output engine mode

0: power mode
4 Engine mode 41600 ENGINE MODE for controlling engine
2: economy mode
output

X1 [mA]
(0 – 1000 [mA])
When engine speed is below
ECMV output Output to FAN EPC 500 rpm = 677 mA
5 command value 41400 FAN EPC DIR output command
(FAN pump) current value While cranking (C terminal
operation) = 850 mA
Switching fan reverse = 850 mA
Fan operating in reverse = 0 mA

Fan reverse FAN REVERSE Output fan reverse 1: ON(CLOSE)

6 93400
switch input SW SW input state 0: OFF

Torque converter
T/C IN OIL Not used by this
7 inlet oil 41501 — —
TEMP machine.
temperature
Torque converter
T/C IN OIL Not used by this
8 inlet oil 41502 — —
TEMP machine.
temperature

Torque converter Not used by this

9 93500 T/C SPEED: IN — —
input shaft speed machine.

Torque converter
T/C TORQUE: Not used by this
10 output shaft 93501 — —
OUT machine.
torque
Output transmission X1 [min-1]
Transmission
11 31200 T/M SPEED: IN input shaft speed
input shaft speed (0 – 32,767 [min-1])
[PLS_AC_IN_0]

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STRUCTURE, FUNCTION AND
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Display of Contents of
No. Check Item ID No. Data Unit (and Range) Remarks
Item Name Display Data

X1 [min-1]
(0 – 32,767 [min-1]
Transmission Output output shaft 0 km/h = 0 rpm
T/M SPEED:
12 output shaft 31400 speed 10 km/h = 788 rpm
OUT
speed [PLS_AC_IN_2] 20 km/h = 1,376 rpm
30 km/h = 2,063 rpm
40 km/h = 2,751 rpm

Transmission
T/M SPEED: Not used by this
13 output shaft 31404 — —
OUT2 machine.
speed

Converted value of
Transmission the set oil pressure
14 cutoff operation 41203 T/M CUT SET (IN oil pressure) to be
setting transmission cutoff is
displayed
X1 [MPa] Displayed value
changes according to
(0.00 – 5.00 [MPa]) the cutoff set operation.

When the foot brake is

released:
Transmission 0.00 ±0.1 MPa
Converted value of X1 [MPa]
cutoff When foot brake is
15 41201 T/M CUT OFF P the brake oil pressure
(Left brake) (0.00 – 5.00 [MPa]) actuated: Displayed
is displayed
pressure value changes
according to the brake-
actuating operation.

When the foot brake is

released: 1.00 ±0.1 V
Transmission
Input voltage value of X1 [mV] When the foot brake is
cutoff
16 41202 T/M CUT OFF P brake oil pressure is actuated: Displayed
(Left brake) (0.00 – 5.00 [V])
displayed value changes
pressure
according to the brake-
actuating operation.

Torque converter TC SPEED Output torque X1 [%]

17 93700
speed ratio RATIO converter speed ratio (0 – 100 [%])

Output oil
Transmission oil X1 [°C]
temperature value of
18 temperature 93600 T/M OIL TEMP
transmission oil (0 – 150 [°C])
input
temperature (A_IN_1)
X1 [mV]
(0.00 – 5.00 [V])
Output input voltage 4.72 V = 0°C
Input voltage of
value of transmission
19 transmission oil 93601 T/M OIL TEMP 4.33 V = 30°C
oil temperature
temperature 3.55 V = 60°C
(A_IN_1)
2.20 V = 100°C
1.61 V = 120°C

MOD/C oil Not used by this

20 92400 MOD/C PRESS — —
pressure input machine.

MOD/C oil
Not used by this
21 pressure input 92401 MOD/C PRESS — —
machine.
voltage

WA500-6 10-455 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Display of Contents of
No. Check Item ID No. Data Unit (and Range) Remarks
Item Name Display Data
MOD/C heat Not used by this
22 92500 MOD/C Q — —
release value machine.

MOD/C heat Not used by this

23 92501 MOD/C q — —
ratio machine.

Throttle lock
switch (pressed THROT LOCK Output the state of 0: RPM set switch OFF
24 95500
upward) A input signal 1: PRM set switch ON
(RPM set switch)
Throttle lock
switch (pressed 0: RPM set auto deceleration
downward) THROT LOCK Output the state of switch OFF
25 95501
(PRM set auto B input signal 1: RPM set auto deceleration
deceleration switch ON
switch)

Throttle Output throttle X1 [%]

THROTTLE
26 correction 95400 correction command
MOD (-100 – 100 [%])
command output output amount

Throttle opening Output throttle upper X0.1 [%]

THROT LIMIT
27 upper limit 44200 limit command output
UP (0.0 – 100.0 [%])
output amount

Output throttle lower X0.1 [%]

Throttle opening THROT LIMIT
28 44201 limit command output
lower limit output LO (0.0 – 100.0 [%])
amount

Depends on accelerator pedal

operation
Depends on Accelerator pedal = 0
accelerator opening Accelerator pedal partial
Accelerator THROTTLE
29 93801 ratio; output pressing (opened side) = 1
mode MODE
acceleration mode on
control Accelerator pedal partial
pressing (pressed side) = 2
Accelerator pedal pressing = 3

Traction setting TRACTION Not used by this

30 94000 — —
input value DIAL machine.

Traction setting TRACTION Not used by this

31 94001 — —
input voltage DIAL machine.

Lockup changing
Output the state of 0: Lockup changing switch OFF
32 switch input 95000 LOCK UP SW
input signal 1: Lockup changing switch ON
signal

ECMV output to 1st

ECMV output
clutch X1 [mA]
33 command value 31602 ECMV 1 DIR
Output command (0 – 1000 [mA])
(1st)
current value

ECMV output to 2nd

ECMV output
clutch X1 [mA]
34 command value 31603 ECMV 2 DIR
Output command (0 – 1000 [mA])
(2nd)
current value

ECMV output to 3rd

ECMV output
clutch X1 [mA]
35 command value 31604 ECMV 3 DIR
Output command (0 – 1000 [mA])
(3rd)
current value

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STRUCTURE, FUNCTION AND
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Display of Contents of
No. Check Item ID No. Data Unit (and Range) Remarks
Item Name Display Data
ECMV output to 4th
ECMV output clutch X1 [mA]
36 command value 31605 ECMV 4 DIR
Output command (0 – 1000 [mA])
(4th)
current value

ECMV output to FWD

ECMV output
clutch X1 [mA]
37 command value 31608 ECMV F DIR
Output command (0 – 1000 [mA])
(FWD)
current value

ECMV output to L/U

ECMV output
clutch X1 [mA]
38 command value 31609 ECMV LU DIR
Output command (0 – 1000 [mA])
(L/U)
current value

ECMV output
ECMV MOD/C Not used by this
39 command value 31640 — —
DIR machine
(MOD/C)

ECMV output to REV

ECMV output
clutch X1 [mA]
40 command value 31606 ECMV R DIR
Output command (0 – 1000 [mA])
(REV)
current value

ECMV output Output to ECSS valve

X1 [mA]
41 command value 93300 ECSS V DIR Output command
(0 – 1000 [mA])
(ECSS) current value
Output 1st clutch fill
time value
Fill time value X0.01 [sec]
42 41802 FILL TIME 1 (State of gear change
(1st) (0 – 2.55 [sec], No fill time: 0)
preceding
immediately before)
Output 2nd clutch fill
time value
Fill time value X0.01 [sec]
43 41803 FILL TIME 2 (State of gear change
(2nd) (0 – 2.55 [sec], No fill time: 0)
preceding
immediately before)

Output 3rd clutch fill

time value
Fill time value X0.01 [sec]
44 41804 FILL TIME 3 (State of gear change
(3rd) (0 – 2.55[sec], No fill time: 0)
preceding
immediately before)
Output 4th clutch fill
time value
Fill time value X0.01 [sec]
45 41805 FILL TIME 4 (State of gear change
(4th) (0 – 2.55 [sec], No fill time: 0)
preceding
immediately before)

Output FWD clutch fill

time value
Fill time value X0.01 [sec]
46 41808 FILL TIME F (State of gear change
(FWD) (0 – 2.55 [sec], No fill time: 0)
preceding
immediately before)

Output REV clutch fill

time value
Fill time value X0.01 [sec]
47 41806 FILL TIME R (State of gear change
(REV) (0 – 2.55 [sec], No fill time: 0)
preceding
immediately before)

WA500-6 10-457 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Display of Contents of
No. Check Item ID No. Data Unit (and Range) Remarks
Item Name Display Data

0*******:
Engine mode selector SW OFF
1*******:
Engine mode selector SW ON
*00*****:
(J/S shift-up/-down SW not D-IN0:
being operated) Engine mode selector
SW
*10*****:
(J/S shift-up SW being D-IN1:
operated) J/S shift-up SW

*01*****: D-IN2:
(J/S shift-down SW being J/S shift-down SW
operated) D-IN3:
***0****: Air conditioner
Input signal Output the state of
48
D_IN_0-7
40905 D-IN--0------7
input signal Air conditioner compressor stop compressor operating
***1****: D-IN4:
Air conditioner compressor Shift mode L
operating D-IN5:
****00**: Manual shift mode Shift mode H

****10**: Shift mode L D-IN6:

J/S or right FNR valid
****11**: Shift mode H SW
******0*: D-IN7:
Right FNR (J/S) selector SW C terminal signal
OFF
******1*:
Right FNR (J/S) selector SW
ON
*******1: Cranking

10**0***:
Transmission cut-off SW ON
11**0***: D-IN8:
Transmission cut-off SW AND Transmission cut-off
setting SW ON SW
**0*0***: Kick-down SW OFF D-IN9:
**1*0***: Kick-down SW ON Transmission cut-off
***00***: Shift hold SW OFF point set SW
***10***: Shift hold SW ON D-IN10:
Kick-down SW
Input signal Output the state of ****00**:
49 40906 D-IN--8-----15 Throttle lock set SW OFF D-IN11:
D_IN_8-15 input signal
Shift hold SW
****01**:
Throttle lock set SW ON D-IN13:
Throttle lock set SW
****0*0*:
Throttle lock resume SW OFF D-IN14:
Throttle lock resume
****0*1*:
SW
Throttle lock resume SW ON
D-IN15:
****0**0:
Left brake pedal SW
Left brake pedal SW OFF
****0**1:
Left brake pedal SW ON

10-458 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Display of Contents of
No. Check Item ID No. Data Unit (and Range) Remarks
Item Name Display Data
D-IN16:
1000****: Gear speed lever 1st
Gear speed lever at 1st speed speed
0100****: D-IN17:
Gear speed lever at 2nd speed Gear speed lever 2nd
0010****: speed
Gear speed lever at 3rd speed D-IN18:
0001****: Gear speed lever 3rd
Gear speed lever at 4th speed speed
Input signal Output the state of ****100*: D-IN19:
50 40907 D-IN-16-----23 Gear speed lever 4th
D_IN_16-23 input signal Direction lever at F
speed
****010*:
Direction lever at N D-IN20:
Direction lever at F
****001*:
Direction lever at R D-IN21:
Direction lever at N
*******0:
Parking brake released D-IN22:
Direction lever at R
*******1:
Parking brake operating D-IN23:
Parking brake signal
D-IN24:
Right FNR (J/S FNR) F
1******0:
D-IN25:
Right FNR (J/S FNR) F
Fill SW at F
0101000*:
D-IN26:
Traveling at F1
Fill SW at R
0010100*:
D-IN27:
Traveling at R2
Fill SW at 1st
Input signal Output the state of 0000010*:
51 40908 D-IN-24-----31 D-IN28:
D_IN_24-31 input signal 3rd speed neutral
Fill SW at 2nd
0100001*:
D-IN29:
Traveling at F4
Fill SW at 3rd
0******1:
D-IN30:
Right FNR (J/S FNR) R
Fill SW at 4th
0******0:
Right FNR (J/S FNR) N D-IN31:
Right FNR (J/S FNR) at
R

Input signal 1*******:

D_IN_32-39 Right FNR (J/S FNR) at N
D-IN32:
(Transmission Output the state of 0*******:
52 40942 D-IN-32-----39 Right FNR (J/SFNR) at
controller does input signal Right FNR (J/S FNR) at F
N
not have 33 – 0*******:
39) Right FNR (J/S FNR) at R

WA500-6 10-459 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Display of Contents of
No. Check Item ID No. Data Unit (and Range) Remarks
Item Name Display Data
0000**00:
Fan reverse solenoid OFF
0001**00:
Fan reverse solenoid ON D-OUT3:
Fan reverse solenoid
000*0*00:
Fan neutral solenoid OFF D-OUT4:
ON/OFF output state
Fan neutral solenoid (if
Output signal of SOL_OUT0 to 7 000*1*00:
53 40949 D-OUT 0-7 equipped)
D_OUT_0-7 “0” is displayed when Fan neutral solenoid ON
setting current output D-OUT5:
000**000: Low temperature
Low temperature bypass bypass solenoid
solenoid OFF (optional)
000**100:
Low temperature bypass
solenoid ON

ON/OFF output state

of SOL_OUT8 to 11B,
Output signal Not used by this
54 40950 D-OUT 8-15 SIG_OUT0 to 1 00000000
D_OUT_8-15 machine.
“0” is displayed when
setting current output

ON/OFF output state

of SIG_OUT2 to 3,
Output signal HSW_OUT0 to 1, Not used by this
55 40951 D-OUT 16-23 00000000
D_OUT_16-23 BATT_RY_OUT machine.
“0” is displayed when
setting current output

Output initial learning 111111:

16-bit data is displayed
Initial learning flag state of trigger (all clutches learned)
56 94100 TRIG FR1234 in the order of F, R, 1, 2,
flag time of each clutch 000000:
3, and 4 on the monitor.
[F,R,1,2,3,4] (all clutches to be learned)

10-460 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Diagnosis
★ Troubleshooting function

★ The transmission controller monitors the input and output signals constantly for troubleshooting the system.

★ If any abnormality is detected by self-diagnosis, the information is transmitted through the network to the machine
monitor. When an abnormality occurs, it can be confirmed on the machine monitor.

WA500-6 10-461 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

Input and Output Signals

Pin Assignment

DEUTSCH-24P [CN-L02]

Input and Input and

Pin Pin
Signal Name Output Signal Name Output
No. No.
Signals Signals
1 T/C lock up SW. Input 13 Throttle with auto decel Input
2 Fan reverse SW. Input 14 NC Input
3 NC Input 15 NC Input
4 GND_SIG_D 16 PWR_OUT_SENS Output
5 A/C compressor signal Input 17 J/S shift up SW. Input
6 Starting switch (IGN-C) Input 18 Shift mode signal H Input
7 E.C.S.S. SW. Input 19 Throttle lock without auto decel Input
8 LH brake press. sensor Input 20 –– Input
9 T/M oil temp. sensor Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
11 J/S shift down SW. Input 23 Engine mode SW. Input
12 SW enabling J/S RH FNR Input 24 Shift mode signal L Input

10-462 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
DEUTSCH-40P(1) [CN-L03]

Input and Input and

Pin Pin
Signal Name Output Signal Name Output
No. No.
Signals Signals
Input and
1 NC Output 21 NC
output
Input and
2 ECMV fill SW.:4th Input 22 COMM_CAN_L_O
output
Input and
3 ECMV fill SW.:3rd Input 23 NC
output
4 232C_RxD Input 24 PWR_CTR_EXT Input
5 Shift lever:4th Input 25 Shift lever:2nd Input
6 Parking brake signal Input 26 Direction lever:N Input
7 ECMV fill SW.:1st Input 27 ECMV fill SW.:F Input
8 NC Output 28 J/S or RH FNR seesaw SW.:N Input
9 NC Output 29 GND_SIG_P
10 NC Input 30 NC Input
11 NC Output 31 NC
Input and
12 NC 32 COMM_CAN_H_O
output
Input and
13 ECMV fill SW.:2nd Input 33 NC
output
14 232_TxD Output 34 232C_GND
15 Shift lever:3rd Input 35 Shift lever:1st Input
16 Direction lever:R Input 36 Direction lever:F Input
17 ECMV fill SW.:R Input 37 J/S or RH FNR seesaw SW.:F Input
18 NC Output 38 J/S or RH FNR seesaw SW.:R Input
19 NC Output 39 GND_SIG_P
20 Output speed sensor Input 40 Input speed sensor Input

WA500-6 10-463 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
DEUTSCH-40P(2) [CN-L04]

Input and Input and

Pin Pin
Signal Name Output Signal Name Output
No. No.
Signals Signals
1 PWR_IN_BATT Input 21 GND_PWR
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 TM power hold relay Output 24 PWR_CTR_KEY Input
5 ECMV:F. clutch Output 25 ECMV:1st clutch Output
6 ECMV:2nd clutch Output 26 ECMV:4th clutch Output
7 NC Output 27 Fan pump EPC Output
8 Indicator with built-in TM cut off SW Output 28 Fan pump neutral solenoid Output
9 NC Input 29 RESUME/DECEL SW Input
10 TM cut off SW Input 30 Kick down SW Input
11 PWR_IN_BATT Input 31 GND_PWR
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 PWR_OUT_5V_1 Output
15 ECMV:R. clutch Output 35 ECMV:lock up clutch Output
16 ECMV:3rd clutch Output 36 NC Output
17 E.C.S.S. solenoid Output 37 Fan pump reverse solenoid Output
18 Reverse lamp relay Output 38 NC Output
19 SET/ACCEL SW Input 39 LH brake pedal SW Input
20 TM cut off position set SW Input 40 Shift hold SW Input

10-464 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

MEMORANDUM

WA500-6 10-465 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

ELECTRONIC TRANSMISSION CONTROL

10-466 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
12

1. Brake valve
2. Transmission cutoff switch
3. Transmission cutoff set switch
4. Relay
5. Fuse box
6. Transmission controller
7. Parking brake switch
8. Gearshift lever
9. Directional lever
10. Speed sensor
11. Transmission control valve
12. Hold switch
13. Kickdown switch
14. Brake pressure sensor

Function

No. Function Operation

Selection of travel direction
1 The travel direction can be changed by operating the directional lever.
and neutral
2 Selection of gear speed
3 Kickdown
4 Hold
5 Transmission cutoff
6 Transmission cutoff set
Selection of transmission
7 OFF, the left brake pedal works as the ordinary brake (similar to the right brake
cutoff
8 Neutralizer
9 Neutral safety
10 Alarm
The gear speed can be changed by operating the gearshift lever.
The gear can be shifted down by pressing the kickdown switch without operating the
gearshift lever. In the manual gear shift mode, the gear is shifted down to the 1st
only while the transmission is in the forward 2nd. In the auto-shift mode, the gear is
shifted down according to the gear speed and travel speed before the switch is
pressed.
If the hold switch is pressed in the auto-shift mode, the current gear speed is held
and is not shifted up even if the travel speed is increased. Even if the travel speed
lowers, the gear is not shifted down.
While the transmission cutoff selector is ON, the transmission is set in neutral at the
adjusted pressing distance of the brake pedal.
The pressing distance of the brake pedal to set the transmission in neutral with the
transmission cutoff function can be adjusted.
The transmission cutoff function can be turned ON and OFF. While this function is
pedal).
While the parking brake is applied, the transmission is set in neutral. With this
function, the machine does not travel while the parking brake is applied; in this
manner, seizure of the parking brake is prevented.
While the directional lever is not in neutral, the engine does not start even if the
starting switch is operated; in this manner, an accident caused by sudden start of the
machine is prevented.
When the machine travels in reverse, the backup lamp and backup buzzer are
turned ON to warn anybody around the machine.

WA500-6 10-467 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Combination Switch

Outline

• The directional lever has three positions; the gearshift lever switch has four positions.

• The detent mechanism is not installed to each switch but installed to the body of the combination switch. Each switch is
positioned with two pins and fixed to the body with three screws.

• If each lever is set in a desired position, the switch connected by the shaft operates to supply the current only to the circuit
of the desired position.

Function

No. Type Operation

1 Directional lever switch
2 Gearshift lever switch
3 Gearshift lever stopper
4 Turn signal
5 Self-cancel
6 Lamp switch
7 Dimmer switch
8 Hazard switch
9 Hazard pilot lamp
Selects the travel direction and neutral.
Selects a gear speed.
Prevents the gearshift lever from moving to the 3rd or 4th position during work.
Turn signal for LH and RH turns
Returns the turn signal lever automatically to neutral when the steering wheel is
returned after turning to the right or left.
Selects the clearance lamp, head lamp, parking lamp, etc.
Selects main beam and low beam.
Flashes turn signals to the left and right simultaneously.
Flashes while the hazard lamp flashes.

10-468 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Operation

• Shaft (2) of directional and gearshift lever (1) of the combination

switch is made one with magnet (3). As lever (1) moves,
magnet (3) moves also.

• Control switch (5), having Hall ICs (4) in it, is installed under
magnet (3). Hall ICs (4) are arranged on the board for each
position.

• When the directional lever is set in the F position, magnet (3)

comes directly above Hall IC (4) of the F position of the control
switch. Magnet (3) magnetizes Hall IC (4) through the clearance
and case (6).

• Hall IC (4) is in the magnetism sensor circuit; it detects the

magnetism of magnet (3) and sends the signal of the F position of
the directional lever to the current amplifier circuit. The current
amplifier circuit outputs the signal to operate the transmission
valve.

WA500-6 10-469 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Engine Starting Circuit

T

Function

• The neutral safety circuit is employed to secure safety when the engine is started.

• The engine can not be started while the directional lever is not in N (Neutral).
• The engine cannot start while the right FNR selector switch (if equipped) is ON or while the right FNR switch is not
in N (Neutral).
• The engine cannot start while the joystick steering (if equipped) is ON or while either of the joystick steering lever
FNR switch or joystick steering lever is not in N (Neutral).

• The KOMTRAX engine cut circuit is used to prevent the engine from starting when the KOMTRAX receives an engine
cut command issued through external operation.

10-470 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Operation

• Starting switch is turned to ON position.

• If the starting switch is turned to the ON position, terminals B and BR of the starting switch are closed. The current
flows from the battery through the starting switch and battery relay coil to the ground; the battery relay contacts are
closed. As a result, the power is supplied to each circuit of the machine.
• The current flows from terminal ACC of the starting switch into the engine controller power relay, operating it to
provide the power supply for operation to the engine controller. The engine is ready to start.

• Neutral safety circuit

• If the directional lever is set in the N (Neutral) position, the current flows from contact (N) of the directional lever
through the exchange relay to the neutral safety relay coil, conducting terminal 3 of the neutral safety relay with
terminal 5 of the same relay.
• While the joystick steering (if equipped) is used, if the joystick steering armrest is tilted forward and the joystick
steering selector switch is turned ON, the current flows from the joystick steering selector switch to the transmission
controller to enable the controller.
• At this time, if the joystick steering lever FNR switch is not in N, the work equipment controller outputs the cutout
current. The current flows to the lever relay coil, cutting terminal 3 of the lever relay out from terminal 6 of the same
relay.
• If the joystick steering lever is not in N, the work equipment controller outputs the cutout current. The current flows
to the lever relay coil, cutting terminal 3 of the lever relay out from terminal 6 of the same relay.
★ If the joystick steering system is installed, the joystick steering lock switch and joystick steering selector switch are
installed instead of the right FNR selector switch indicated in the engine starting circuit diagram. The joystick
steering lever FNR switch is installed instead of the right FNR switch.

• While the right FNR switch (if equipped) is used (the right FNR selector switch is ON), the current flows from the
right FNR selector switch to the transmission controller to enable the controller. At this time, if the FNR switch is not
in N, the work equipment controller outputs the cutout current. The current flows to the lever relay coil, cutting
terminal 3 of the lever relay out from terminal 6 of the same relay.

• Starting switch is turned to Start position.

• If the starting switch is turned to the Start position, the current flows through terminal B of the starting switch,
terminal C of the same switch, terminal 3 of the KOMTRAX engine cut relay, terminal 6 of the same relay, terminal 3
of the neutral safety relay, terminal 5 of the same relay, terminal 3 of the lever relay, and terminal 6 of the same relay
to the starting motor to start the engine.
• At the same time, the current flows from terminal C of the starting switch to the engine controller, where the engine
speed and coolant temperature signals are processed to optimize the injection rate.
• When the directional lever is not in N, or the right FNR switch is not in N (if the right FNR switch is used), or the
joystick steering lever FNR switch is in N, and the joystick steering lever is not in N (if the joystick steering is used),
the neutral safety relay does not operate and the engine does not start.
• When the right FNR switch is not in N (if the right FNR switch is used), or the joystick steering lever FNR switch is
in N, and the joystick steering lever is not in N (if the joystick steering is used), the lever relay does not operate and
the engine does not start.
• When the KOMTRAX controller receives an engine cut command issued through external operation, it grounds
terminal 2 of the KOMTRAX engine cut relay to operate the relay. This cuts out the current from terminal 6 of the
KOMTRAX engine cut relay to terminal 3 of the neutral safety relay, preventing the engine from starting.

WA500-6 10-471 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Engine Stopping Circuit

10-472 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Operation

• If the starting switch is set in the OFF position, the current of the ACC terminal is cut out and the ACC signal to the
engine controller is cut out accordingly. The engine controller stops the fuel supply to the engine. As the fuel supply is
stopped, the engine slows down and stops.

• When the alternator stops generating electricity, the voltage supply from the R terminal of the alternator and the current
from the BR terminal of the starting switch are cut out. The contact of the battery relay opens and the power supply
provided to various circuits in the machine is cut out.

• About 10 seconds after the starting switch is turned OFF, the current from the engine controller to the two engine
controller cut relays is cut out. This turns the relay OFF and cuts out the engine controller operating power supply to
prevent unexpected operation.

WA500-6 10-473 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Preheating Circuit
(Automatic preheating system)

10-474 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Outline

• The automatic preheating system is installed so that the engine will start easily in a cold district. This system reduces and
sets the preheating time according to the engine coolant temperature when the starting switch is operated.

• When the starting switch is set in the ON position, the current flows to the electrical intake air heater to preheat the intake
air. The engine controller determines the preheating time according to the coolant temperature detected by the engine
coolant temperature sensor.

• The preheater pilot lamp, on the main monitor, lights up during preheating. When the preheating is completed, the
preheater pilot lamp goes out.

Operation

• When the starting switch is set in the ON position, the engine controller sends signals to operate the heater relay and
closes the contact.

• The current flows from the battery through the battery relay and heater relay to the electrical intake air heater for
preheating.

• When the preheating is completed, the current from the engine controller to the heater relay is cut out and the heater relay
contact is opened.

• During preheating, the current flows through the terminal (BR) of the starting terminal and terminal 1 and terminal 2 of
the preheating relay to the engine controller to energize the coil of the preheating relay. The preheater pilot lamp on the
main monitor lights up.

★ When the preheating is completed, the preheater relay turns OFF and the preheater pilot lamp goes out.

WA500-6 10-475 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Parking Brake Circuit

Starting Switch Turned OFF

Operation

• If the starting switch is turned OFF, the contacts of the battery relay open and no current flows to the parking brake circuit.

• While the starting switch is OFF, the current does not flow into the parking brake solenoid valve and the parking brake is
kept applied, regardless of the position of the parking brake switch (whether it is ON (applied) or OFF (released)).

10-476 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Starting Switch Turned ON

★ When the parking brake switch is turned ON (actuate) before the starting switch is turned ON.
.

Operation

• Since the parking brake selector switch is ON (actuate), the current flows through the battery relay, contact 6 of the
parking brake selector switch, contact 5 of the same switch, and the parking brake safety relay coil to the chassis ground,
closing terminal 3 and terminal 5 of the parking brake safety relay. The current from the battery relay keeps flowing into
the parking brake relay coil to hold its contacts until the battery relay contacts open and the current does not flow into the
parking brake circuit any longer.

• At this time, the current does not flow into the parking brake solenoid and the parking brake is kept applied.

• This signal is input to the transmission controller to keep the transmission in neutral and prevent the parking brake from
dragging while the parking brake is applied.

• After that, if the parking brake switch is turned OFF (released), the current flows through the battery relay, parking brake
safety relay, contact 4 of the parking brake selector switch, contact 3 of the same switch, emergency brake switch, and the
parking brake solenoid to the chassis ground, releasing the parking brake.

WA500-6 10-477 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
★ When parking brake switch is turned OFF (released) before starting switch is turned ON.

Operation

• While the starting switch is OFF, the current does not flow into the parking brake safety relay and its contacts are open.

• Even if the starting switch is turned ON at this time, the current does not flow into the parking brake solenoid.
Accordingly, the parking brake is not released automatically.

10-478 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Main Brake Oil Pressure Lowers (emergency brake is applied)

Operation

• If the main brake oil pressure lowers, the contacts of the emergency brake switch installed to the accumulator open. As a
result, the current flowing into the parking brake solenoid valve is stopped and the oil in the parking brake cylinder is
drained. The parking brake is applied.

• In this case, however, unlike the case where the parking brake switch is turned ON (actuate), the transmission is not set in
neutral since the parking brake release signal is flowing into the transmission controller.

• Because of this operation, when the emergency brake is applied, the braking distance can be reduced by using the engine
as a brake. Even if the emergency brake is applied, the machine can be moved.

WA500-6 10-479 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Parking Brake Emergency Release Circuit

Operation

• When the vehicle stops due to engine trouble, the oil pressure from the transmission pump to the parking brake cylinder is
cut out, triggering the parking brake. Under this condition, oil pressure in the main brake line is held in the accumulator.

• When the emergency release switch is turned to ON (released), the buzzer sounds and the current flows to the emergency
parking brake release solenoid valve. The oil pressure held in the accumulator of the main brake line flows into the
parking brake cylinder, releasing the parking brake.

• The emergency release switch must be in the OFF position during normal operation and after emergency release is
completed.

10-480 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Backup and Stop Lamp circuit

Stop Lamp Circuit

Operation

• When the brake pedal is pressed, the contact of the stop lamp switch is closed to cause the current to flow to the stop lamp
relay coil. This closes the contact of the relay to complete the circuit from the fuse through terminal 5 of the stop lamp
relay, terminal 3 of the same relay, and the right and left stop lamps to the chassis ground. The right and left stop lamps
light up.

• When the brake pedal is released, the contact of the stop lamp switch is opened. This opens the contact of the stop lamp
relay and the stop lamps go out.

• Because the current flows through the stop lamp circuit when the battery relay operates, the stop lamps do not light up
when the starting switch is in the OFF position.

WA500-6 10-481 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Backup Lamp Circuit

Operation

• Because the current flows through the backup lamp circuit when the battery relay operates, the backup lamps do not light
up and the backup buzzer does not sound when the starting switch is in the OFF position.

• When the directional lever is in the R position

When the directional lever is turned to the R position, the transmission controller sends a signal to the backup lamp relay
to open its contact. This completes the circuit from the fuse through terminal 5 of the backup lamp relay, terminal 3 of the
same relay, and right and left backup lamps to the chassis ground. The right and left backup lamps light up and the backup
buzzer sounds.

• When the right FNR switch is used

Even if the directional lever is in N (Neutral), turning the right FNR switch to R causes the transmission controller to send
the signal to operate the backup lamp relay. The right and left backup lamps light up and the backup buzzer sounds.

• When the joystick steering is used

When the right FNR switch is used and even if the directional lever is in N (Neutral), turning the joystick steering lever
FNR switch to R causes the transmission controller to send the signal to operate the backup lamp relay. The right and left
backup lamps light up and the backup buzzer sounds.

10-482 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Small Lamp and Head Lamp Circuits

Operation

• Because the current flows through the small lamp and head lamp circuits when the battery relay operates, the small lamps
and head lamps do not light up when the starting switch is in the OFF position.

• When the lighting switch is in the Small position

When the lighting switch is turned to the Small position, the current flows through the switch and fuse to the front, rear,
right, and left small lamps; the lamps light up. The small lamp signal is input to the main monitor and turns the main
monitor night lamp on. The circuit supplies the current in the small lamp circuit to the working lamp switch, prohibiting
the working lamp from lighting up when the small lamps are off.

• When the lighting switch is in the Head position

When the lighting switch is turned to the Head position, the current flows through the switch and fuse to the small lamp
and head lamp circuits. The current flows from the head lamp through the dimmer switch (Hi/Lo selector switch) to the
chassis ground. The high beam or low beam selected with the dimmer switch lights up. The high beam signal is input to
the main monitor and turns on the high beam pilot lamp on the main monitor.

WA500-6 10-483 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Working Lamp Circuit

Operation

• The current is supplied to the front and rear working lamp switches from the small lamp circuit.

• When the working lamp switch is turned ON, the working lamp relay operates to close the contact. The current flows
through the fuse, working lamp relay, and working lamp to the chassis ground.

• The working lamp and the indicator in the working lamp switch light up.

10-484 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Horn Circuit

Operation

• Because the current flows through the horn circuit when the battery relay operates, the horn does not sound when the
starting switch is in the OFF position.

• When the steering wheel horn switch is pressed, the horn relay operates to close the relay contact. The current flows
through the fuse, horn, and horn relay to the chassis ground; the horn sounds.

• When the joystick steering horn switch is pressed, the horn relay operates to close the relay contact. The current flows
through the fuse, horn, and horn relay to the chassis ground; the horn sounds.

WA500-6 10-485 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Wiper and Window Washer Circuits

Operation

Because the current flows through the wiper and window washer circuits when the battery relay operates, the wiper and
window washer do not operate when the starting switch is in the OFF position. When the starting switch is turned OFF during
operation, window washing and wiper action stop.

• Front wiper circuit

• When the front wiper switch is in the Lo position.

The current flows through the fuse, terminal 7 of the front wiper switch, and terminal 5 of the same switch to the front
wiper motor (Lo). The wiper operates at the low speed.
• When the front wiper switch is in the Hi position.
The current flows through the fuse, terminal 7 of the front wiper switch, and terminal 4 of the same switch to the front
wiper motor (Hi). The wiper operates at the high speed.
• When the front wiper switch is in the INT (intermittent) position.
The current flows through the fuse, terminal 7 of the front wiper switch, and terminal 2 of the same switch to the
wiper relay; the relay contact closes. Then the current flows through the fuse, wiper relay, terminal 3 of the front
wiper switch, and terminal 5 of the same switch to the front wiper motor (Lo).
The wiper operates at the low speed. The wiper relay repeats the timer-controlled operation where the wiper makes
reciprocating motions at intervals of four to six seconds.

10-486 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
• When the washer switch is in the ON position.
The current flows through the fuse and front wiper switch to the washer motor; the washer operates.
At the same time, the current flows to the wiper relay and operates the wiper 0.2 – 0.8 seconds after the washer switch
is turned ON. The wiper relay moves the wiper two to four times after the washer switch is turned OFF. This
operation occurs when the washer switch is turned OFF after it has been ON while the wiper makes more than one
reciprocating motion.
• When the front wiper switch is in the OFF position.
When the front wiper switch is turned OFF while the wiper is operating, contacts P1 and P2 of the front wiper motor
close. The current flows through the fuse, contact P2 of the wiper motor, contact P1 of the same motor, the wiper
relay, terminal 3 of the front wiper switch, and terminal 5 of the same switch to the front wiper motor (Lo). The wiper
operates. When the wiper comes to the stop position, contacts P1 and P2 of the wiper motor open and the wiper stops.

• Rear wiper circuit

• When the rear wiper switch is in the Lo position.

The current flows through the fuse, terminal 7 of the rear wiper switch, and terminal 9 of the same switch to the rear
wiper motor; the rear wiper operates.
• When the rear wiper switch is in the Washer position.
The current flows through the fuse, terminal 7 of the rear wiper switch, and terminal 10 of the same switch to the
washer motor; the washer operates.
• When the rear wiper switch is in the Washer or Lo position.
The current flows through the fuse, terminal 7 of the rear wiper switch, and terminal 9 of the same switch to the rear
wiper motor; the rear wiper operates.
The current also flows through the fuse, terminal 7 of the rear wiper switch, and terminal 10 of the same switch to the
washer motor; the washer operates.
• When the rear wiper switch is in the OFF position.
When the rear wiper switch is turned OFF while the wiper is operating, contacts P1 and P2 of the rear wiper motor
close. The current flows through the fuse, contact P2 of the wiper motor, contact P1 of the same motor, terminal 8 of
the rear wiper switch, and terminal 9 of the same switch to the rear wiper motor; the wiper operates. When the wiper
comes to the stop position, contacts P1 and P2 of the wiper motor open and the wiper stops.

WA500-6 10-487 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Relay

★ 1 = Case, 2 = Base

★ 1 = Case, 2 = Base

10-488 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Sensors and Switches

Input Shaft Speed Sensor
Output Shaft Speed Sensor

1. Magnet
2. Locknut
3. Harness
4. Connector

Function

• The input shaft speed sensor is installed on the transmission unit input shaft; the output shaft speed sensor is installed in
the output gear section at the transmission unit. These sensors emit pulse signals according to the gear rotation signal,
which are detected by the transmission controller.

• Signals are converted from pulse to the number of rotations (rpm) in the transmission controller and transmitted to the
machine monitor over the network. The rpm is then converted into travel speed and displayed on the machine monitor.

WA500-6 10-489 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Left Brake Pressure Sensor

1. Sensor
2. Lead wire
3. Connector

Function

• Installed to the brake pilot circuit and detecting brake operating

pressure, the left brake pressure sensor is used to set brake pressure
for the transmission cutoff function and to operate the function.

★ The brake pressure of this sensor changes when either the right or
left brake pedal is pressed.

10-490 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Transmission Oil Temperature Sensor

Torque Converter Oil Temperature Sensor
Hydraulic Oil Temperature Sensor
Axle Oil Temperature Sensor

1. Thermistor
2. Plug
3. Harness
4. Connector

Function

• The oil temperature sensors convert changes in temperature into changes in thermistor resistance; each controller detects
temperature.

• The transmission oil temperature sensor detects the internal temperature of the transmission case. The temperature data is
used by the transmission controller to select the temperature table of electronic modulation in order to control a
modulation best matched to the oil temperature.

• Data from the torque converter oil temperature sensor and hydraulic oil temperature sensor is detected by the machine
monitor and indicated on the gauges. At the same time, the data is transmitted to the transmission controller via the
network and used as the cooling fan control data.

• The axle oil temperature sensor detects the internal oil temperature of the rear axle with the monitor and outputs a caution
signal when the temperature rises to a high level.

WA500-6 10-491 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Kickdown Hold Switch

1. Switch A (white wiring harness)

2. Spring
3. Harness
4. Spring B (yellow wiring harness)

Function

• These switches are installed to the knob of the lift arm control lever. Switch A (1) works as the kickdown switch;
switch B (4) works as the hold switch.

• These switches are installed to the knob of the lift arm control lever when the load meter (if equipped) is installed.
Switch A works as the cancel switch; switch B works as the subtotal switch.

• Switch A (1) and switch B (4) are the automatic-reset type; their contacts are closed only while they are pressed.

10-492 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Joystick Knob (if equipped)

1. Horn switch: Horn sounding switch

2. Shift down switch: Selects a gear speed (shift down)
3. Shift up switch: Selects a gear speed (shift up)
4. Directional switch: Selects the travel direction and neutral

Function

• The directional switch is held at a selected position. The transmission controller shifts gear according to the signal from
the directional switch.

• The shift-up/-down switch selects a circuit only while the switch is being depressed. The transmission controller uses this
signal for gear shifting operation accordingly.

• The NC (normally close) side of the shift up/down switch is not connected to the controller.

• The horn switch operates the relay and sounds the horn while it is being depressed.

WA500-6 10-493 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Right FNR Switch (if equipped)

Function

• The directional switch is held at a selected position.

• The transmission controller shifts gear according to the signal from the directional switch.

10-494 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Lift Arm Angle Sensor (if equipped)

1. Oil seal
2. Case
3. Resistor assembly
4. Brush
5. Shaft
6. Connector

Function

• The lift arm angle sensor is installed to the front frame. When the lift arm angle changes, the shaft receives the sliding
resistance through the link installed to the lift arm; the lift arm angle is detected from that sliding resistance.

• The angle sensor is installed on a machine equipped with a load meter or electric work equipment lever.

WA500-6 10-495 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Loader Pump Pressure Sensor

Lift Arm Cylinder Bottom Pressure Sensor
Lift Arm Cylinder Head Pressure Sensor (Load Meter) (if equipped)

1. Sensor
2. Connector

10-496 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL
Function

Installed to the inlet port circuit for the control valve, these sensors
convert pump discharge pressure to voltage and transmit to the
governor pump controller.

Function (lift arm sensors)

Installed on the bottom and rod pipes of the lift arm cylinder, these
sensors measure cylinder pressure for loaded/unloaded judgment and
load weight calculation.

Operation

• When oil pressure led from the pressure input port applies pressure
to the diaphragm of the oil pressure sensor, the diaphragm is
deformed by deflection.

• The gauge layer is installed opposite the diaphragm. Deflection of

the diaphragm is converted into output voltage by the resistance of
the gauge layer and is sent to the amplifier.

• After amplifying the voltage, the amplifier transmits the voltage to

the governor controller.

• Relational expression of pressure P (MPa {kg/ cm2}) and output

voltage (V):

V = 0.08 {0.008} x P + 0.5

WA500-6 10-497 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Fuel Level Sensor

1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer

Function

• The fuel level sensor is installed to the side of the fuel tank.

• The float moves up and down according to the fuel level. The float moves the variable resistor through the arm.

• The voltage signal is sent to the machine monitor to indicate the fuel level. When the machine monitor indicator reaches a
specified position, the caution lamp is lit.

10-498 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Parking Brake Pressure Switch

Stop Lamp Pressure Switch

1. Case
2. Tube
3. Connector

Function

• When the parking brake is released, oil pressure is fed to the brake piston. The oil pressure operates the pressure switch to
turn out the parking brake pilot lamp on the machine monitor.

• When the foot brake is pressed and the brake operating pressure is generated, the pressure switch contact is closed; the
relay is operated; and the stop lamp illuminates.

WA500-6 10-499 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Air Cleaner Clogging Sensor

1. Indicator
2. Spring
3. Adapter

Function

• The air cleaner clogging sensor is installed to the air cleaner outlet.

• If the air cleaner is clogged and the pressure reaches the specified level (negative pressure), the caution lamp on the
machine monitor lights up to indicate a warning.

10-500 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Transmission Clogging Sensor

1. Body
2. Tube
3. Connector

A. Takeout port on low pressure side

B. Takeout port on high pressure side

Function

• The clogging sensor is installed to the filter section.

• If the filter is clogged and the pressure difference between the

lower and higher sides reaches a specified level, the switch turns
OFF; the maintenance caution lamp lights up. At the same time, a
message appears on the character display to warn about the
abnormal situation.

Operating pressure: . . . . . . . . . . . . . . . . . . . . . 275 kPa (39.89 psi)

Principle of switching: . . . . . Differential pressure sliding piston type

WA500-6 10-501 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Steering Oil Pressure Sensor Switch

1. Body
2. Shaft
3. Tube
4. Connector

Function

• The steering oil pressure sensor switch detects the operation of the diverter valve spool, which is tripped to operate when
the steering oil pressure drops.

• If the steering oil pressure drops and the spool operates, the switch piston is turned OFF and the circuit opens.

10-502 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Radiator Coolant Level Sensor

1. Stopper
2. Float
3. Sensor
4. Plug
5. Tube
6. Connector

Function

• The radiator coolant level sensor is installed on the coolant subtank.

• If the coolant level drops below the specified level, the float lowers and the switch is turned OFF.

• The caution lamp on the machine monitor lights up to indicate a warning.

WA500-6 10-503 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Brake Accumulator Pressure Switch (front and rear)

1. Case
2. Tube
3. Connector

Function

• If the brake accumulator oil pressure drops, the contact becomes OPEN.

• The caution lamp lights up on the machine monitor to warn about an abnormality.

10-504 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Battery Electrolyte Level Sensor

1. Body
2. Connector
3. Filter
4. Packing
5. Pin

Function

• The battery electrolyte level sensor is installed to the battery.

• If the battery electrolyte level drops below the specified level, the sensor tip is exposed to air and a voltage signal change
is generated. The signal is sent to the machine monitor to warn about the abnormal situation.

WA500-6 10-505 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Accelerator Pedal Sensor

1. Pedal
2. Connector

Accelerator Signal

• The accelerator pedal installed on the floor is provided with an

accelerator sensor for the engine controller.

• When the accelerator pedal is pressed, the potentiometer shaft

inside the accelerator sensor starts rotation and the resistance value
changes accordingly. The potentiometer is applied with a constant
level of voltage from the engine controller. A voltage signal is
transmitted to the engine controller according to the depressed
angle of the accelerator pedal. In addition, the depressed angle is
transmitted to each controller over the network as the accelerator
pedal opening data.

Idle Validation Signal

• This sensor is installed in the same case as the accelerator sensor.

• While the accelerator pedal is released, signal 2 is connected to the ground; when the accelerator pedal is pressed, signal 3
is connected to the ground. Using these signals, the engine controller detects whether the accelerator pedal is pressed.

10-506 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Emergency Brake Pressure Switch (front)

Emergency Brake Pressure Switch (rear)

1. Case
2. Tube
3. Connector

Function

• When the brake accumulator pressure lowers, the switch contact opens. The circuit between the parking brake switch and
parking brake solenoid is cut off.

• The parking brake is tripped to operate.

WA500-6 10-507 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

KOMTRAX Terminal System (if equipped)

• The KOMTRAX terminal sends information about the machine by wireless communication. The KOMTRAX operator
refers to this information in the office and can provide different services for the customer.

★ To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.

• The following information can be sent from the KOMTRAX terminal:

• Operation history
• Service meter
• Location information
• Error history

10-508 ➁ WA500-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

KOMTRAX Terminal

1. DRC connector (40-pole) contacts

2. Do not connect.
3. GPS antenna connector
4. ORBCOMM antenna connector

Outline

• The KOMTRAX terminal can acquire machine information with an intermachine network or input signals and transmit
the information via a radio communication antenna. Equipped with a CPU (central processing unit), this terminal has
radio communication and GPS functions.

• The display monitor has LED lamps and a 7-segment indicator lamp for inspection and troubleshooting.

WA500-6 10-509 ➁
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC TRANSMISSION CONTROL

Input and Output Signals

Input and Input and

Pin No. Signal Name Pin No. Signal Name
Output Output
1 232C (0CH) control signal Input 21 Inspection mode Input
2 232C (0CH) control signal Output 22 Inspection mode Input
3 232C (0CH) control signal Input 23 232C (0CH) control signal Input
4 232C (0CH) reception Input 24 (if equipped) Input
5 232C (0CH) transmission Output 25 (if equipped) Input
6 CAN shield GND — 26 (if equipped) Input
7 CAN signal (L) Input/output 27 Terminal C input (Hi side) Input
8 CAN signal (H) Input/output 28 Alternator terminal R input Input
9 S-NET shield GND — 29 EXGND —
10 S-NET signal — 30 (if equipped) Output
11 232C (0CH) shield GND — 31 (If equipped) (5 V MAX) Input
12 Write signal Input 32 (If equipped) (5 V MAX) Input
13 232C (1CH) reception Input 33 232C (0CH) control signal Input
14 232C (1CH) transmission Output 34 (if equipped) Input
15 232C (0CH) control signal Output 35 (if equipped) Output
16 (if equipped) Input 36 ACC input Input
17 (if equipped) Input 37 Power supply GND —
18 (if equipped) Output 38 Power supply GND —
Constant power supply (12 V/
19 (if equipped) Output 39 Input
24 V)
Constant power supply (12 V/
20 Engine start output Output 40 Input
24 V)

10-510 ➁ WA500-6
 20 STANDARD VALUE TABLES

STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

Standard Service Value Table for Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Standard Service Value Table for Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
MACHINE POSTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10

WA500-6 20-1 ➁
STANDARD VALUE TABLES TABLE OF CONTENTS
12

MEMORANDUM

WA500-6 20-2 ➁
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
STANDARD VALUE TABLES
Standard Service Value Table for Engine
Machine Model WA500-6
Engine SAA6D140E-5
Standard
Service Limit
Item Measurement Conditions Unit Value for
Value
New Machine
High idle 2,120 ±50 2,120 ±50
Low idle 790 ±25 790 ±25
Engine coolant temperature:
Engine speed rpm
Within operating range Engine speed
set min. low idle 700 ±25 700 ±25
(*1)
Exhaust All revolution ranges °C Max. 650 700
temperature Atmospheric temperature: 20°C (68°F) (°F) (Max. 1202) (Max. 1292)
Intake air pressure kPa Min. 116 89
At rated output
(Boost pressure) (psi) (Min. 16.82) (12.91)
%
At sudden Max. 25 35
(Bosch
acceleration (Max. 2.5) (3.5)
Engine coolant temperature: index)
Exhaust gas color
Within operating range
At rated output (Bosch Max. 1.5 2.5
At high idle index) Max. 1.0 2.0
Intake valve mm 0.35 (0.014) —
Valve clearance Normal temperature
Exhaust valve (in) 0.57 (0.022) —
At rated output kPa Max. 2.94 3.92
Blow-by pressure
Engine coolant temperature: Min. 70°C (158°F) (psi) (0.426) (0.569)
At rated output
SAE0W30EOS Min. 0.34 0.21
Engine oil temperature: Min.
SAE5W40EOS (Min. 49.31) (30.46)
80°C (176°F) MPa
Oil pressure SAE10W30DH
At low idle (psi)
SAE15W40DH Min. 0.10 0.08
Engine oil temperature: Min. SAE30DH (Min. 14.50) (11.60)
80°C (176°F)
°C 90 – 110 120
Oil temperature All engine speed ranges (Inside oil pan)
(°F) (194 – 230) (248)
Alternator belt Deflection made by finger pressure of about mm 13 – 16 13 – 16
tension 98 N (22.03 lbf) (in) (0.51 – 0.63) (0.51 – 0.63)

★ *1: Denotes the low idle speed when the engine speed is decreased to the minimum speed with the
RPM idle-up/down selector switch.

WA500-6 20-3 ➁
STANDARD VALUE TABLES STANDARD VALUE TABLES

Standard Service Value Table for Chassis

Machine Model WA500-6
Category

Standard Value for

Item Measurement Conditions Unit Service Limit Value
New Machine

N→
5.9 ±2.9 5.9 ±2.9
Directional

FORWARD,
(1.33 ±0.65) (1.33 ±0.65)
lever

Operating REVERSE • Engine stopped N

effort • Measure at center of lever knob (lbf)
FORWARD, 5.9 ±2.9 5.9 ±2.9
REVERSE → N (1.33 ±0.65) (1.33 ±0.65)

5.9 ±2.9 5.9 ±2.9

1st → 2nd
(1.33 ±0.65) (1.33 ±0.65)

Operating 5.9 ±2.9 5.9 ±2.9

2nd → 3rd
effort (1.33 ±0.65) (1.33 ±0.65)
Gearshift lever

5.9 ±2.9 5.9 ±2.9

3rd → 4th
• Engine stopped N (1.33 ±0.65) (1.33 ±0.65)
• Measure at center of lever knob (lbf) 5.9 ±2.9 5.9 ±2.9
4th → 3rd
(1.33 ±0.65) (1.33 ±0.65)

5.9 ±2.9 5.9 ±2.9

Stroke 3rd → 2nd
(1.33 ±0.65) (1.33 ±0.65)

5.9 ±2.9 5.9 ±2.9

2nd → 1st
(1.33 ±0.65) (1.33 ±0.65)

HOLD → RAISE Max. 10.8 Max. 16.2

(*2) (Max. 2.43) (Max. 3.64)

Max. 15.2 Max. 22.9

RAISE → HOLD
(Max. 3.42) (Max. 5.15)

HOLD → Max. 10.8 Max. 16.2

Work equipment control lever

LOWER (*2) (Max. 2.43) (Max. 3.64)

Lift arm
LOWER →
— —
Operating effort

HOLD
• Engine speed: Low idle (*1)
LOWER → N Max. 18.6 Max. 28.4
• Hydraulic oil temperature: Within
FLOAT (lbf) (Max. 4.18) (Max. 6.38)
operating range
FLOAT → Max. 10.8 Max. 16.2
HOLD (Max. 2.43) (Max. 3.64)

Max. 10.8 Max. 16.2

HOLD → DUMP
(Max. 2.43) (Max. 3.64)

HOLD → TILT Max. 10.8 Max. 16.2

Bucket
(*2) (Max. 2.43) (Max. 3.64)

Max. 10.8 Max. 16.2

TILT → HOLD
(Max. 2.43) (Max. 3.64)

HOLD ↔ 40 ±10 40 ±15

Work equipment control lever

RAISE (*2) (1.57 ±0.39) (1.57 ±0.59)

HOLD ↔ 40 ±10 40 ±15
Lift arm
LOWER (*2) (1.57 ±0.39) (1.57 ±0.59)
• Engine speed: Low idle (*1)
Stroke

HOLD ↔ mm 45 ±10 45 ±15

• Hydraulic oil temperature: Within
FLOAT (in) (1.77 ±0.39) (1.77 ±0.59)
operating range
40 ±10 40 ±15
HOLD → DUMP
(1.57 ±0.39) (1.57 ±0.59)
Bucket
HOLD → TILT 40 ±10 40 ±15
(*2) (1.57 ±0.39) (1.57 ±0.59)

20-4 ➁ WA500-6
STANDARD VALUE TABLES STANDARD VALUE TABLES

Machine Model WA500-6

Category
Standard Value for
Item Measurement Conditions Unit Service Limit Value
New Machine

• Engine stopped mm Max. 40 50 – 100

Play
• Machine facing straight to front (in) (Max. 1.57) (1.97 – 3.94)

• Flat, level, straight, dry, and paved road

N 9.8 ±2.0 Max. 19.6
Operating effort • Engine speed: Low idle (Bucket empty)
Steering wheel

(lbf) (2.20 ±0.45) (Max. 4.41)

(*1)

• Engine speed: High idle

Turns (Not including play) Turns 4.0 ±0.3 Max. 4.5
• Left lock – right lock

Low idle (*1) • Engine started Max. 6.0 Max. 7.0

Operating • Hydraulic oil temperature: Within
sec.
time High idle operating range Max. 3.5 Max. 4.0
• Left lock – right lock

• Engine started
N Max. 58.8 Max. 107.9
Operating effort • Measure at 150 mm (5.91 in) from
Accelerator pedal

(lbf) (Max. 13.22) (Max. 24.26)

fulcrum of pedal.
Neutral (a1) ★ For measuring posture, see Fig. A at 52 —
end of this section.
Operating
• Engine speed: Low idle (*1) deg.
angle Max. (a3) 17 —
• Hydraulic oil temperature: Within
operating range

N Max. 363 ±39.2 Max. 520.3

Operating effort
(lbf) (Max. 81.61 ±8.81) (Max. 116.97)
★ For measuring posture, see Fig. B at
Brake pedal

Neutral (a1) end of this section. 53 —

Operating
• Engine speed: Low idle (*1) deg.
angle Max. (a2) 16 (+1/0) —
• Hydraulic oil temperature: Within
operating range mm 5 ±0.5
Play —
(in) (0.20 ±0.02)

Max. 2.5
A —
(Max. 0.10)
Fitting of wheel lock ★ For measuring posture, see Fig. C at
ring end of this section. mm Max. 4.0
Tire

B —
• Tire inflation pressure: Specified (in) (Max. 0.16)
pressure
Clearance of wheel 2 – 15
C —
lock ring (0.08 – 0.60)

P-mode 1,840 ±100 1,840 ±200

Torque converter stall • Engine coolant temperature:
E-mode 1,810 ±100 1,810 ±200
Engine speed

Within operating range

• Torque converter oil P-mode 2,100 ±100 2,100 ±200
Hydraulic stall temperature: Within rpm
operating range E-mode 2,000 ±100 2,000 ±200
• Hydraulic oil temperature:
Torque converter stall + P-mode 1,800 ±100 1,800 ±300
Within operating range
hydraulic stall E-mode 1,765 ±100 1,765 ±300

WA500-6 20-5 ➁
STANDARD VALUE TABLES STANDARD VALUE TABLES

Machine Model WA500-6

Category
Standard Value for
Item Measurement Conditions Unit Service Limit Value
New Machine

0.84 ±0.10 0.84 ±0.10

Low idle (*1)
Main relief (121.83 ±14.50) (121.83 ±14.50)
pressure 3.64 ± 0.15 3.64 ±0.15
High idle • Torque converter oil temperature: Within (527.94 ±21.76) (527.94 ±21.76)
operating range
Torque converter inlet oil • Engine speed: High idle 0.64 ±0.2 0.64 ±0.2
pressure (92.82 ±29.01) (92.82 ±29.01)

Torque converter outlet port 0.39 ±0.1 0.39 ±0.1

Transmission, torque converter

oil pressure (56.56 ±14.50) (56.56 ±14.50)

3.24 ±0.2 3.24 ±0.2
1st
(469.92 ±29.01) (469.92 ±29.01)

MPa 3.28 ±0.2 3.28 ±0.2

2nd
(psi) (475.72 ±29.01) (475.72 ±29.01)

3.28 ±0.2 3.28 ±0.2

3rd
• Torque converter oil (475.72 ±29.01) (475.72 ±29.01)
temperature: Within
ECMV output (clutch) oil 3.19 ±0.2 3.19 ±0.2
operating range 4th
pressure (462.67 ±29.01) (462.67 ±29.01)
• Engine speed: Hi idle
• Manual switch: ON 1.86 ±0.15 1.86 ±0.15
Lockup
(269.77 ±21.76) (269.77 ±21.76)
3.38 ±0.2 3.38 ±0.2
Forward
(490.23 ±29.01) (490.23 ±29.01)

3.34 ±0.2 3.34 ±0.2

Reverse
(484.43 ±29.01) (484.43 ±29.01)

• Hydraulic oil temperature: Within 24.5 (+1.18 ) 24.5 (+1.18 )

-0.49 -1.47
Steering relief pressure operating range
• Engine speed: High idle (3553.43 (+171.14
-71.07
)) (3553.43 (+171.14
-213.21
))

• Hydraulic oil temperature: Within

3.72 (+0.2 ) 3.72 (+0.2 )
Steering

operating range 0 -0.2

Orbitrol basic pressure MPa
• Engine speed: High idle (539.54 (+29.01)) (539.54 (+29.01 ))
(psi) 0 -29.01
• Steering wheel operation

• Hydraulic oil temperature: Within

operating range 1.27 ±0.1 1.27 ±0.2
LS pressure
• Engine speed: Low idle (184.20 ±14.50) (184.20 ±29.01)
• Steering wheel: Stopped

• Point where
brake oil 5.88 (+0.49 ) 5.88 (+0.98 )
0 -0.49
Charge cut-in pressure pressure
• Engine speed: Low (852.82 (+71.07)) (852.82 (+142.14 ))
Accumulator

warning lamp 0 -71.07

idle (*1) goes out MPa
• Hydraulic oil
(psi)
temperature: Within • Point where oil
operating range pressure is 9.8 (+0.98 ) 9.8 (+1.47 )
0 -0.49
Charge cut-out pressure going up and
then starts to go (1421.37 (+142.14
0
)) (1421.37 (+213.21
-71.07
))
down

20-6 ➁ WA500-6
STANDARD VALUE TABLES STANDARD VALUE TABLES

Machine Model WA500-6

Category
Standard Value for
Item Measurement Conditions Unit Service Limit Value
New Machine

7.7 ±0.4 7.7 ±0.4

1st
(4.8 ±0.25) (4.8 ±0.25)
12.5 ±0.6 (7.8 ±0.37) 12.5 ±0.6 (7.8 ±0.37)
2nd
P-mode {14.2 ±0.7} (8.8 ±0.43) {14.2 ±0.7} (8.8 ±0.43)
• {}: at lockup 22.3 ±1.1 (13.9 ±0.68) 22.3 ±1.1 (13.9 ±0.68)
3rd
{23.4 ±1.2} (14.5 ±0.76) {23.4 ±1.2} (14.5 ±0.76)

34.9 ±1.7 (21.7 ±1.1) 34.9 ±1.7 (21.7 ±1.1)

4th km/h
FORWARD {38.8 ±1.9} (24.1 ±1.2) {38.8 ±1.9} (24.1 ±1.2)
(mph)
1st 7.3 ±0.4 (4.5 ±0.25) 7.3 ±0.4 (4.5 ±0.25)

12.5 ±0.6 (7.8 ±0.37) 12.5 ±0.6 (7.8 ±0.37)

2nd
{14.2 ±0.7} (8.8 ±0.43) {14.2 ±0.7} (8.8 ±0.43)
E-mode
• {}: at lockup 20.9 ±1.0 (13.0 ±0.62) 20.9 ±1.0 (13.0 ±0.62)
3rd
{22.2 ±1.1} (13.8 ±0.68) {22.2 ±1.1} (13.8 ±0.68)
Power train

32.1 ±1.6 (19.9 ±1.0) 32.1 ±1.6 (19.9 ±1.0)

Travel speed 4th
{36.7 ±1.8} (22.8 ±1.1) {36.7 ±1.8} (22.8 ±1.1)
(Bucket empty)
1st 8.6 ±0.4 (5.3 ±0.25) 8.6 ±0.4 (5.3 ±0.25)

13.0 ±0.7 (8.1 ±0.43) 13.0 ±0.7 (8.1 ±0.43)

2nd
{15.9 ±0.8} (9.9 ±0.5) {15.9 ±0.8} (9.9 ±0.5)
P-mode
• {}: at lockup 24.8 ±1.2 (15.4 ±0.75) 24.8 ±1.2 (15.4 ±0.75)
3rd
{26.2 ±1.3} (16.3 ±0.81) {26.2 ±1.3} (16.3 ±0.81)

37.5 ±1.9 (23.3 ±1.2) 37.5 ±1.9 (23.3 ±1.2)

4th
km/h {43.2 ±2.2} (26.8 ±1.4) {43.2 ±2.2} (26.8 ±1.4)
REVERSE
1st (mph) 8.1 ±0.4 (5.0 ±0.2) 8.1 ±0.4 (5.0 ±0.2)

13.0 ±0.7 (8.1 ±0.43) 13.0 ±0.7 (8.1 ±0.43)

2nd
{15.1 ±0.8} (9.4 ±0.50) {15.1 ±0.8} (9.4 ±0.50)
E-mode
• {}: at lockup 23.2 ±1.2 (14.4 ±0.75) 23.2 ±1.2 (14.4 ±0.75)
3rd
{25.0 ±1.3} (15.5 ±0.81) {25.0 ±1.3} (15.5 ±0.81)

35.0 ±1.8 (21.7 ±1.1) 35.0 ±1.8 (21.7 ±1.1)

4th
{41.0 ±2.1} (25.5 ±1.3) {41.0 ±2.1} (25.5 ±1.3)

• Hydraulic oil temperature: Within 4.9 (+0.69

0
) 4.9 (+0.88
-0.20
)
Brake oil pressure
operating range (710.68 (+100.08 ) (710.68 (+127.63 )
0 -29.01
MPa
• Engine stopped (psi)
• Keep brake pedal depressed at 4.9 MPa Max. 0.49 Max. 0.49
Drop in brake pressure
(710.68 psi) and measure drop in oil (Max. 71.07) (Max. 71.07)
pressure after 5 min.
Wheel brake

• Tire inflation pressure: Specified

pressure
• Flat, level, straight, dry, and paved road
• Braking initial speed: 20 km/h (12 mph),
Performance Braking delay: Within 0.1 sec. m (ft) Max. 4 (13.12) Max. 4 (13.12)
• Brake pedal pressing force: Specified
pressing force 294 ± 29.4 N (66.09
±6.61 lbf)
• Measure braking distance

Disc wear • Measure with disc wear indicator mm (in) 0 (0) Max. 4.0 (0.16)

WA500-6 20-7 ➁
STANDARD VALUE TABLES STANDARD VALUE TABLES

Machine Model WA500-6

Category
Standard Value for
Item Measurement Conditions Unit Service Limit Value
New Machine

When brake 3.53 ±0.15 3.53 ±0.15

Parking released • Torque converter oil temperature: Within (511.98 ±21.76) (511.98 ±21.76)
MPa
brake inlet operating range
When brake (psi) Min. 0.14 Min. 0.14
pressure • Engine speed: Low idle (*1)
operated (Min. 20.31) (Min. 20.31)
Parking brake

• Tire inflation pressure: Specified

pressure
• Flat paved road with 1/5 (11° 20') grade.
Performance Dry, paved road surface — Holds in position Holds in position
• Machine at operating condition
• For measuring posture, see Figs. D and
E at end of this section.
mm 3.2 ±0.1 2.77
Disc thickness
(in) (0.13 ±0.004) (0.109)
Work equipment EPC

• Hydraulic oil temperature: Within 3.72 (+0.2 ) 3.72 (+0.2 )

EPC valve basic pressure 0 -0.2
operating range
(Orbit-roll basic pressure) (539.54 (+29.01)) (539.54 (+29.01
• Engine speed: High idle 0 -29.01))
MPa
Lift arm RAISE, • Hydraulic oil temperature: Within (psi)
EPC valve 3.72 (+0.2 ) 3.72 (+0.2 )
FLOAT; Bucket operating range 0 -0.2
output
DUMP, TILT, Lift • Engine speed: High idle (539.54 (+29.01)) (539.54 (+29.01
pressure 0 -29.01))
arm LOWER • Control lever operated fully

Work equipment relief

• Hydraulic oil temperature: Within 33.3 (+1.47
-0.49
) 33.3 (+1.47
-0.49
)
operating range
pressure (4829.76 (+213.21 )) (4829.76 (+213.21 ))
• Engine speed: High idle -71.07 -71.07

• Hydraulic oil temperature: Within

operating range 2.26 ±0.1 2.26 ±0.2
Unload pressure MPa
• Engine speed: High idle (327.79 ±14.50) (327.79 ±14.50)
(psi)}
• Work equipment control lever: Neutral

• Hydraulic oil temperature: Within

operating range 1.37 ±0.1 1.37 ±0.2
LS differential pressure
• Engine speed: High idle (198.70 ±14.50) (198.70 ±29.01)
Work equipment

• Lift arm lever: at half stroke

• Hydraulic oil temperature: P-mode 7.2 ±0.5 Max. 8.9

Lift arm RAISE Within operating range
E-mode 8.1 ±0.5 Max. 9.7
• Engine speed: High idle
• Apply no load
Work equipment speed

P-mode 4.2 ±0.5 Max. 5.4

• For measuring posture, see
Lift arm LOWER
Figs. F and G at end of this E-mode 4.2 ±0.5 Max. 5.4
section.
sec.
Bucket full • Hydraulic oil temperature: P-mode 2.5 ±0.3 Max. 3.4
stroke Within operating range
• Engine speed: High idle E-mode 2.7 ±0.3 Max. 3.5
Bucket
• Apply no load P-mode 1.8 ±0.3 Max. 2.6
tilt back Moving bucket
• For measuring posture, see
from level Figs. H and J at end of this
position E-mode 1.9 ±0.3 Max. 2.7
section.

20-8 ➁ WA500-6
STANDARD VALUE TABLES STANDARD VALUE TABLES

Machine Model WA500-6

Category
Standard Value for
Item Measurement Conditions Unit Service Limit Value
New Machine

Retraction of lift arm • Hydraulic oil temperature: Within Max. 40 Max. 40

cylinder rod operating range (Max. 1.57) (Max. 1.57)
Hydraulic drift

• Stop engine and leave for 5 minutes,

then measure for 15 minutes. mm
Work equipment

Retraction of bucket • Apply no load to bucket and set lift arm (in) Max. 20 Max. 20
cylinder rod and bucket in level position. (Max. 0.79) (Max. 0.79)
• For measuring posture, see Fig. K at
end of this section.
Proximity switch

Clearance of bucket
mm 3–5
positioner proximity —
(in) (0.12 – 0.20)
switch

• Engine speed: High idle

• Engine coolant temperature:
Min. 95°C (Min. 203°F)
Max. fan speed • Hydraulic oil temperature: 1,055 ±50 1,055 ±100
Min. 95°C (Min. 203°F)
• Torque converter oil temperature:
Min. 105°C (Min. 221°F)
• Engine speed: Low idle (*1) rpm
• Engine coolant temperature:
Max. 75°C (Max. 167°F)
• Hydraulic oil temperature:
Min. fan speed 170 ±30 170 ±50
Max. 75°C (Max. 167°F)
Hydraulic drive fan

• Torque converter oil temperature:

Max. 85°C (Max. 185°F)
• Air conditioner OFF

• Engine speed: High idle

• Engine coolant temperature:
Min. 95°C (Min. 203°F)
17.7 ±2.5 17.7 ±2.5
Fan drive pressure • Hydraulic oil temperature:
(2567.17 ±362.59) (2567.17 ±362.59)
Min. 95°C (Min. 203°F)
• Torque converter oil temperature:
Min. 105°C (Min. 221°F) MPa
• Engine speed: High idle (psi)
• Engine coolant temperature:
Min. 95°C (Min. 203°F)
Fan reverse solenoid output 19.6 ±2.5 19.6 ±2.5
• Hydraulic oil temperature:
pressure (2842.74 ±362.59) (2842.74 ±362.59)
Min. 95°C (Min. 203°F)
• Torque converter oil temperature:
Min. 105°C (Min. 221°F)

★ *1: Denotes the low idle speed when the engine speed is decreased to the minimum speed with the RPM idle-up/down
selector switch.

★ *2: The value before the detent

WA500-6 20-9 ➁
STANDARD VALUE TABLES MACHINE POSTURE

MACHINE POSTURE
(for performance measurment)

★ Fig. A ★ Fig. D

★ Fig. B ★ Fig. E

★ Fig. C ★ Fig. F

20-10 ➁ WA500-6
STANDARD VALUE TABLES MACHINE POSTURE

★ Fig. G ★ Fig. K

★ Fig. H

★ Fig. J

WA500-6 20-11 ➁
STANDARD VALUE TABLES MACHINE POSTURE

MEMORANDUM

20-12 ➁ WA500-6
 30 TESTING AND ADJUSTING

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Tools for Testing, Adjusting, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
Measuring Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
Measuring Exhaust Gas Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
Using Handy Smoke Checker (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
Using Smoke Meter (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
Measuring Exhaust Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
Adjusting Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Testing Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Measuring Blow-By Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Measuring Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
Measuring Intake Air (Boost) Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
Handling Fuel System Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
Releasing Residual Pressure in Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
Testing Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
Testing Fuel Return Rate and Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
Bleeding Air from Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
Testing Leakage in Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Handling Reduced-Cylinder Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
Handling No-Injection Cranking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
Handling Controller Voltage Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
Alternator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
Air Conditioner Compressor Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
TRANSMISSION SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
DIRECTIONAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
POWER TRAIN OIL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
Transmission Main Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
Torque Converter Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
Torque Converter Outlet Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
Lockup Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
F (Forward) Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
R (Reverse) Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
1st Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
2nd Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
3rd Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
4th Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49

WA500-6 30-1 ➁
TESTING AND ADJUSTING TABLE OF CONTENTS

Lubrication Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
Transmission Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
Torque Converter Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
FLUSHING TRANSMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
Torque Converter and Transmission Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
WHEN TRANSMISSION VALVE FAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
Moving Machine when Transmission Valve is Broken . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
Steering Stop Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-59
Measuring Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-59
Measuring Operating Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
Measuring Operating Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
Steering Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
Measuring Steering Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
Measuring Pilot Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
Measuring LS Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
Adjusting Steering Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
Bleeding Air From Steering Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-67
HYDRAULIC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68
Measuring Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
Measuring Fan Drive Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
Measuring Fan Reverse Solenoid Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71
Bleeding Air from Hydraulic Drive Fan Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
Measuring Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
Measuring Brake Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
Accumulator Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
Testing Wheel Brake Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
Measuring Wear of Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
Bleeding Air from Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83
Bleeding Air from Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83
Bleeding Air from Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
Releasing Residual Pressure in Brake Accumulator Circuit . . . . . . . . . . . . . . . . . . . . . 30-85
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
Testing Parking Brake Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
Measuring Parking Brake Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87
Testing Wear of Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
Releasing Parking Brake Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
Measuring Operating Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
Measuring Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
PPC Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
Shutoff Valve Basic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
Shutoff Valve Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96

30-2 ➁ WA500-6
TESTING AND ADJUSTING TABLE OF CONTENTS

Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97

Preparation Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
Measuring Work Equipment Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
Measuring Unload Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
Measuring LS Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
Adjusting Unload Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
Adjusting Work Equipment Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
Adjusting LS Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103
Bleeding Air from Work Equipment Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
From Work Equipment Pump (piston pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
From Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
Releasing Residual Pressure in Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
Between Respective Hydraulic Cylinders and Control Valve . . . . . . . . . . . . . . . . . 30-105
From ECSS (Travel Damper) Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
Moving Machine When Removing Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
Bucket Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
Testing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
Adjusting Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
Adjusting Bucket-Levelness Detecting Proximity Switch . . . . . . . . . . . . . . . . . . . 30-108
Adjusting Maximum Tilt-Detecting Proximity Switch . . . . . . . . . . . . . . . . . . . . . . 30-109
Position-Detecting Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
Checking Proximity Switch Operation Pilot Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111
ELECTRICAL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
Procedure for Testing Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
Using Digital-Type Circuit Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
Using Analog-Type Circuit Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
Preparation Work for Troubleshooting Electrical System . . . . . . . . . . . . . . . . . . . . . . . 30-114
Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
Transmission Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
Work Equipment Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
KOMTRAX Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
KOMTRAX TERMINAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
Starting KOMTRAX Terminal Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
Station Opening Check in Machine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
Application for the Start of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121
KOMTRAX Terminal Indicator Lamps (if equipped) . . . . . . . . . . . . . . . . . . . . . . 30-122
MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
Adjusting Replaced, Reassembled, or Added Sensor, Controller, Etc. . . . . . . . . . . . . . 30-125
Items to Be Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
Adjustment for User’s Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-126
Normal and Special Functions of Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
Normal Functions: Operator Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
Special Functions: Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
Functions and Flow of Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
Operator Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-131
Service Meter/Clock Display Function (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-131
Load Meter Function (if equipped) (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-131
Odometer Display Function (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-131
Maintenance Monitoring Function (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132

WA500-6 30-3 ➁
TESTING AND ADJUSTING TABLE OF CONTENTS

Telephone Number Input Function (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132

Language Selection Function (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
Monitor Brightness Adjustment Function (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
Time Adjustment Function (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
Travel Speed/Engine Speed Display Selecting Function (9) . . . . . . . . . . . . . . . . . . 30-133
Travel Speed/Engine Speed Display/Non-Display Selecting Function (10) . . . . . . 30-134
Action Code Display Function (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134
Failure Code Display Function (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
Switching to Service Mode and Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
Electrical System Failure History Display Function (ELECTRIC FAULT) (2) . . . 30-138
Mechanical System Failure History Display Function (MACHINE FAULT) (3) . 30-140
Real-Time Monitoring Function (REAL-TIME MONITOR) (4) . . . . . . . . . . . . . . 30-141
Real-Time Monitoring Codes Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-144
Cylinder Cutout Function (CYLINDER CUT-OUT) (5) . . . . . . . . . . . . . . . . . . . . 30-169
No-Injection Cranking Function (NO INJECTION) (6) . . . . . . . . . . . . . . . . . . . . . 30-170
Adjustment Function (TUNING) (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-171
Maintenance Monitoring Function (MAINTENANCE MONITOR) (8) . . . . . . . . 30-202
Operating Information Display Function (OPERATION INFO) (9) . . . . . . . . . . . 30-208
Optional Device Selecting Function (OPTIONAL SELECT) (10) . . . . . . . . . . . . . 30-211
Machine Serial Number Input Function (MACHINE No. SET) (11) . . . . . . . . . . . 30-215
Model Selection Function (MACHINE WA500) (12) . . . . . . . . . . . . . . . . . . . . . . 30-216
Initialize Function (INITIALIZE) (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
PM CLINIC INSPECTION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219

30-4 ➁ WA500-6
TESTING AND ADJUSTING TOOLS

TOOLS
Tools for Testing, Adjusting, and Troubleshooting
Testing and
Symbol Part No. Part Name Qty Remarks
Adjusting Item
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Measuring exhaust gas
A Commercially
color 2 Smoke meter 1
available
Measuring exhaust
B 799-101-1502 Digital thermometer 1 -99.9 – 1,299 °C
temperature
Adjusting valve Commercially
C Clearance gauge 1
clearance available
1 795-502-1590 Compression gauge 1 0 – 7 MPa (0 – 1,015.26 psi)
Testing compression
D 795-471-1330 Adapter 1
pressure 2
6261-71-6150 Gasket 1
Measuring blow-by
E 799-201-1504 Blow-by checker 1 0 – 5 kPa (0 – 0.73 psi)
pressure
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.59, 870.23,
Measuring engine oil 1 5,801.51, 8,702.26 psi)
F
pressure Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa (8,702.26 psi)
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa (145.04 psi)
Measuring intake air
G 799-201-2202 Boost gauge kit 1 -101 – 200 kPa (-14.65 – 29.01 psi)
(boost) pressure
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.59, 870.23,
1 5,801.51, 8,702.26 psi)
Testing fuel pressure H Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa (8,702.26 psi)
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa (145.04 psi)
3 795-471-1450 Adapter 1 8 × 1.25 mm → R1/8
1 6151-51-8490 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 φ5mm x 2 – 3 m
available
Testing return rate and Commercially
leakage
J 4 Hose 1 φ5mm x 2 – 3 m
available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring directional
lever (steering wheel K 79A-264-0021 Push-pull scale 1 0 – 294 N (0 – 66.09 lbf)
specification)

WA500-6 30-5 ➁
TESTING AND ADJUSTING TOOLS

Testing and
Symbol Part No. Part Name Qty Remarks
Adjusting Item
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.59, 870.23,
1 5,801.51, 8,702.26 psi)
Testing and adjusting Pressure gauge:
L 790-261-1204 Digital hydraulic tester 1
power train oil pressure 60 MPa (8,702.26 psi)
799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1 Pressure gauge: 1 MPa (145.04 psi)
Method of moving
machine when M 794-423-1190 Plug 1 20 x 1.5 mm
transmission is broken
Testing and adjusting
N 79A-264-0021 Push-pull scale 1 0 – 294 N (0 – 66.09 lbf)
steering wheel
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.59, 870.23,
1 5,801.51, 8,702.26 psi)
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
Testing steering oil 60 MPa (8,702.26 psi)
Q
pressure 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3200 Adapter 1 Size 03
4 799-401-2701 Differential pressure gauge 1
1 799-205-1100 Tachometer kit 1 Digital display: 6 – 99999.9 rpm
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.59, 870.23,
2 5,801.51, 8,702.26 psi)
Testing hydraulic drive Pressure gauge:
R 790-261-1204 Digital hydraulic tester 1
fan 60 MPa (8,702.26 psi)
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
3
07002-11023 O-ring 1
4 799-401-3500 Adapter 1 Size 06
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.60, 870.23,
1 5,801.51, 8,702.26 psi)
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
Bleeding air from 60 MPa (8,702.26 psi)
S
hydraulic drive fan circuit 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3500 Adapter 1 Size 06
4 790-261-1130 Coupling 1
Pressure gauge:
Testing and adjusting 799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.59, 870.23,
accumulator charge T 5,801.51, 8,702.26 psi)
pressure Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa (8,702.26 psi)
1 793-520-1821 Nipplet 1
Testing wheel brake oil 2 793-520-1810 Joint 1
U
pressure 3 385-10178481 Bleeder screw 1
4 793-520-18310 Gauge assembly 1 G1/4 → R1/8

30-6 ➁ WA500-6
TESTING AND ADJUSTING TOOLS

Testing and
Symbol Part No. Part Name Qty Remarks
Adjusting Item
Measuring wear of wheel Commercially
V Slide calipers 1
brake disc available
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.59, 870.23,
1 5,801.51, 8,702.26 psi)

Measuring parking brake Pressure gauge:

W 790-261-1204 Digital hydraulic tester 1
oil pressure 60 MPa (8,702.26 psi)
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3100 Adapter 1 Size 02
Testing wear of parking Commercially
X Slide calipers 1
brake disc available
1 79A-264-0021 Push-pull scale 1
Measuring and adjusting
Y Commercially
work equipment lever 2 Scale 1
available
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.59, 870.23,
Testing and adjusting 1 5,801.51, 8,702.26 psi)
work equipment PPC oil Z
Pressure gauge:
pressure 790-261-1204 Digital hydraulic tester 1
60 MPa (8,702.26 psi)
2 799-401-3200 Adapter 1 Size 03
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa (362.59, 870.23,
1 5,801.51, 8,702.26 psi)
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
Measuring work 60 MPa (8,702.26 psi)
ZA
equipment oil pressure 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-2701 Differential pressure gauge 1
4 799-401-3200 Adapter 1 Size 03
Measuring coolant and
— 799-101-1502 Digital thermometer 1
oil temperature
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294 N (66.09 lbf)
—
effort and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N (110.16 lbf)
Measuring stroke and Commercially
— Scale 1
hydraulic lift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Circuit tester ‘
resistance available

★ For the model names and part Nos. of the T-adapters and boxes used for troubleshooting of the controllers, sensors,
actuators, and wiring harnesses, see T-Branch Box and T-Branch Adapter Table in the Troubleshooting section.

WA500-6 30-7 ➁
TESTING AND ADJUSTING ENGINE COMPONENTS

ENGINE COMPONENTS
Remark
See the Engine Shop Manual for additional information regarding testing and adjusting procedures.

Measuring Engine Speed

WARNING! Put chocks securely under the tires.

Make sure that there is nobody near the machine.

★ Measure the engine speed under the following conditions.

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
Torque converter oil temperature:. . . . . . . . .Within operating range

1. Measure engine speed (low idle and high idle).

A. Refer to Machine Monitor System in this section and select the

Real-Time Monitoring function of the Service mode.

B. Select and display “ENG SPEED” from the monitoring items

of the machine monitor.
★ Monitoring item:
Code No. 01001: ENG SPEED (Engine speed)

C. Start the engine; set it to the measurement condition; and

measure the engine speed.

2. Measure torque converter stall speed.

A. Refer to Machine Monitor System in this section and select the

Real-Time Monitoring function of the Service mode.

B. Select the two-item simultaneous monitoring (2 ITEMS) and

enter the following code numbers directly.
★ Monitoring items:
[1] Code No. 01001: ENG SPEED (Engine speed)
[2] Code No. 40100: TC OIL TEMP
(Torque converter oil temperature)

C. Start the engine.

D. Turn off the transmission cutoff switch and press the left brake pedal securely.

E. Set the transmission auto-shift and manual shift selector switch in the MANUAL position.

F. Set the gear shift lever or gear shift switch to the 4th speed while keeping the directional lever, joystick steering
directional switch, or right directional switch at the N (Neutral) position.

G. Release the parking brake.

30-8 ➁ WA500-6
TESTING AND ADJUSTING ENGINE COMPONENTS
H. While pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional
switch to the F (forward) or R (reverse) position.

WARNING! Keep pressing the brake pedal securely.

I. While running the engine at high idle, press the accelerator pedal gradually. When the torque converter stalls,
measure the engine speed.
• Measure the stall speed two to three times.
• Do not stall the torque converter for more than 20 seconds. Be careful that the torque converter oil temperature
does not exceed 120°C (248°F).
• Measure the torque converter stall speed when the power mode and economy mode are turned on.

3. Measure hydraulic stall speed.

A. Refer to Machine Monitor System in this section and select the

Real-Time Monitoring function of the Service mode.

B. Select the two-item simultaneous monitoring (2 ITEMS) and

then enter the following code numbers directly.
★ Monitoring items:
[1] Code No. 01001: ENG SPEED (Engine speed)
[2] Code No. 04401: HYD TEMP
(Hydraulic oil temperature)

C. Run the engine at high idle.

D. Relieve the lift arm cylinder or bucket cylinder on the

extraction side and measure the engine speed.
• Measure the hydraulic stall speed when the power mode and economy mode are turned on.

4. Measure torque converter stall and hydraulic stall (full stall) speed.

A. Refer to Machine Monitor System in this section and select the

Real-Time Monitoring function of the Service mode.

B. Select the two-item simultaneous monitoring (2 ITEMS) and

then enter the following code numbers directly.
★ Monitoring items:
[1] Code No. 01001: ENG SPEED (Engine speed)
[2] Code No. 40100: TC OIL TEMP
(Torque converter oil temperature)

C. Start the engine.

D. Turn off the transmission cutoff switch and press the left brake
pedal securely.

E. Set the transmission auto-shift and manual shift selector switch in the MANUAL position.

F. Set the gear shift lever to the 4th speed while keeping the directional lever, joystick steering directional switch, or
right directional switch at the N (Neutral) position.

G. Release the parking brake.

WA500-6 30-9 ➁
TESTING AND ADJUSTING ENGINE COMPONENTS
H. While pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional
switch to the F (forward) or R (reverse) position.

WARNING! Keep pressing the brake pedal securely

I. While running the engine at high idle, stall the torque converter and relieve the lift arm cylinder or bucket cylinder on
the extraction side simultaneously. Measure the engine speed at this time.
• Do not stall the torque converter for more than 20 seconds. Be careful that the torque converter oil temperature
does not exceed 120°C (248°F).
• Measure the full stall speed when the power mode and economy mode are turned on.

30-10 ➁ WA500-6
TESTING AND ADJUSTING ENGINE COMPONENTS

Measuring Exhaust Gas Color

Special Tools Required

Symbol Part No. Part Name

1 799-201-9001 Handy smoke checker
A
2 Commercially available Smoke meter

WARNING! When installing and removing the measurement instruments,

be careful that you do not touch a hot part of the engine.

★ 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).

★ Measure the exhaust gas color under the following condition.

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Using Handy Smoke Checker (A1)

1. Stick a sheet of filter paper to smoke checker (A1).

2. Insert the exhaust gas intake pipe in the muffler (exhaust pipe).

3. Start the engine and raise the engine coolant temperature to the
operating range.

4. Accelerate the engine suddenly and run it at high idle. Operate the
handle of smoke checker (A1) so that the filter paper absorbs the
exhaust gas.

5. Remove the filter paper and compare it with the attached scale to
obtain a value.

6. Remove the measurement tool after completing the measurement

and confirm that the machine is back to normal condition.

Using Smoke Meter (A2)

1. Insert the probe of smoke meter (A2) in the outlet of the muffler
(exhaust pipe) and use a clip to attach the probe to the exhaust
pipe.

2. Connect the probe hose, accelerator switch receptacle, and air hose
to smoke meter (A2).
• Keep the pressure of the supplied compressed air at 1.5 MPa
(217.56 psi) or lower.

3. Connect the power cable to a 100 V AC receptacle.

• Confirm that the smoke meter power switch is in the OFF
position before connecting the power cable to an outlet.

WA500-6 30-11 ➁
TESTING AND ADJUSTING ENGINE COMPONENTS
4. Loosen the cap nut of the suction pump and fit the filter paper.
• Fit the filter paper securely so that the exhaust gas does not
leak.

5. Turn on the power switch of smoke meter (A2).

6. Start the engine and keep it running until the engine coolant
temperature reaches the operating range.

7. Accelerate the engine suddenly or run it at high idle and press the
accelerator pedal of smoke meter (A2). Collect the exhaust gas in
the filter paper.

8. Put the polluted filter paper on non-polluted filter paper (more than
ten sheets) in the filter paper holder and read the indicated value.

9. After completing the work, remove the measurement tool and confirm that the machine is back to normal condition.

30-12 ➁ WA500-6
TESTING AND ADJUSTING ENGINE COMPONENTS

Measuring Exhaust Temperature

Special Tools Required

Symbol Part No. Part Name

B 799-101-1502 Digital thermometer

WARNING! Install and remove the measurement instruments after the

exhaust manifold is cooled.

★ Measure the exhaust gas temperature under the following conditions.

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
Torque converter oil temperature:. . . . . . . . .Within operating range

1. Open the engine left side cover.

2. Remove exhaust temperature pickup plug (1) (R1/8) at the bottom

of the exhaust manifold.
★ You may measure at either front or rear plug.

3. Install sensor [1] of digital thermometer (B) and connect them to

meter [2].
★ Be careful that the wiring harness of the digital thermometer
does not touch a hot part during measurement.

4. Procedure for periodic measurement done in preventive

maintenance
★ To prevent the torque converter from overheating, increase the
exhaust temperature once through full-stall operation (torque
converter stall + hydraulic stall), and then measure the exhaust
temperature while only the torque converter is stalled.

A. Start the engine and raise the coolant temperature to the

operating range.

B. Turn off the transmission cutoff switch and press the left brake
pedal securely.

C. Set the transmission auto-shift and manual shift selector

switch in the MANUAL position.

D. Set the gear shift lever or gear shift switch to the 4th speed
while keeping the directional lever, joystick steering
directional switch, or right directional switch at the N
(Neutral) position.

WA500-6 30-13 ➁
TESTING AND ADJUSTING ENGINE COMPONENTS
E. Release the parking brake.

F. While pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional
switch to the F (forward) or R (reverse) position.

WARNING! Keep pressing the brake pedal securely.

G. Press the accelerator pedal gradually to the high idle. While running the engine at high idle, stall the torque converter
and relieve the lift arm cylinder or bucket cylinder on the extraction side simultaneously (full stall).
• Increase the exhaust temperature to about 650°C (1202°F) (the state of (a) in the figure).
• Do not stall the torque converter for more than 20 seconds. Be careful that the torque converter oil temperature
does not exceed 120°C (248°F).

H. As the exhaust temperature reaches about 650°C (1202°F),

release the hydraulic relief and then lower the exhaust
temperature by stalling only the torque converter (the state of
(b) in the figure).
★ The exhaust temperature starts lowering from the level of
the full-stall operation.
• Measure the exhaust temperature as it stabilizes (the state
of (c) in the figure).
• If the exhaust temperature rises instead of going down,
set a higher full-stall temperature than the current one
(650°C {1202°F}).

5. Procedure for measuring the maximum exhaust temperature

A. Operate the machine and measure the maximum exhaust temperature.

★ Use the PEAK mode of the thermometer (in which the maximum value can be saved).
★ The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine).
• If any abnormal value is obtained, correct it by using the following calculation:
Corrected value [°C] = Measured value + 2 x (20 – Outside air temperature)

6. After completing the work, remove the measurement tool and confirm that the machine is back to normal condition.

30-14 ➁ WA500-6
TESTING AND ADJUSTING ENGINE COMPONENTS

Adjusting Valve Clearance

Special Tools Required

Symbol Part No. Part Name

C Commercially available Clearance gauge

1. Remove six cylinder head covers (1). For details, see Engine and
Cooling System: Cylinder Head Assembly in the Disassembly and
Assembly section.
★ The shape of the engine shown in this photo is not identical
with that of the SAA6D140E-5 engine installed in the
WA500-6.

2. Rotate the crankshaft forward to bring the stamped “1.6TOP”

line (a) of the damper to pointer (2) and set the No. 1 cylinder to
the compression top dead center.

A. Rotate the crankshaft with the hexagonal part at the end of the
water pump drive shaft.

B. When the No. 1 cylinder is at the compression top dead center,

you can use your hand to move the rocker arm of the No. 1
cylinder by the valve clearance. If the rocker arm cannot be
moved, rotate the crankshaft one more turn.

3. While fixing adjustment screw (3), loosen locknut (4).

• After setting the No. 1 cylinder to the compression top dead
center, adjust the valve clearance of the No. 1 cylinder.

4. Insert clearance gauge (C) in the clearance between rocker arm (5)
and crosshead (6). Adjust the valve clearance with adjustment
screw (3).

A. With the clearance gauge inserted, turn the adjustment screw

so that a light force is sufficient to move the clearance gauge.
★ Valve clearance:
Intake valve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm
Exhaust valve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.57 mm

5. While fixing adjustment screw (3), tighten locknut (4).

Locknut: 45.1 – 51.0 N•m (33.26 – 37.62 lbf ft)

★ After tightening the locknut, check the valve clearance again.

WA500-6 30-15 ➁
TESTING AND ADJUSTING ENGINE COMPONENTS
6. After adjusting the No. 1 cylinder, rotate the crankshaft forward by 120° and adjust the clearance of each cylinder
according to the firing order.
★ Firing order: 1 – 5 – 3 – 6 – 2 – 4

7. After finishing the adjustment, return the parts you removed.

Cylinder head cover mounting bolt: 29.4 – 34.3 N•m (21.68 – 25.30 lbf ft)

30-16 ➁ WA500-6
TESTING AND ADJUSTING ENGINE COMPONENTS

Testing Compression Pressure

Special Tools Required

Symbol Part No. Part Name

1 795-502-1590 Compression gauge
D 795-471-1330 Adapter
2
6261-71-6150 Gasket

WARNING! When measuring the compression pressure,

be careful not to burn yourself on the exhaust
manifold or muffler.

Be careful not to get caught in a rotating part.

★ Measure the compression pressure after the engine is warmed up.

Engine oil temperature: . . . . . . . . . . . . . . 40 – 60°C (104 – 140°F)

1. Remove cylinder head cover (1) of the cylinder whose

compression pressure you want to check. For details, see Engine
and Cooling System: Cylinder Head Assembly in the Disassembly
and Assembly section.
★ The shape of the engine shown in this photo is not identical
with that of the SAA6D140E-5 engine installed on WA500-6.

2. Set the target cylinder to be inspected to the compression top dead

center and then remove rocker arm assembly (2).
★ See Adjusting Valve Clearance in this section.

3. Disconnect fuel high-pressure tube (3) and the injector wiring

harness and remove injector (4).
• Disconnect the terminal of the injector wiring harness on the
injector side and the bracket on the rocker housing side and
remove the injector wiring harness from the injector.
• Loosen the two terminal nuts alternately.
• Pass a wire, etc. under the fuel path projected sideways and
pull up the injector.
• Do not pry up the injector top.

4. Install adapter (D2) to the mounting hole on the injector and

compression gauge (D1).
• Fit the gasket to the injector end.
• Fix the adapter with the injector holder.

Holder mounting bolt: 58.8 – 73.5 N•m (43.37 – 54.21 lbf ft)

★ Apply a small amount of engine oil to the connecting parts of

the adapter and gauge so that air does not leak easily.

WA500-6 30-17 ➁
TESTING AND ADJUSTING ENGINE COMPONENTS
5. Install rocker arm assembly (2) and adjust the valve clearance.

Rocker arm assembly mounting bolt: 93 – 103 N•m (68.59 – 75.97 lbf ft)

★ See Adjusting Valve Clearance in this section.

6. Set the mode to the no-injection cranking operation. See Machine Monitor System: Service Mode: No-Injection Cranking
Function in this section.

WARNING! Be sure to set the no-injection cranking mode,

otherwise the engine may start and create a
dangerous condition.

7. Rotate the engine cranking with the starting motor and measure the compression pressure.
• Read the pressure gauge pointer when it is stabilized.

8. After finishing testing, remove the testing tools and return the parts you removed.

A. Install the injector and fuel high-pressure tube according to the following procedure.
• Use your hand to push in injector (11) to assemble
holder (12) temporarily.
• Tighten bolt (13) and washer (14) temporarily.
• Spherical portion of washer: Engine oil
• Tighten sleeve nut (15) of the fuel high-pressure tube
temporarily.
• Tighten bolt (13) permanently.

Bolt: 58.8 – 73.5 N•m (43.37 – 54.21 lbf ft)

• Tighten sleeve nut (15) permanently.

Sleeve nut: 39.2 – 49.0 N•m (28.91 – 36.14 lbf ft)

B. Install the injector wiring harness according to the following procedure.

• Install the injector wiring harness to the rocker arm housing and fix the connector side with the plate.
• Fix the clamp in the intermediate position with the clip.
• Tighten the nut on the injector side.

Nut: 2 ±0.2 N•m (17.70 ±1.77 lbf in)

• Secure the clamp and spacer with the bolt.

Rocker arm assembly mounting bolt: 93 – 103 N•m (68.59 – 75.97 lbf ft)

C. Adjust the valve clearance. See Adjusting Valve Clearance in this section.

Cylinder head cover mounting bolt: 29.4 – 34.3 N•m (21.68 – 25.30 lbf ft)

30-18 ➁ WA500-6
TESTING AND ADJUSTING ENGINE COMPONENTS

Measuring Blow-By Pressure

Special Tools Required

Symbol Part No. Part Name

E 799-201-1504 Blow-by checker

★ Measure the blow-by pressure under the following conditions.

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
Torque converter oil temperature: . . . . . . . .Within operating range

1. Stop the engine. Install nozzle [1] and hose [2] of blow-by
checker (E) to blow-by hose (1) and connect them to gauge [3].

2. Start the engine and increase the engine coolant temperature to the
operating range.

3. Drain oil in the hose while running the engine at medium speed or
higher.
• Insert approximately half of the gauge and hose connection to
the hose and then repeat opening the self-seal of the hose to
drain the oil.
★ If Pm kit (A) is available, the air bleeding coupling (790-261-
1130) in it may be used.
★ If oil is left in the hose, the gauge does not work. Be sure to
drain the oil.

4. Turn off the transmission cutoff switch and press the left brake
pedal securely.

5. Set the transmission auto-shift and manual shift selector switch in

the MANUAL position.

6. Set the gear shift lever or gear shift switch to the 4th speed while
keeping the directional lever, joystick steering directional switch,
or right directional switch at the N (Neutral) position.

7. Release the parking brake.

8. While pressing the brake pedal, set the directional lever, joystick
steering directional switch, or right directional switch to the F
(forward) or R (reverse) position.

WARNING! Keep pressing the brake securely.

WA500-6 30-19 ➁
TESTING AND ADJUSTING ENGINE COMPONENTS
9. Press the accelerator pedal gradually to the high idle. While running the engine at high idle, stall the torque converter and
measure the blow-by pressure.
★ Do not stall the torque converter for more than 20 seconds. Be careful that the torque converter oil temperature does
not exceed 120°C (248°F).
★ Normally the blow-by pressure should be measured while the engine is operated at the rated output. In the field,
however, an approximate value can be obtained by stalling the torque converter.
★ If it is impossible to run the engine at the rated output or stall the torque converter, measure while the engine is
running at high idle. The value obtained in this case is about 80% of the blow-by pressure at the rated output.
★ Precaution for measuring blow-by pressure:
The blow-by pressure may vary depending on the condition of the engine. If you determine that the measured value is
abnormal, check for increase of oil consumption, bad exhaust gas color, deterioration of oil, high deterioration speed
of oil, etc. which are related to the abnormal blow-by pressure.

10. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal
condition.

30-20 ➁ WA500-6
TESTING AND ADJUSTING ENGINE COMPONENTS

Measuring Engine Oil Pressure

Special Tools Required

Symbol Part No. Part Name

799-101-5002 Hydraulic tester
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester (gauge)

★ Measure the engine oil pressure under the following condition.

Engine coolant temperature: . . . . . . . . . . . .Within operating range

1. Open the engine right side cover.

2. Remove engine oil pressure pickup plug (1) (R1/4) on the cylinder
block.

3. Install nipples [1] and [2] of hydraulic tester (F1) and connect
them to hydraulic tester (F2).
★ Quick nipple (799-101-5210) is usable since the plug hole size
is R1/4.

4. Start the engine and raise the coolant temperature to the operating
range.

5. While running the engine at low or high idle speed, measure the
engine oil pressure.

6. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

Oil pressure pickup plug: 45 – 49 N•m (33.19 – 36.14 lbf ft)

WA500-6 30-21 ➁
TESTING AND ADJUSTING ENGINE COMPONENTS

Measuring Intake Air (Boost) Pressure

Special Tools Required

Symbol Part No. Part Name

G 2 799-201-2202 Boost gauge kit

WARNING! When installing and removing the

measurement instruments, be careful that you
do not touch a hot part of the engine.

★ Measure the intake air pressure (boost pressure) under the following conditions.

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
Torque converter oil temperature: . . . . . . . .Within operating range

1. Remove radiator top cover (1).

2. Remove cover (2) between the engine and cooling.

3. Remove exhaust temperature pickup plug (3) (R1/8) in the rear

side of the air intake manifold.

30-22 ➁ WA500-6
TESTING AND ADJUSTING ENGINE COMPONENTS
4. Install nipple [1] in boost gauge kit (G) and connect pressure
gauge [2].

5. Start the engine.

6. Turn off the transmission cutoff switch and press the left brake
pedal securely.

7. Set the transmission auto-shift and manual shift selector switch in

the MANUAL position.

8. Set the gear shift lever or gear shift switch to the 4th speed while
keeping the directional lever, joystick steering directional switch,
or right directional switch at the N (Neutral) position.

9. Release the parking brake.

10. While pressing the brake pedal, set the directional lever, joystick
steering directional switch, or right directional switch to the
F (forward) or R (reverse) position.

WARNING! Keep pressing the brake pedal securely.

11. Press the accelerator pedal gradually to the high idle. While
running the engine at high idle, stall the torque converter and
measure the intake air pressure (boost pressure).
★ Do not stall the torque converter for more than 20 seconds. Be
careful that the torque converter oil temperature does not
exceed 120°C (248°F).

12. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal
condition.

WA500-6 30-23 ➁
TESTING AND ADJUSTING FUEL SYSTEM

FUEL SYSTEM
Handling Fuel System Equipment
Precautions for Testing and Maintaining Fuel System

The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and
nozzle. If foreign matter enters this system, it can cause trouble.

When testing and maintaining the fuel system, be very careful. If dust, etc. sticks to any part, wash that part thoroughly with
clean fuel.

Precautions for Replacement of Fuel Filter Cartridge

You must use a genuine Komatsu fuel filter cartridge.

The fuel injection pump and nozzle of the common rail-type fuel injection system (CRI) consist of more precise parts than
those used for the current pumps and nozzles. This system uses a special filter with a highly efficient filtering performance to
prevent mixing of foreign substances. Substituting it with a non-genuine filter could cause trouble in the fuel system. It is
strictly prohibited to use a substitute part.

Releasing Residual Pressure in Fuel System

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.

Low-pressure circuit: . . . . . Feed pump – Fuel filter – Supply pump

High-pressure circuit: . . . . . Supply pump – Common rail – Injector
The pressure in both the low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after
the engine is stopped.

★ Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released
completely. Observe the following warning.

WARNING! Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the
engine until the residual pressure in the fuel circuit is released. Do not start the work immediately
after stopping the engine since there is residual pressure in the fuel circuit.

30-24 ➁ WA500-6
TESTING AND ADJUSTING FUEL SYSTEM

Testing Fuel Pressure

Special Tools Required

Symbol Part No. Part name

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
H
2 799-401-2320 Hydraulic tester
3 795-471-1450 Adapter

★ Test only the fuel pressure in the low-pressure circuit (between the feed pump, fuel filter, and supply pump).

WARNING! The pressure check is not available in the high pressure circuit between the supply pump, common
rail, and injector because extremely high pressure is generated there.

1. Open the engine right side cover.

2. Remove fuel pressure pickup plug (1) on the fuel filter head.

3. Install adapter (H3) and 90° elbow [1] and nipple [2] of hydraulic
tester (H1). Connect them to hydraulic tester (H2).

4. Run the engine at high idle and measure the fuel pressure.
★ If the fuel pressure is in the following range, it is normal.
Engine Speed Fuel Pressure
0.15 – 0.3 MPa
High idle
(21.76 – 43.51 psi)

5. After completing the test, remove the testing tools and return the
parts you removed.

WA500-6 30-25 ➁
TESTING AND ADJUSTING FUEL SYSTEM

Testing Fuel Return Rate and Leakage

★ Engine with intake manifold equipped with return block

Special Tools Required

Symbol Part No. Part Name

1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available

J Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available

★ Prepare a 20-liter pan to hold the fuel which flows out during inspection.

30-26 ➁ WA500-6
TESTING AND ADJUSTING FUEL SYSTEM
1. Preparation work

A. Open the engine right side cover.

B. Remove tube (3) between common rail (1) and supply

pump (2).

C. Insert spacer (J1) to supply pump (2) side and tighten the
currently removed joint bolt again.
• Connect the return pipe to the fuel tank again.
★ Be sure to provide a gasket for both ends of the spacer.

D. Insert joint (J2) to common rail (1) side and tighten the
removed joint bolt again.
★ Be sure to fit the gaskets to both ends of the joint.

E. Connect inspection hose (J3) to the tip of joint (J2).

• Bind the connecting part of the test hose with a wire, etc.
to prevent it from coming off.
★ This completes the preparations needed for testing the
leakage from the pressure limiter.

2. Testing leakage from pressure limiter

A. Lay test hose (J3) so that it will not slacken and put its end in
the oil pan.

B. Set the mode that allows confirmation of the engine speed.

Refer to Machine Monitor System in this section and select
Service Mode: Real-Time Monitoring Function.

C. Start the engine and keep its speed to 1,600 rpm with no load.

D. When the engine speed is stabilized, check the leakage

amount per minute with measuring cylinder (J5).
★ You may test for 20 seconds and judge by multiplying the
result by 3.
Engine Speed (rpm) Leakage (cc/min)
1,600 Max. 10

WA500-6 30-27 ➁
TESTING AND ADJUSTING FUEL SYSTEM
E. After finishing the test, stop the engine.

3. Testing return rate from injector

★ Keep the hose on the pressure limiter side connected and keep
its end in the oil pan while testing the return rate from the
injector.

A. Open the air cleaner inspection cover.

B. Disconnect return hose (5) of return block (4) and connect

inspection hose (J4) instead.
• Stop the return hose with a plug, etc. and fix it to the fuel
tank.
Plug: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07376-70315
• Bind the connecting part of the test hose with a wire, etc.
to prevent it from coming off.

C. Adjust the route of inspection hose (J4) to remove its sag and
insert the hose end into the oil pan (receiver).

D. Set the mode that allows confirmation of the engine speed.

Refer to Machine Monitor System in this section and select
Service Mode: Real-Time Monitoring Function.

E. Stall the torque converter while the engine is run at high idle.
As the engine speed is stabilized, measure the return rate per
minute with measuring cylinder (J5).
★ Refer to Measuring Engine Speed in this section for the
torque converter stalling procedure.

F. When the engine speed is stabilized, check the leakage

amount per minute with measuring cylinder (J5).
★ You may test for 20 seconds and judge by multiplying the
result by 3.
★ If the supply pump is not supplying fuel, the engine speed
may not rise. In this case, also record the engine speed
during the test.
★ If the return rate (spill) from the injector is in the
following range, it is normal.
Rated Output Speed Limit of Return Rate
(rpm) (spill) (cc/min)

1,600 960

1,700 1,020

1,800 1,080

1,900 1,140

2,000 1,200

G. After finishing the test, stop the engine.

4. Work after finishing the test

After completing the test, remove the testing tools and return the parts you removed.

30-28 ➁ WA500-6
TESTING AND ADJUSTING FUEL SYSTEM

Bleeding Air from Fuel Circuit

★ If you use all the fuel or remove and install a fuel circuit part, bleed air from the fuel circuit according to this procedure.

1. Open the engine right side cover.

2. Remove fuel prefilter (1) and then fill up the prefilter with fuel.
• Fill the fuel filter with clean fuel and be careful that dirt does
not get into the filter.
• Confirm that the cap is installed to portion (a) (center hole) of
the fuel prefilter and add fuel from portion (b) (peripheral
holes).
• After filling up the fuel prefilter, remove the cap in portion (a).
• If clean fuel is not available, do not remove the fuel prefilter
but fill it with the fuel by operating priming pump (4).
★ Do not add fuel to fuel main filter (2).

WA500-6 30-29 ➁
TESTING AND ADJUSTING FUEL SYSTEM
3. Install fuel prefilter (1) to the filter head.
• Coat the packing surface of the fuel prefilter side with a small
amount of engine oil.
• Tighten the packing surface of the fuel prefilter by 3/4 of a
turn after confirming that it is in contact against the sealing
surface of the filter head.

4. Remove air bleeding plug (3) on fuel main filter (2) and then
operate priming pump (4).
• Operate the priming pump until the fuel flows out of the plug
hole and install the plug.

Air bleeding plug: 7.8 – 9.8 N•m (69.04 – 86.74 lbf in)

5. Loosen air bleeding plug (5) on fuel main filter (2) and then
operate priming pump (4).
• Operate the priming pump until the fuel flows out of the plug
hole and install the plug.

Air bleeding plug: 7.8 – 9.8 N•m (69.04 – 86.74 lbf in)

6. Loosen air bleeder (6) of the fuel supply pump and operate priming pump (4) 90 – 100 times.
• Operate the priming pump until the fuel flows out of the air bleeder and tighten the air bleeder. Then operate the
priming pump several times more until it becomes heavy.

Air bleeder: 4.9 – 6.9 N•m (43.37 – 61.07 lbf in)

7. Start the engine cranking with the starting motor.

★ The air in the high-pressure circuit is bled automatically if the engine is cranked.
★ If the engine does not start, there may be air still in the low-pressure circuit. In this case, repeat this procedure from
Step 3.

30-30 ➁ WA500-6
TESTING AND ADJUSTING FUEL SYSTEM

Testing Leakage in Fuel System

WARNING! Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while
the engine is running, it can catch fire. This is dangerous.

After testing the fuel system or removing its parts, test it for fuel leakage according to the following
procedure

★ Clean and degrease the engine and the parts around it in advance so that you can test it easily 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 speeds below 1,000 rpm and stop it after its speed is stabilized.

3. Inspect the fuel piping and devices for fuel leakage.

★ Check for fuel leakage mainly around the high-pressure circuit parts coated with the color checker.
★ If you detect fuel leakage, repeat the procedure from Step 1 after repairing the leakage.

4. Run the engine at low idle.

5. Inspect the fuel piping and devices for fuel leakage.

★ Check for fuel leakage mainly around the high-pressure circuit parts coated with the color checker.
★ If you detect fuel leakage, repeat the procedure from Step 1 after repairing the leakage.

6. Run the engine at high idle.

7. Inspect the fuel piping and devices for fuel leakage.

★ Check for fuel leakage mainly around the high-pressure circuit parts coated with the color checker.
★ If you detect fuel leakage, repeat the procedure from Step 1 after repairing the leakage.

8. Run the engine at high idle and load it.

★ Stall the torque converter or relieve the hydraulic pump.
★ Refer to Measuring Engine Speed in this section.

9. Inspect the fuel piping and devices for fuel leakage.

★ Check for fuel leakage mainly around the high-pressure circuit parts coated with the color checker.
★ If you detect fuel leakage, repeat the procedure from Step 1 after repairing the leakage.

★ If no fuel leakage is detected, the check is completed.

WA500-6 30-31 ➁
TESTING AND ADJUSTING FUEL SYSTEM

Handling Reduced-Cylinder Mode Operation

★ Reduced-cylinder mode operation means to run the engine with the fuel injectors of one or more cylinders electrically
disabled in order to reduce the number of effective cylinders. The purposes and effects of this operation are described
below.

1. This operation is used to determine which cylinder does not output power normally (or combustion in the cylinder is
abnormal).

2. If a cylinder is selected for the reduced-cylinder mode operation and the engine speed and output do not change from the
normal operation (all-cylinder operation), that cylinder has one or more defects. The possible defects are:
• Leakage through cylinder head gasket
• Defective injection
• Defective piston, piston ring, or cylinder liner
• Defective valve mechanism (moving valve system)
• Defect in electrical system

3. Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform
the reduced-cylinder mode operation easily using switches to determine the defective cylinder.
★ The reduced-cylinder mode operation is set from the Service mode of the machine monitor.
For details, see Machine Monitor System: Service Mode: Engine Reduced-Cylinder Function in this section.

Handling No-Injection Cranking Operation

★ No-injection cranking means to crank the engine with the starting motor while all injections are stopped electrically.

• Use this method when a machine or engine has been stored for a long time. Implementing the no-injection cranking
before starting the engine lubricates the engine parts and prevents the engine from seizing.

★ The no-injection cranking operation is set from the Service mode of the machine monitor.
For details, see Machine Monitor System: Service Mode: No-Injection Cranking Function in this section.

Handling Controller Voltage Circuit

1. When plugging or unplugging a connector between the engine controller and engine, be sure to turn the starting switch
OFF.

2. If a T-adapter is inserted in (or connected to) a connector between the engine controller and engine for troubleshooting
purposes, do not start the engine.
★ You may turn the starting switch to the OFF or ON position but must not turn it to the START position.

30-32 ➁ WA500-6
TESTING AND ADJUSTING BELTS

BELTS
Alternator Belt Tension
This procedure describes how to test and adjust the alternator belt tension.

Testing

1. Open the engine right side cover.

2. Using a finger, press the belt at midpoint between the alternator

pulley and water pump pulley to check deflection (a).
Pressing force: . . . . . . . . . . . . . . . . . . . . . . . . Approx. 98 N (22 lbf)
Deflection (a): . . . . . . . . . . . . . . . . . . .13 – 16 mm (0.51 – 0.63 in)

Adjusting

★ If the deflection of the belt is abnormal, adjust it according to the following procedure.

1. Remove two mounting bolts and then remove belt cover (1).
★ Remove the belt cover only when the belt is replaced.

2. Loosen two mounting bolts (3) of alternator (2) as well as lock

bolt (4) of adjustment rod (5).

3. Loosen the locknut of adjustment rod (5); slide alternator (2) using
adjustment nut (6); then adjust the belt tension.

4. While fixing adjustment screw (6), tighten the locknut of

adjustment rod (5).

5. Tighten lock bolt (4) of adjustment rod (5) and two mounting
bolts (3) of alternator (2).

6. Using two mounting bolts, install belt cover (1).

★ Check for breakage of the pulleys, wear of the V-grooves, contact of V belts and V-grooves, and contact of the belt
covers and rotating parts.
★ The V belt must be replaced with a new one if it is stretched and its adjustment allowance is lost or when cuts or
cracks are observed on the belt.
★ Whenever a V belt is replaced, test and adjust it again after operating the machine for an hour.
★ After tightening the bolt, make sure that the belt tension is normal following this procedure.

7. Restore the original state after the testing and adjusting procedure.

WA500-6 30-33 ➁
TESTING AND ADJUSTING BELTS

Air Conditioner Compressor Belt Tension

This procedure describes how to test and adjust the air conditioner compressor belt tension.

Testing

1. Open the engine left side cover.

2. Using a finger, press the belt at midpoint between the supply pump
pulley and compressor pulley to check deflection (a).
Pressing force: . . . . . . . . . . . . . . . . . . . . . . . . Approx. 59 N (13 lbf)
Deflection (a): . . . . . . . . . . . . . . . . . . . . . . Approx. 10 mm (0.39 in)

Adjusting

★ If the deflection of the belt is abnormal, adjust it according to the

following procedure.

1. Loosen locknut (2); slide air conditioner compressor (4) along with
the bracket using adjustment nut (3); and then adjust tension of air
conditioner compressor belt (5).

2. While fixing adjustment screw (3), tighten locknut (2).

3. Tighten four mounting bolts (1) of the bracket.

★ Check for breakage of the pulleys, wear of the V-grooves, and
contact of the V belts and V-grooves.
★ The V belt must be replaced with a new one if it is stretched
and its adjustment allowance is lost or when cuts or cracks are
observed on the belt.
★ Whenever a V belt is replaced, test and adjust it again after
operating the machine for an hour.
★ After tightening the bolt, make sure that the belt tension is
normal following this procedure.

4. Restore the original state after the testing and adjusting procedure.

30-34 ➁ WA500-6
TESTING AND ADJUSTING TRANSMISSION SPEED SENSOR

TRANSMISSION SPEED SENSOR

Adjusting

1. Transmission input shaft speed sensor

A. Loosen locknut (2) of transmission input shaft speed sensor (1).

B. Screw in transmission input shaft speed sensor (1) until its tip
lightly contacts against the tooth tip of gear (3).
★ Before installing the sensor, check that its tip is free from
steel chips and flaws.

Threaded portion: Gasket sealant (LG-5)

C. From that position, return transmission input shaft speed

sensor (1) by 1/2 – 1 turn.
Clearance between speed sensor and gear:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.75 – 1.5 mm (0.03 – 0.06 in)

WA500-6 30-35 ➁
TESTING AND ADJUSTING TRANSMISSION SPEED SENSOR
D. Fix speed sensor (1) with locknut (2).

Locknut: 49.0 – 68.6 N•m (36.14 – 50.60 lbf ft)

2. Transmission output shaft speed sensor

A. Loosen locknut (5) of transmission output shaft speed

sensor (4).

B. Screw in transmission output shaft speed sensor (4) until its

tip lightly contacts against the tooth tip of gear (6).
★ Before installing the sensor, check that its tip is free from
steel chips and flaws.

Threaded portion: Gasket sealant (LG-5)

C. From that position, return transmission output shaft speed

sensor (4) by 1/2 – 1 turn.
Clearance between speed sensor and gear:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.75 – 1.5 mm (0.03 – 0.06 in)

D. Fix speed sensor (4) with locknut (5).

Locknut: 49.0 – 68.6 N•m (36.14 – 50.60 lbf ft)

30-36 ➁ WA500-6
TESTING AND ADJUSTING DIRECTIONAL LEVER

DIRECTIONAL LEVER
★ Steering wheel specification

Special Tools Required

Symbol Part No. Part Name

K 1 79A-264-0021 Push-pull scale

WARNING! Stop the machine on level ground; lower the

work equipment to the ground; and set chocks
securely under the tires.

Testing the Operating Effort

1. Stop the engine.

2. Install tool (K) or a spring balance to a point 10 mm (0.40 in) from

the control lever end and pull it in the operating direction to
measure the operating effort at that time.
• Measure the operating effort at each gear speed.
★ The shape of the lever shown in the photo is not identical with
that on WA500-6.

Testing the Stroke

1. Stop the engine.

2. Make mark (a) on the center of the control lever knob. Move the
knob in the operating direction and measure its stroke.
★ The shape of the lever shown in figure is not identical with
that on WA500-6.

WA500-6 30-37 ➁
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

POWER TRAIN OIL PRESSURES

30-38 ➁ WA500-6
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES
Special Tools Required

Symbol Part Number Part Name

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

★ Oil pressure measuring point and measuring gauge

Measuring
No. Measured oil pressure Gauge
MPa (psi)
1 Main relief pressure 6.0 (870.23)
2 Torque converter relief pressure 2.5 (362.59)
3 Torque converter outlet pressure 1.0 (145.04)
4 Lockup clutch pressure 6.0 (870.23)
5 Transmission F clutch pressure 6.0 (870.23)
6 Transmission R clutch pressure 6.0 (870.23)
7 Transmission 1st clutch pressure 6.0 (870.23)
8 Transmission 2nd clutch pressure 6.0 (870.23)
9 Transmission 3rd clutch pressure 6.0 (870.23)
10 Transmission 4th clutch pressure 6.0 (870.23)
11 Lubrication pressure 1.0 (145.04)

WARNING! Put chocks securely under the tires.

★ Measure the power train oil pressure under the following

conditions.

Engine coolant temperature: . . . . . . . . . . . Within operating range

Torque converter oil temperature: . . . . . . . .Within operating range

1. Remove rear frame left side cover (12) and right side cover (13).

WA500-6 30-39 ➁
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

Measuring
Transmission Main Relief Pressure
1. Remove transmission main relief pressure pickup plug (1) (10 x
1.25 mm).

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

3. Start the engine and then maintain the directional lever, joystick
steering directional switch, or right directional switch at the N
(Neutral) position.

4. While running the engine at low idle and high idle, measure the
transmission main relief pressure.

5. After completing the measurement, remove the measuring

instruments and return the parts you removed.

30-40 ➁ WA500-6
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

Torque Converter Relief Pressure

★ Inlet pressure

1. Remove torque converter relief pressure (inlet pressure) pickup

plug (2) (10 x 1.25 mm).
★ Prepare an oil pan since oil flows out as the pickup plug is
removed.

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 2.5 MPa
(362.59 psi).

3. Start the engine and then maintain the directional lever, joystick
steering directional switch, or right directional switch at the N
(Neutral) position.

4. While running the engine at high idle, measure the torque

converter relief pressure (inlet pressure).

5. After completing the measurement, remove the measuring

instruments and return the parts you removed.

WA500-6 30-41 ➁
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

Torque Converter Outlet Pressure

1. Remove torque converter outlet pressure pickup plug (3) (10 x
1.25 mm).

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 0 MPa
(145.04 psi).

3. Start the engine and then maintain the directional lever, joystick
steering directional switch, or right directional switch at the N
(Neutral) position.

4. While running the engine at high idle, measure the torque

converter outlet pressure.

5. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

30-42 ➁ WA500-6
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

Lockup Clutch Pressure

★ Lockup clutch specification

WARNING! This measurement is done in the traveling

condition. Reasonable care must be paid to
the safety of the surrounding area.

1. Remove lockup clutch pressure pickup plug (4) (10 x 1.25 mm).

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

3. Turn the torque converter lockup switch ON.

4. Set the transmission auto-shift and manual shift selector switch in

the AUTO position.

5. Start the engine and turn the parking brake switch OFF.

6. Set the gear shift lever or gear shift switch to the 2nd position.

7. Start traveling while setting the directional lever, joystick steering

directional switch, or right directional switch to the F (forward) or
R (reverse) position.

8. Measure the lockup clutch oil pressure as the lockup pilot lamp
comes on while continuing to travel with the engine at high idle.

9. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

WA500-6 30-43 ➁
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

F (Forward) Clutch Pressure

1. Remove the F (forward) clutch oil pressure pickup plug (5) (10 x
1.25 mm).

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

3. Set the transmission auto-shift and manual shift selector switch in

the MANUAL position.

4. Press the brake pedal.

5. Start the engine and turn the parking brake switch OFF.

6. Set the gear shift lever to the 4th speed while keeping the
directional lever, joystick steering directional switch, or right
directional switch at the N (Neutral) position.

7. Run the engine at low idle and while pressing the brake pedal, set
the directional lever, joystick steering directional switch, or right
directional switch to the F (forward).

WARNING! Keep pressing the brake pedal securely.

8. Measure the F (forward) clutch oil pressure when the engine is run
at high idle.

9. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

30-44 ➁ WA500-6
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

R (Reverse) Clutch Pressure

1. Remove the R (reverse) clutch oil pressure pickup plug (6) (10 x
1.25 mm).

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

3. Set the transmission auto-shift and manual shift selector switch in

the MANUAL position.

4. Press the brake pedal.

5. Start the engine and turn the parking brake switch OFF.

6. Set the gear shift lever to the 4th speed while keeping the
directional lever, joystick steering directional switch, or right
directional switch at the N (Neutral) position.

7. Run the engine at low idle and, while pressing the brake pedal, set
the directional lever, joystick steering directional switch, or right
directional switch to the R (reverse).

WARNING! Keep pressing the brake pedal securely.

8. Measure the R (reverse) clutch oil pressure when the engine is run
at high idle.

9. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

WA500-6 30-45 ➁
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

1st Clutch Pressure

1. Remove the 1st clutch oil pressure pickup plug (7) (10 x 1.25 mm).

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

3. Set the transmission auto-shift and manual shift selector switch in

the MANUAL position.

4. Press the brake pedal.

5. Start the engine and turn the parking brake switch OFF.

6. Set the gear shift lever to the 1st speed while maintaining the
directional lever, joystick steering directional switch, or right
directional switch at the N (Neutral) position.

7. Run the engine at low idle and, while pressing the brake pedal, set
the directional lever, joystick steering directional switch, or right
directional switch to the F (forward) or R (reverse) position once
and then return it to N (Neutral) again.

Keep pressing the brake pedal securely.

★ The above operation is required because moving the gear shift

lever does not change the gear speed if the directional lever,
joystick steering switch, or right directional switch is set at the
N (neutral) position.

8. While running the engine at high idle, measure the 1st clutch oil
pressure.

9. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal
condition.

30-46 ➁ WA500-6
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

2nd Clutch Pressure

1. Remove the 2nd clutch oil pressure pickup plug (8) (10 x 1.25
mm).

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

3. Set the transmission auto-shift and manual shift selector switch in

the MANUAL position.

4. Press the brake pedal.

5. Start the engine and turn the parking brake switch OFF.

6. Set the gear shift lever to the 2nd speed while maintaining the
directional lever, joystick steering directional switch, or right
directional switch at the N (Neutral) position.

7. Run the engine at low idle and, while pressing the brake pedal, set
the directional lever, joystick steering directional switch, or right
directional switch to the F (forward) or R (reverse) position once
and then return it to N (Neutral) again.

Keep pressing the brake pedal securely.

★ The above operation is required because moving the gear shift

lever does not change the gear speed if the directional lever,
joystick steering switch, or right directional switch is set at the
N (neutral) position.

8. While running the engine at high idle, measure the 2nd clutch oil
pressure.

9. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal
condition.

WA500-6 30-47 ➁
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

3rd Clutch Pressure

1. Remove the 3rd clutch oil pressure pickup plug (9) (10 x 1.25
mm).

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

3. Set the transmission auto-shift and manual shift selector switch in

the MANUAL position.

4. Press the brake pedal.

5. Start the engine and turn the parking brake switch OFF.

6. Set the gear shift lever to the 3rd speed while keeping the
directional lever, joystick steering directional switch, or right
directional switch at the N (Neutral) position.

7. Run the engine at low idle and, while pressing the brake pedal, set
the directional lever, joystick steering directional switch, or right
directional switch to the F (forward) or R (reverse) position once
and then return it to N (Neutral) again.

Keep pressing the brake pedal securely.

★ The above operation is required because moving the gear shift

lever does not change the gear speed if the directional lever,
joystick steering switch, or right directional switch is set at the
N (neutral) position.

8. While running the engine at high idle, measure the 3rd clutch oil
pressure.

9. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal
condition.

30-48 ➁ WA500-6
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

4th Clutch Pressure

1. Remove the 4th clutch oil pressure pickup plug (10) (10 x 1.25
mm).

2. Connect nipple (L2) and oil pressure gauge [1] in hydraulic

tester (L1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

3. Set the transmission auto-shift and manual shift selector switch in

the MANUAL position.

4. Press the brake pedal.

5. Start the engine and turn the parking brake switch OFF.

6. Set the gear shift lever to the 4th speed while keeping the
directional lever, joystick steering directional switch, or right
directional switch at the N (Neutral) position.

7. Run the engine at low idle and, while pressing the brake pedal, set
the directional lever, joystick steering directional switch, or right
directional switch to the F (forward) or R (reverse) position once
and then return it to N (Neutral) again.

Keep pressing the brake pedal securely.

★ The above operation is required because moving the gear shift

lever does not change the gear speed if the directional lever,
joystick steering switch, or right directional switch is set at the
N (neutral) position.

8. While running the engine at high idle, measure the 4th clutch oil
pressure.

9. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal
condition.

WA500-6 30-49 ➁
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

Lubrication Pressure
1. Remove the lubrication pressure pickup plug (11) (10 x 1.25 mm).

2. Install elbow [2] and nipple [3] in hydraulic tester (L1) and
connect oil pressure gauge [1] to them.
★ Use an oil pressure gauge with capacity of 1.0 MPa
(145.04 psi).

3. Start the engine and then maintain the directional lever, joystick
steering directional switch, or right directional switch at the N
(Neutral) position.

4. Measure the lubrication pressure as the engine is run at high idle.

5. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

30-50 ➁ WA500-6
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURES

Adjusting
Transmission Main Relief Valve

WARNING! Stop the engine before starting adjustment of

the transmission main relief valve.

★ If the transmission main relief pressure is out of the specified

range, adjust it according to the following procedure.

1. Remove plug (13) from the transmission and torque converter

relief valve (12).

2. Remove inner spring (14) and outer spring (15).

3. Adjust the main relief pressure by changing the number of

shims (16).
Standard shim thickness: . . . . . . . . . . 4.5 mm (0.5 mm x 9 pieces)
Quantity of adjustment per shim: . . . . . . . . . . 0.039 MPa (5.66 psi)

Torque Converter Relief Valve

★ Adjustment of the torque converter relief valve is not available.

WA500-6 30-51 ➁
TESTING AND ADJUSTING FLUSHING TRANSMISSION SYSTEM

FLUSHING TRANSMISSION SYSTEM

Torque Converter and Transmission Hydraulic Circuit
★ Metal chips and dirt in the torque converter and transmission hydraulic circuit shorten the lives of these components and
can cause internal breakage. Flush the hydraulic circuit to remove the metal chips and dirt.

1. Flush the hydraulic circuit in the following cases.

• When metal chips are circulated in the hydraulic circuit because of damage of the torque converter, transmission, or
another hydraulic device.
• When the torque converter or transmission is overhauled or repaired.

2. Install the element for flushing.

A. Remove cover (1) on the transmission oil filter installation

position situated on the left side of the machine.

B. Remove drain plugs (3) on two transmission oil filter cases (2)
to drain the oil.
★ Before draining the oil, prepare an oil pan.

30-52 ➁ WA500-6
TESTING AND ADJUSTING FLUSHING TRANSMISSION SYSTEM
C. Loosen the hexagonal portion (a) of two transmission oil filter
cases (2) to remove the cases.
★ After removing each transmission oil filter case, clean
inside the case as well as the removed parts, other than
the filter.

D. Remove two filter elements (4) and replace them with two
flushing elements (561-15-55670).

E. Install two transmission oil filter cases (2).

Hexagonal portion (a) of transmission oil filter case:

58.8 – 78.5 N•m (43.37 – 57.90 lbf ft)

Drain plug: 49 – 58.8 N•m (36.14 – 43.37 lbf ft)

3. Fill the transmission case with oil.

• Add oil through oil filler (5) to the specified level.
• Run the engine to circulate the oil through the system.
• Check the oil level again.

Transmission case: 76 l (20 gal) (Refill capacity)

4. Flush the hydraulic circuit according to the following procedure.

A. Start the engine and run it at low idle without operating the
gear shift lever or directional lever for about 20 minutes.
• Increase the engine speed to about 1,500 rpm at times.
• If the engine coolant temperature gauge does not rise to
the operating range because of low atmospheric temperature, continue the warm-up operation further.

B. Operate or drive the machine for at least 20 minutes.

★ Use all the gear speeds (Forward, reverse, and 1st – 4th).

C. Run the engine at low idle for about 20 minutes, similar to Step 4A.

WA500-6 30-53 ➁
TESTING AND ADJUSTING FLUSHING TRANSMISSION SYSTEM
5. Replace the filter element.

A. Replace element (4) used for flushing with a new element (424-16-11140) following the same procedure as described
in Step 2.

WARNING! Using the element used for flushing for long

periods causes premature clogging. Be sure to
replace it with a new one.

★ Replace the current O-ring with a new one; coat it with a small amount of oil; and then install it.

B. Add oil and check the oil level again.

6. Replace the transmission last chance filter.

A. Remove cover (6) on the left side of the rear frame.

B. Loosen hexagonal portion (b) of the transmission last chance

filter case (7) to remove the case.
★ After removing the transmission oil filter case, clean
inside the case as well as the removed parts, other than
the filter.

C. Remove filter element (8) and replace it with a new element

(569-15-51730).

D. Install transmission last chance filter case (7).

★ Replace the current O-ring with a new one; coat it with a
small amount of oil; and then install it.

Hexagonal portion (b) of transmission oil filter case:

34.3 – 44.1 N•m (25.30 – 32.53 lbf ft)

30-54 ➁ WA500-6
TESTING AND ADJUSTING WHEN TRANSMISSION VALVE FAILS

WHEN TRANSMISSION VALVE FAILS

Moving Machine when Transmission Valve is Broken
★ Position of ECMV devices and connector numbers

★ Device for moving machine when transmission valve is broken

Symbol Part Number Part Name

M 794-423-1190 Plug

★ Even if the machine is not movable because of a failure on the transmission valve portions (electrical system, solenoid
valve, spool, etc.), install plug (M) to enable you to move the machine.

WARNING! Installing plug M to the ECMV enables you to move the machine from a dangerous job site to a safe
place for repair. This approach should be used only when the machine is not movable at any gear
speed because of a failure on the transmission control valve and should not be employed for any
other purpose.

When moving the machine using this method, follow the procedure and pay strict attention to
safety.

Lower the work equipment completely to the ground; apply the parking brake; and put chocks
under the tires so that the machine does not move.

Stop the engine.

When working while the oil temperature is still high, be careful not to burn yourself.

WA500-6 30-55 ➁
TESTING AND ADJUSTING WHEN TRANSMISSION VALVE FAILS
1. Remove cover (1) on the left side of the rear frame.
★ Remove mud and dirt from around the ECMV.

2. Disconnect the connector of the 2nd ECMV and the connector of

the F or R ECMV.
F ECMV (Forward) connector: . . . . . . . . . . . . . . . . .F.SW and F.PS
R ECMV (Reverse) connector: . . . . . . . . . . . . . . . . .SW and R.PS
2nd ECMV (2nd speed) connector: . . . . . . . . . . . . 2.SW and 2.PS
★ Select either F ECMV or R ECMV depending on the direction
in which the machine is moving (Forward or Reverse).

3. Remove two solenoids (2) on the 2nd ECMV and the F or R

ECMV and install plug M.
For forward travel: . . . . . . . . . . . . . . . F solenoid and 2nd solenoid
For reverse travel: . . . . . . . . . . . . . . . R solenoid and 2nd solenoid
★ If an incorrect solenoid is removed, the transmission may be
broken. Be careful.
• Install each plug with its projection side toward the ECMV.
Make sure that the O-ring is fitted to the mating face.
• Be careful that mud or dirt does not enter the removed
solenoids and valves.

4. Press the brake pedal securely.

5. Start the engine and release the parking brake gradually to start and
move the machine.
★ If the parking brake cannot be released because of trouble in
the electrical system, see Releasing Parking Brake Manually
in this section.

WARNING! Remove the chocks.

If the engine is started, the transmission is

engaged and the machine starts immediately.
When starting the engine, check the moving
direction of the machine and ensure that there
is a safe perimeter around the machine. Keep
pressing the brake pedal.

After moving the machine, stop the engine;

apply the parking brake; and put chocks under
the tires.

6. After moving the machine, remove the devices and return the parts you removed.

30-56 ➁ WA500-6
TESTING AND ADJUSTING STEERING SYSTEM

STEERING SYSTEM
Steering Stop Valve
Testing
1. Straighten the front frame and rear frame.

2. Make sure locknut (2) of stopper bolt (1) is not loosened.

3. Start the engine and turn the steering wheel to the right and left.
★ Make sure that a clearance is maintained between the front
frame stopper and rear frame stopper when the steering wheel
is turned.

WARNING! Stop the engine before measuring the

clearance.

★ If you cannot do the checkup because of a missing frame

stopper or another missing item, do the necessary repair and
then make sure clearance is provided on both sides.
• Measure clearance (a) between front frame (4) and rear
frame (5) on both sides as the turning is stopped due to the
contact of steering stop valve (3) and stopper bolt (1).
Standard clearance (a): . . . . . . . . . . . . . .36 ±5 mm (1.42 ±0.20 in)

WA500-6 30-57 ➁
TESTING AND ADJUSTING STEERING SYSTEM

Adjusting
★ When clearance (a) between front frame (4) and rear frame (5) is
out of the specified range, use the following procedure to adjust it.

1. Loosen locknut (2) and then tighten stopper bolt (1) to set
distance (b) to the minimum.

2. Run the engine at low idle and then bring front frame (4) and rear
frame (5) into contact with each other by turning the steering
wheel slowly.

WARNING! Be careful during this operation so that your

body or arm does not get caught between the
front and rear frames.

3. Stop the engine and then loosen stop bolt (1) until it touches the
contact surface of steering stop valve (3).
★ Be careful not to loosen the stopper bolt excessively.
Excessive loosening can result in pushing spool (6) at the tip
of steering stop valve (3).

4. Start the engine and return the steering wheel slowly, at low idle, to
set the machine in a straight travel path; then stop the engine.

5. Rotate stopper bolt (1) 8.5 turns in the loosening direction and then
fix it with locknut (2).
★ Adjust both the right and left side according to Steps 1 to 5.

6. Start the engine; turn the machine; and then measure clearance (a)
between front frame (4) and rear frame (5) as the turning is stopped
due to the contact of steering stop valve (3) and stopper bolt (1).
★ Make sure clearance (a) is compliant with the standard
dimension on both sides.

30-58 ➁ WA500-6
TESTING AND ADJUSTING STEERING SYSTEM

Steering Wheel
Special Tools Required

Symbol Part No. Part Name

N 79A-264-0021 Push-pull scale

Measuring Play
★ Measurement conditions:

Engine speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopped

Machine posture: . . . . . . . . . . . . . . . . . . . . Facing straight forward

1. Move the steering wheel (1) two or three times lightly to the left
and right; check that the steering mechanism is at the neutral
position; then make mark (A) on the outside frame of the machine
monitor.

2. Turn the steering wheel to the right and make mark (B) at the
position where the operating effort starts to become heavy.

3. Turn the steering wheel to the left and make mark (C) at the point
where the operating effort becomes heavy.

4. Measure the distance in a straight line between marks (B) and (C).

WA500-6 30-59 ➁
TESTING AND ADJUSTING STEERING SYSTEM

Measuring Operating Effort

★ Measurement conditions:

Road surface: . . . . . . . . . . . . . . Flat, horizontal, dry paved surface

Engine coolant temperature: . . . . . . . . . . . .Within operating range
Hydraulic oil temperature:. . . . . . . . . . . . . . .Within operating range
Tire inflation pressure: . . . . . . . . . . . . . . . . . . . . Specified pressure
Engine speed: . . . . . . . . . . . . . . . . . . . . . . Low idle (bucket empty)

1. Install push-pull scale (N) on the steering wheel knob.

★ Be sure to install push-pull scale (N) at the center.

2. Start the engine.

★ After starting the engine, raise the bucket approx. 400 mm
(15.75 in) and release the frame lock lever.

3. Pull push-pull scale (N) in the tangential direction and read the
value when the steering wheel moves smoothly.
★ Do not use the value when the steering wheel starts to move.
★ The shape in the photo is not identical to that of the WA500-6.

4. After finishing the work, remove the measuring instrument.

30-60 ➁ WA500-6
TESTING AND ADJUSTING STEERING SYSTEM

Measuring Operating Time

★ Measurement conditions:

Road surface: . . . . . . . . . . . . . . Flat, horizontal, dry paved surface

Engine coolant temperature: . . . . . . . . . . . .Within operating range
Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
Tire inflation pressure: . . . . . . . . . . . . . . . . . . . Specified pressure
Engine speed: . . . . . . . . . . . . . . . . . . . . . . . Low idle and high idle

1. Start the engine.

★ After starting the engine, raise the bucket approx. 400 mm
(15.75 in) and release the frame lock lever.

2. Turn the steering wheel to the left or right stroke end.

3. Measure the time taken to operate the steering wheel to the right or
left stroke end.
★ Turn the steering wheel smoothly at a speed of 60 rpm. Do not
turn the steering wheel forcibly.
★ Carry out the measurements both at low idle and high idle,
turning the machine both in the left and right direction.
★ The shape in the photo is not identical to that on the WA500-6.

4. After finishing the work, remove the measuring instrument.

WA500-6 30-61 ➁
TESTING AND ADJUSTING STEERING SYSTEM

Steering Oil Pressure

Special Tools Required

Symbol Part Number Part Name

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
799-101-5220 Nipple (10 x 1.25 mm)
Q 2
07002-11023 O-ring
3 799-401-3200 Adapter (Size 03)
4 799-401-2701 Differential pressure gauge

★ Measurement conditions:

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Hydraulic oil temperature:. . . . . . . . . . . . . . .Within operating range

WARNING! Loosen the oil filler cap of the hydraulic tank to

release the internal pressure of the hydraulic
tank. Operate the steering wheel two to three
times to release the residual pressure from the
piping.

Apply frame lock lever (1).

Measuring Steering Relief Pressure

1. Remove steering circuit pressure pickup plug (2) (10 x 1.25 mm)
on the right steering cylinder head side.

2. Connect nipple (Q2) and oil pressure gauge [1] in hydraulic

tester (Q1).
★ Use an oil pressure gauge with capacity of 40 MPa
(5801.51 psi).

30-62 ➁ WA500-6
TESTING AND ADJUSTING STEERING SYSTEM
3. Run the engine at high idle and turn the steering wheel to the right.
When the steering relief valve operates, measure the oil pressure.
★ When the gauge is connected to the steering circuit pressure
pickup plug on the left side steering cylinder head, measure
the pressure by turning the steering wheel counterclockwise.

4. After completing the measurement, remove the measuring

instruments and return the parts you removed.

WA500-6 30-63 ➁
TESTING AND ADJUSTING STEERING SYSTEM

Measuring Pilot Circuit Pressure

1. Remove side covers (3) and (4) of the steering valve situated on
the left side of the machine.

2. Remove steering pilot circuit pressure hose (6) or (7) of steering

valve assembly (5).

3. Connect adapter (Q3) and steering pilot circuit pressure hose (6) or
(7).

4. Connect nipple [2] and oil pressure gauge [1] in hydraulic

tester (Q1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

5. While running the engine at high idle, measure the oil pressure as
the steering wheel is turned.
• When measuring at hose (6): Turn the steering wheel
clockwise (or turn the joystick steering lever rightward).
• When measuring at hose (7): Turn the steering wheel
counterclockwise (or turn the joystick steering lever leftward).

6. After completing the measurement, remove the measuring

instruments and return the parts you removed.

30-64 ➁ WA500-6
TESTING AND ADJUSTING STEERING SYSTEM

Measuring LS Circuit Pressure

1. Remove side covers (3) and (4) of the steering valve situated on
the left side of the machine.

2. Remove steering LS circuit pressure hose (11) of steering valve

assembly (5).

3. Connect adapter (Q3) and steering LS circuit pressure hose (11).

4. Connect nipple [2] and oil pressure gauge [1] in hydraulic

tester (Q1).
★ Use the oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

5. While running the engine at low idle, measure the oil pressure as
the steering wheel is stopped.

6. After completing the measurement, remove the measuring

instruments and return the parts you removed.

WA500-6 30-65 ➁
TESTING AND ADJUSTING STEERING SYSTEM

Adjusting Steering Relief Pressure

WARNING! When adjusting the oil pressure, you must

stop the engine.

1. If the steering relief pressure is abnormal, adjust steering relief

valve (8) of steering valve assembly (5) by doing the following
procedure.

2. Loosen locknut (9) and turn adjustment screw (10) to adjust the
pressure.
★ Adjustment screw:
• Turned to the right, the pressure rises.
• Turned to the left, the pressure lowers.
★ Quantity of adjustment of adjustment screw (per turn):
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9 MPa (2596.18 psi)

Locknut: 27 – 31 N•m (19.91 – 22.86 lbf ft)

30-66 ➁ WA500-6
TESTING AND ADJUSTING STEERING SYSTEM

Bleeding Air From Steering Cylinder Circuit

★ Before starting the operation, make sure the specified level of hydraulic oil is provided.

★ If the steering valve or the steering cylinder was removed and installed again, bleed the air from the steering circuit as
described in this procedure.

1. Run the engine at idle for approximately five minutes.

2. Run the engine at low idle and steer the machine to the right and
left four to five times.
★ Stop the piston rod about 100 mm (3.94 in) before the end of
each stroke. Be careful not to relieve the circuit.

3. Repeat Step 2 while running the engine at high idle.

4. While running the engine at low idle, move the piston rod to the
stroke end and relieve the circuit.

WA500-6 30-67 ➁
TESTING AND ADJUSTING HYDRAULIC FAN

HYDRAULIC FAN
Special Tools Required

Symbol Part Number Part Name

1 799-205-1100 Tachometer kit
799-101-5002 Hydraulic tester
2
790-261-1204 Digital hydraulic tester
R
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
4 799-401-3500 Adapter (Size 06)

WARNING! Stop the machine on level ground; lower the

work equipment to the ground; and set chocks
securely under the tires.

When removing the oil pressure pickup plug

and disconnecting the hose, loosen the oil filler
cap of the hydraulic tank slowly to release the
pressure inside the tank.

★ Measurement conditions:

Engine coolant temperature: . . . . . . . . . . . . . . . Min. 95°C (203°F)

Hydraulic oil temperature:. . . . . . . . . . . . . . . . . . Min. 95°C (203°F)
Torque converter oil temperature:. . . . . . . . . . . Min. 105°C (221°F)

30-68 ➁ WA500-6
TESTING AND ADJUSTING HYDRAULIC FAN

Measuring Fan Speed

This procedure describes how to measure the fan speed.

1. Set probe [2] to stand [1] of tachometer kit (R1) and stick
reflective tape [3] to the fan.

★ See tachometer kit (R1) in the photo to the right.

2. While running the engine at high idle and low idle, measure the fan
speed.

3. After completing the measurement, remove the measuring

instruments and return the parts you removed.

WA500-6 30-69 ➁
TESTING AND ADJUSTING HYDRAULIC FAN

Measuring Fan Drive Oil Pressure

This procedure describes how to measure the fan drive oil pressure.

1. Open the radiator grille (1).

2. Remove fan net (2) at the center.

3. Disconnect P port hose (4) of fan motor (3).

4. Connect adapter (R4) and hose (4).

5. Connect nipple (R3) (10 x 1.25 mm) and oil pressure gauge [1] in
hydraulic tester (R2).
★ Use an oil pressure gauge with capacity of 40 MPa
(5801.51 psi).

6. While running the engine at high idle, measure the fan drive oil
pressure.

7. After completing the measurement, remove the measuring

instruments and return the parts you removed.

30-70 ➁ WA500-6
TESTING AND ADJUSTING HYDRAULIC FAN

Measuring Fan Reverse Solenoid Output Pressure

1. Open radiator grille (1).

2. Remove fan net (2) at the center.

3. Remove fan reverse solenoid output pressure pickup plug (10 x

1.25 mm) (5) from fan motor (3).

4. Connect nipple (R3) (10 x 1.25 mm) and oil pressure gauge [1] in
hydraulic tester (R2).
★ Use an oil pressure gauge with capacity of 39.2 MPa
(5685.48 psi).

5. Turn the cooling fan reverse switch ON.

6. While running the engine at high idle, measure the fan reverse
solenoid drive oil pressure.
★ Measure the fan forward and reverse drive oil pressures.
When the fan is reversed, check that the solenoid operates and
the specified oil pressure is applied.

7. After completing the measurement, remove the measuring

instruments and return the parts you removed.

Fan reverse solenoid output pressure pickup plug:

9.8 – 12.7 N•m (86.74 – 112.40 lbf in)

WA500-6 30-71 ➁
TESTING AND ADJUSTING HYDRAULIC FAN

Bleeding Air from Hydraulic Drive Fan Circuit

Special Tools Required

Symbol Part Number Part Name

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
799-101-5220 Nipple (10 x 1.25 mm)
S 2
07002-11023 O-ring
3 799-401-3500 Adapter (Size 06)
4 790-261-1130 Coupling

★ Before starting the operation, make sure that the specified level of hydraulic oil is provided.

1. Bleeding air from fan pump

A. Remove pump side cover (1) on the right side of the machine.

B. Stop the engine and then loosen air bleeder (3) of fan
pump (2) to connect air bleeding hose [1].

C. As oil free from air starts to flow out of air bleeder (3), tighten
air bleeder (3).

Air bleeder: 7.8 – 9.8 N•m (69.04 – 86.74 lbf in)

D. Start the engine and run it at low idle for a minimum of five
minutes.

2. Bleeding air from fan motor circuit

A. Open radiator grille (4).

B. Remove fan net (5) at the center.

30-72 ➁ WA500-6
TESTING AND ADJUSTING HYDRAULIC FAN
C. Disconnect P port hose (7) of fan motor (6).

D. Connect adapter (S3) and hose (7).

E. Connect nipple (S2) (10 x 1.25 mm) and hose [1] in hydraulic
tester (S1). Also connect air bleeder coupling (S4) to the outlet
end of the hose.
★ Put the outlet end of the hose in an oil receiver.

F. Run the engine. When the oil flows out of the outlet end of the
hose, stop the engine.

G. After completing the bleeding air procedure, remove the tools

and return the parts you removed.

WA500-6 30-73 ➁
TESTING AND ADJUSTING BRAKE SYSTEM

BRAKE SYSTEM
Measuring Brake Pedal
★ Measurement conditions:

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Engine speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low idle

Measuring Pressing Angle of Pedal

1. Install push gauge [1] to the operator’s foot.

★ Set the push gauge at a point 150 mm (5.91 in) from the
fulcrum of the pedal.

2. While running the engine at low idle, measure pedal pressing

angle (α1).

3. Apply angle gauge [2] to the brake pedal and measure pressing
angle (α2) between pressing angles (α1) and (α3) (α2 = α1 – α3).
Operating effort at (α2): . . . . . . . . . . 321 ±32.1 N (72.16 ±7.22 lbf)

30-74 ➁ WA500-6
TESTING AND ADJUSTING BRAKE SYSTEM

Measuring Brake Performance

★ Measurement conditions:

Road: . . . . . . . . . . . . . . . . . . . . Flat, horizontal, dry, paved surface

Braking initial speed: . . . . . . . . . . . . . . . . . . . . . .20 km/h (12 mph)
Tire inflation pressure: . . . . . . . . . . . . . . . . . . . . Specified pressure
Tire size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29.5-25-22PR
Brake pedal pressing force:
Specified pressing force: . . . . 294 ±29.4 N•m (66.09 ±6.61 lbf)
Pressing time lag: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 second

Measurement Method

1. Start the engine and drive the machine.

2. Set the gear shift lever or gear shift switch to 4th position for run-up.

3. When the travel speed reaches the braking initial speed (20 km/h (12 mph)), press the left brake pedal with the specified
force.
★ Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the
brakes when the machine reaches that point.

4. Measure the distance from the point where the brakes were applied to the point where the machine stopped.
★ Repeat this measurement three times and take the average.

WA500-6 30-75 ➁
TESTING AND ADJUSTING BRAKE SYSTEM

Accumulator Charge Pressure

Special Tools Required

Symbol Part No. Part Name

799-101-5002 Analog-type hydraulic tester
R
790-261-1204 Digital-type hydraulic tester

★ Measurement conditions:

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range

WARNING! Stop the machine on level ground; lower the

work equipment to the ground; and set chocks
securely under the tires.

Stop the engine then depress the brake pedal

at least 100 times to release the pressure
inside the accumulator circuit.

Measuring

1. Remove front cover (1) of the accumulator installation position

situated on the right side of the machine.

2. Connect oil pressure gauge [1] of hydraulic tester (T) to

accumulator charge pressure measuring nipple (2).
★ Use an oil pressure gauge with capacity of 40 MPa
(5801.51 psi).

30-76 ➁ WA500-6
TESTING AND ADJUSTING BRAKE SYSTEM
3. Measure the accumulator charge cut-in pressure.
• Run the engine at low idle and then measure the oil pressure
when the brake pressure caution lamp on the monitor panel
goes out.
Cut-in pressure: . . . . . . . . . . . . . 5.9 +0.5
0.0
MPa (855.7 +72.5
0.0
psi)

4. Measure the accumulator charge cutout pressure.

★ After the accumulator charge cut-in operation, measure the oil
pressure when the indicator of the oil pressure gauge has risen
and suddenly starts to drop.
Cutout pressure: . . . . . . . . 9.8 +0.98
0.00
MPa (1,421.4 +142.1
0.0
psi)

5. After completing the work, remove the measuring instruments and

return the parts you removed.

WA500-6 30-77 ➁
TESTING AND ADJUSTING BRAKE SYSTEM
Adjusting

★ When the accumulator charge cutout pressure is adjusted, the cut-

in pressure also changes in proportion to the ratio of the valve area.

1. Remove cover (3) in the accumulator installation position.

2. Loosen locknut (5) of accumulator charge valve (4) and turn

adjustment screw (6) to adjust the pressure.
★ Adjustment screw:
• Turned to the right, the pressure rises.
• Turned to the left, the pressure lowers.
★ Quantity of adjustment of adjustment screw (per turn):
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.59 MPa (810.76 psi)

Locknut: 9.8 – 11.8 N•m (86.74 – 104.44 lbf in)

3. After completing the measurement, check the accumulator charge

cut-in and cutout pressures again following this procedure.

30-78 ➁ WA500-6
TESTING AND ADJUSTING BRAKE SYSTEM

Testing Wheel Brake Oil Pressure

Special Tools Required

Symbol Part Number Part Name

1 793-520-1821 Nipple
2 793-520-1810 Joint
U
3 385-10178481 Bleeder screw
4 793-520-1831 Gauge assembly

WARNING! Stop the machine on level ground; lower the work equipment to the ground; and set chocks
securely under the tires. Apply the parking brake.

Even when the brake pedal is not usable due to problems with the brake-related equipment,
high-pressure oil in the accumulator can erupt. It is mandatory to release pressure in the
accumulator circuit by pressing the brake pedal at least 100 times while maintaining the
engine at a stopped state.

★ Measure the oil pressure of the front brakes (right and left) and rear brakes (right and left) in a similar manner.

★ Measurement conditions:

Engine coolant temperature: . . . . . . . . . . . Within operating range

Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range

Measuring Wheel Brake Oil Pressure

1. Remove cover (1).

2. Remove bleeder screw (2).

WA500-6 30-79 ➁
TESTING AND ADJUSTING BRAKE SYSTEM
3. Install nipple (U1), joint (U2), bleeder screw (U3), and gauge
assembly (U4).

4. Connect hose [1] to bleeder screw (U3) and then bleed air from the
wheel brake circuit.
★ Refer to Bleeding Air from Wheel Brake Circuit in this
section.

5. Start the engine and measure the wheel brake oil pressure as the
left brake pedal is pressed.

Drop in Wheel Brake Pressure

1. Remove cover (1).

2. Remove bleeder screw (2).

3. Install nipple (U1), joint (U2), bleeder screw (U3), and gauge
assembly (U4).

4. Connect hose [1] to bleeder screw (U3) and then bleed air from the
brake circuit.
★ Refer to Bleeding Air from Wheel Brake Circuit in this
section.

5. Start the engine and accumulate pressure in the accumulator.

6. Stop the engine and press the left brake to set the oil pressure to
5.9 MPa (855.72 psi). Maintain this state for five minutes and then
measure the pressure drop.
★ Use care so that the brake pedal is not moved for five minutes.
★ After completing the measurement, remove the measuring instruments and return the currently removed parts to their
original positions. Then bleed air from the wheel brake circuit. Refer to Bleeding Air from Wheel Brake Circuit in this
section.

30-80 ➁ WA500-6
TESTING AND ADJUSTING BRAKE SYSTEM

Measuring Wear of Brake Disc

Special Tools Required

Symbol Part No. Part Name

Commercially
V Slide calipers
available

WARNING! Stop the machine on level ground; lower the

work equipment to the ground; and set chocks
securely under the tires.

1. Remove cap (1).

2. Lightly press the brake pedal to the stroke end.

3. While shaft (2) is pushed in, measure projection (x) from guide (3)
using slide caliper (V).
★ Keep pressing the brake pedal during measurement.

WA500-6 30-81 ➁
TESTING AND ADJUSTING BRAKE SYSTEM
★ If the protrusion (x) in the figure is below 0, replace the disc.
Wear (y): 4.0 – (x): . . . . . . . . . . . . . . . . . . . . Max. 4.0 mm (0.16 in)

4. After testing, return cap (1).

Cap (1): 29.4 – 39.2 N•m (21.68 – 28.91 lbf ft)

30-82 ➁ WA500-6
TESTING AND ADJUSTING BRAKE SYSTEM

Bleeding Air from Brake Circuit

WARNING! Stop the machine on level ground; lower the work equipment to the ground;
and apply the parking brake.

Set chocks securely under the tires and support the lift arm with the fall-prevention rod.

★ After removing and installing a brake circuit part, bleed air from the brake circuit according to the following procedure.

★ Use the same procedure to bleed air from the front brake circuit and rear brake circuit.

Bleeding Air from Slack Adjuster

WARNING! Never bleed air while the engine is running
since the drive shaft is rotating.

1. Start the engine and increase the accumulator pressure. Check that
the accumulator pressure is increased and stop the engine.

2. Remove inspection cover (1) on the front side of the machine.

3. Connect one end of the hose to bleeder screw (2) of the front slack
adjuster and put the other end in an oil receiver.

4. Press the brake pedal and loosen bleeder screw (2) about 1/2 turn
to drain the oil.
• Tighten bleeder screw (2) and then release the brake pedal
slowly.
★ This work must be performed by two workers. One worker
presses the brake pedal and the other drains the oil through the
bleeder screw.
• If the accumulator pressure decreases, start the engine to
increase the pressure.

5. Repeat the above procedure. When there are no bubbles in the oil
flowing out of the hose, press the pedal fully and tighten the
bleeder screw while the oil is flowing out.

Bleeder screw: 7 – 9 N•m (5.16 – 6.64 lbf ft)

6. Following this same procedure, bleed air from rear slack

adjuster (3).

WA500-6 30-83 ➁
TESTING AND ADJUSTING BRAKE SYSTEM

Bleeding Air from Brake Cylinder

WARNING! Never bleed air while the engine is running

since the drive shaft is rotating.

1. Remove cover (1).

2. Connect one end of hose [1] to bleeder screw (2) and put the other
end in an oil receiver.

3. Press the brake pedal and loosen bleeder screw (2) about 1/2 turn
to drain the oil.
• Tighten bleeder screw (2) and then release the brake pedal
slowly.
★ This work must be performed by two workers. One worker
presses the brake pedal and the other drains the oil through the
bleeder screw.
• If the accumulator pressure decreases, start the engine to
increase the pressure.

4. Repeat the above procedure. When there are no bubbles in the oil
flowing out of hose [1], press the pedal fully and tighten the bleeder screw while the oil is flowing out.

5. Following this same procedure, bleed air from each brake cylinder.
• Bleed air from the brake cylinders in order, from the one farthest from the brake valve.
★ Air bleeding order of cylinders:
(1) Left rear brake cylinder
↓
(2) Right rear brake cylinder
↓
(3) Right front brake cylinder
↓
(4) Left front brake cylinder

• After bleeding air, carry out the brake performance test to check for any abnormality. See Brake System: Measuring
Brake Performance in this section.
• Drain oil again through each bleeder screw to see if there are any bubbles in the oil.

30-84 ➁ WA500-6
TESTING AND ADJUSTING BRAKE SYSTEM

Releasing Residual Pressure in Brake Accumulator Circuit

WARNING! Before disconnecting any of the following

brake accumulator circuits, release residual
pressure in those brake circuits.

★ Piping between accumulator charge valve and brake accumulator

★ Piping between accumulator charge valve and parking brake emergency release valve

★ Piping between brake accumulator and brake valve

1. Stop the engine.

2. Press the brake pedal at least 100 times to release the pressure from the brake accumulator circuit.

WA500-6 30-85 ➁
TESTING AND ADJUSTING BRAKE SYSTEM

Parking Brake
Testing Parking Brake Performance
★ Measurement conditions:

Tire inflation pressure: . . . . . . . . . . . . . . . . . . . Specified pressure

Road: . . . . . . . . . . . . . . . . . . . . . 1/5 gradient (11° 20'), flat, and dry
Machine: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ready for operation

Measuring Method

1. Start the engine and set the machine in the straight travel position.
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. Turn the parking brake switch ON (to park) and then release the
brake gradually. At this time, the machine must not move.
★ When the engine is stopped, the parking brake is turned ON
(to park) automatically.
★ Measure the parking brake performance on an uphill and a
downhill gradient.

30-86 ➁ WA500-6
TESTING AND ADJUSTING BRAKE SYSTEM

Measuring Parking Brake Oil Pressure

Special Tools Required

Symbol Part Number Part Name

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
W 799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
3 799-401-3100 Adapter (Size 02)

WARNING! Put chocks under the tires.

Install and remove the measuring instruments

after the oil temperature drops completely.

★ Measurement conditions:

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Power train oil temperature: . . . . . . . . . . . . .Within operating range

Parking Brake Inlet Pressure

1. Open rear frame left side cover (1).

2. Remove parking brake inlet pressure pickup plug (10 x

1.25 mm) (2).

WA500-6 30-87 ➁
TESTING AND ADJUSTING BRAKE SYSTEM
3. Connect nipple (W2) and oil pressure gauge [1] of hydraulic
tester (W1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

4. While running the engine at low idle, measure the parking brake
inlet pressure.

WARNING! Keep pressing the brake pedal for safety.

• Measure the oil pressure both when the parking brake is ON

and OFF.
★ If the parking brake solenoid valve output pressure is normal
and the parking brake inlet pressure is abnormal, failure on the
parking brake emergency release valve can be suspected.

5. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

30-88 ➁ WA500-6
TESTING AND ADJUSTING BRAKE SYSTEM
Parking Brake Emergency Release Valve Pilot Pressure

★ Transmission ECMV basic pressure

1. Open rear frame left side cover (1).

2. Disconnect parking brake emergency release valve pilot pressure

hose (3).

3. Install adapter (W3) and connect parking brake pilot pressure

hose (3).

4. Connect nipple [2] and oil pressure gauge [1] in hydraulic

tester (W1).
★ Use the oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

5. While running the engine at low idle, measure the parking brake
pilot pressure.

WARNING! Keep pressing the brake pedal for safety.

★ Measure the oil pressure when the parking brake is OFF.

6. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

WA500-6 30-89 ➁
TESTING AND ADJUSTING BRAKE SYSTEM
Parking Brake Solenoid Valve Output Pressure

1. Remove rear frame left side cover (1).

2. Disconnect parking brake solenoid valve output pressure hose (4).

3. Install adapter (W3) and connect parking brake solenoid valve

output pressure hose (5).

4. Connect nipple [2] and oil pressure gauge [1] in hydraulic

tester (W1).
★ Use the oil pressure gauge with capacity of 6.0 MPa
(870.23 psi.

5. Run the engine at low idle and measure output pressure of the
parking brake solenoid valve.

WARNING! Keep pressing the brake pedal for safety.

• Measure the oil pressure when the parking brake is OFF.

★ If the parking brake pilot pressure is normal and the parking brake solenoid valve output pressure is abnormal, failure
on the check valve on the parking brake solenoid inlet side or failure on the parking brake solenoid can be suspected.

6. After completing the measurement, remove the measurement tool after the measurement and make sure that the machine
is back to normal condition.

30-90 ➁ WA500-6
TESTING AND ADJUSTING BRAKE SYSTEM

Testing Wear of Parking Brake Disc

Special Tools Required

Symbol Part No. Part Name

Commercially
X Slide calipers
available

★ If the parking brake does not work effectively, use this procedure
to check the parking brake disc for wear.

WARNING! Lower the work equipment to the ground and

put chocks under the tires.

When checking, stop the engine.

1. Drain the oil from the transmission case.

Transmission case: 76 l (20 gal)

2. Remove either of two plugs (1).

3. Measure depth (a) from the end of cage (2) to piston (3) with slide
calipers (X).
Depth at new disc (a): . . . . . . . . . . . . . . . . . . . . .28.9 mm (1.14 in)
Wear limit depth (a): . . . . . . . . . . . . . . . . . . . . . .30.0 mm (1.18 in)

4. If depth (a) exceeds the wear limit, remove parking brake disc (4)
and measure its thickness (W).
★ Refer to POWER TRAIN: Parking Brake Assembly in the
Disassembly and Assembly section.
Service limit thickness (W):. . . . . . . . . . . . . . . . . 2.97 mm (0.12 in)
★ If the thickness of the parking brake disc is less than the
service limit, replace the disc.

Refilling with Oil (Transmission Case)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

WA500-6 30-91 ➁
TESTING AND ADJUSTING BRAKE SYSTEM

Releasing Parking Brake Manually

★ The parking brake is controlled hydraulically. If you cannot release the parking brake because of a problem with the
transmission, emergency release solenoid valve, etc., you can move the machine by releasing the parking brake manually.

WARNING! Releasing the parking brake manually enables you to move the machine from a dangerous
job site to a safe place. Use this method only in an emergency.

Lower the work equipment to the ground and put chocks under the tires to prevent the
machine from moving.

When releasing the parking brake manually, stop the engine.

1. Drain the oil from the transmission case.

Transmission case: 76 l (20 gal)

2. Remove two plugs (1) (right and left).

3. Prepare two cage mounting bolts (2) and tighten them alternately
in plug (1) installation position.
• Remove two bolts (2) on the diagonal positions.
• Tighten two bolts (2) to pull piston (3) and release the parking
brake.
• Tighten the two bolts gradually and evenly. (After they reach
the seats, turn them four more turns.)

4. After moving to a safe place, restore the machine to the original

condition.
Mounting bolt (2): . . . . . . . . . . . . . . . . . . . . . . . . . . Adhesive (LT-2)

Mounting bolt (2): 98 – 123 N•m (72.28 – 90.72 lbf ft)

Refilling with Oil (Transmission Case)

1. After releasing the parking brake manually, add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

30-92 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT

WORK EQUIPMENT
Control Lever
Special Tools Required

Symbol Part No. Part Name

1 79A-264-0021 Push-pull scale

Y
2 Commercially available Scale

WARNING! Install the frame lock bar to the frame.

★ Measurement conditions:

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
Engine speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low idle

Measuring Operating Effort

1. Install and fix tool (Y1) to the work equipment control lever.
• Install tool (Y1) to the center of the knob.
• Operate the work equipment control lever at the normal
operating speed and measure the minimum effort necessary to
operate the knob.
★ The shape in the photo is not identical with that of the
WA500-6.

Measuring Stroke
1. Operate the work equipment control lever and measure its stroke at
each position.
• Apply a mark to the lever knob and measure the stroke with
scale (Y2).
• If the stroke is out of the standard range, check the linkage for
play and the bushing for wear.
★ The shape in the photo is not identical with that of the
WA500-6.

WA500-6 30-93 ➁
TESTING AND ADJUSTING WORK EQUIPMENT

PPC Oil Pressure

Special Tools Required

Symbol Part Number Part Name

799-101-5002 Hydraulic tester
1
Z 790-261-1204 Digital hydraulic tester
2 799-401-3200 Adapter (Size 03)

WARNING! Loosen the oil filler cap of the hydraulic oil tank
slowly to release the pressure inside the tank.

Operate the work equipment control lever

several times to release the remaining
pressure from the PPC accumulator circuit.

★ Measurement condition:

Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range

Shutoff Valve Basic Pressure

1. Remove front cover (1) in the accumulator installation position
situated on the right side of the machine.

30-94 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT
2. Disconnect hose (3) between the accumulator for PPC (2) and the
shutoff valve.
★ Measurement at pickup plug (4) installation position is
difficult.

3. Connect adapter (Z2) and hose (3).

4. Connect nipple [2] and oil pressure gauge [1] of hydraulic

tester (Z1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

5. Maintain the work equipment lock lever at the LOCK position.

6. Start and run the engine at high idle and then measure the PPC oil
pressure (shutoff valve basic pressure).

7. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

WA500-6 30-95 ➁
TESTING AND ADJUSTING WORK EQUIPMENT

Shutoff Valve Output Pressure

1. Disconnect target PPC circuit hose (4) of measurement from the
articulate on the right side of the machine.

2. Connect adapter (Z2) and hose (4).

3. Connect nipple [2] and oil pressure gauge [1] of hydraulic

tester (Z1).
★ Use an oil pressure gauge with capacity of 6.0 MPa
(870.23 psi).

4. Set the work equipment lock lever to the Free position.

5. Start and run the engine at high idle and then measure the PPC oil
pressure (shutoff valve output pressure).

6. Do not operate the work equipment control lever.

7. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

★ Adjustment of PPC oil pressure is not available.

30-96 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT

Oil Pressure
Special Tools Required

Symbol Part Number Part Name

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
799-101-5220 Nipple (10 x 1.25 mm)
ZA 2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
4 799-401-3200 Adapter (size 03)

Preparation Work
1. Lower section (b) to the ground keeping (a) of bucket 30 – 50 mm
(1.18 – 1.97 in) off the ground.

2. After stopping the engine, lower bucket bottom (a) and (b) to the
ground using the work equipment control lever. Make sure the
bucket is completely on the ground.

Measuring Work Equipment Relief Pressure

1. Remove front frame left side cover (1).

2. Disconnect hose (4) from union (3) of work equipment control

valve (2).

WA500-6 30-97 ➁
TESTING AND ADJUSTING WORK EQUIPMENT
3. Connect adapter (ZA4) between union (3) and hose (4).

4. Connect nipple [2] in hydraulic tester (ZA1) and oil pressure

gauge [1] of hydraulic tester (ZA1).
★ Use an oil pressure gauge with capacity of 40 MPa
(5801.51 psi).

5. Start the engine and raise the lift arm up about 400 mm (15.75 in).
• Measure the oil pressure when the bucket is tilted back at high
idle.

6. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

WARNING! After measuring the oil pressure, release

pressure in the circuit and then remove the oil
pressure gauge, nipple, and adapter using the
same procedure as described in Preparation
Work.

Measuring Unload Pressure

1. Remove front frame left side cover (1).

2. Disconnect hose (4) from union (3) of work equipment control

valve (2).

30-98 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT
3. Connect adapter (ZA4) between union (3) and hose (4).

4. Connect nipple [2] in hydraulic tester (ZA1) and oil pressure

gauge [1] of hydraulic tester (ZA1).
★ Use an oil pressure gauge with capacity of 40 MPa
(5801.51 psi).

5. Start and run the engine at high idle and then measure the oil
pressure when all levers are set to neutral.

6. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

WARNING! After measuring the oil pressure, release

pressure in the circuit and then remove the oil
pressure gauge, nipple, and adapter using the
same procedure as described in Preparation
Work.

Measuring LS Differential Pressure

★ Before measuring LS differential pressure, make sure the work
equipment relief oil pressure and work equipment PPC oil pressure
are normal.

★ Determine the LS differential pressure by measuring the work

pump discharge pressure and LS pressure (negative pressure of
actuator) at the same time and calculating the difference between
them.

1. Remove front frame left side cover (1).

2. Remove side cover (4) on the work equipment pump.

WA500-6 30-99 ➁
TESTING AND ADJUSTING WORK EQUIPMENT
3. Disconnect hose (4) from union (3) of work equipment control
valve (2).

4. Connect adapter (ZA4) between union (3) and hose (4).

5. Connect nipple [2] in hydraulic tester (ZA1) and oil pressure

gauge [1] of hydraulic tester (ZA1) or differential pressure gauge
(ZA3).
★ When using the differential oil pressure gauge, connect its
high-pressure side. (Connect the low-pressure side to LS.)
The differential pressure gauge requires a 12 V power supply;
connect a battery.
★ Use an oil pressure gauge with capacity of 40 MPa
(5801.51 psi).
Since the differential pressure is 1.5 MPa (217.56 psi) at
maximum, the same gauge can be used throughout the
measurement.

6. Remove LS pressure pickup plug (10 x 1.25 mm) (6) from the
work equipment pump.

30-100 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT
7. Connect nipple (ZA2) and oil pressure gauge [1] or differential
pressure gauge (ZA3) of hydraulic tester (ZA1).
★ When using the differential oil pressure gauge, connect its
low-pressure side. (Connect the high-pressure side to PS.)
The differential pressure gauge requires a 12 V power supply;
connect a battery.
★ Use an oil pressure gauge with capacity of 40 MPa
(5801.51 psi).
Since the differential pressure is 1.5 MPa (217.56 psi) at
maximum, the same gauge can be used throughout the
measurement.

8. Start the engine and raise the lift arm upward about 400 mm
(15.75 in).

9. Start and run the engine at high idle and then measure the work
equipment pump discharge pressure and LS pressure (actuator
negative pressure) at the same time under the following conditions.
★ When the lift arm lever is set to half stroke
★ Prevent the lift arm cylinder from turning to full stroke as long
as measurement is continued.
★ Calculation of LS differential pressure:
LS differential pressure = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .Pump discharge pressure – LS pressure

10. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

WARNING! After measuring the oil pressure, release

pressure in the circuit and then remove the oil
pressure gauge, nipple, and adapter using the
same procedure as described in Preparation
Work.

WA500-6 30-101 ➁
TESTING AND ADJUSTING WORK EQUIPMENT

Adjusting Unload Valve

★ Adjustment of the unload valve is not available.

Adjusting Work Equipment Relief Pressure

1. Remove front frame right side cover (7).

2. Loosen locknut (9) of main relief valve (8) of work equipment

control valve (2) and then adjust the pressure by turning
adjustment screw (10).
★ Adjustment screw:
• When turned clockwise, the oil pressure increases.
• When turned counterclockwise, the oil pressure
decreases.
Quantity of adjustment per turn of adjustment screw: . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.55 MPa (1820.22 psi)

Locknut: 29.4 – 39.2 N•m (21.68 – 28.91lbf ft)

3. After completing the measurement, remove the measurement tool

and make sure that the machine is back to normal condition.

30-102 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT

Adjusting LS Differential Pressure

1. Loosen locknut (12) of LS valves (11) of work equipment pump
assembly (5) and then adjust the pressure by turning adjustment
screw (13).
★ Adjustment screw:
• Turning the screw clockwise increases the pressure.
• Turning it counterclockwise decreases the pressure.
Quantity of adjustment per turn of adjustment screw: . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MPa (188.55 psi)

Locknut: 49 – 68.6 N•m (36.14 – 50.60 lbf ft)

2. After the adjustment, measure the LS differential pressure again

using the Measuring LS Differential Pressure procedure.

WA500-6 30-103 ➁
TESTING AND ADJUSTING WORK EQUIPMENT

Bleeding Air from Work Equipment Circuit

From Work Equipment Pump (piston pump)
1. Remove side cover (1) on the work equipment pump.

2. Stop the engine and then loosen air bleeding plug (3) of work
equipment pump (2) by 1/2 to 1 turn.

3. As oil free from air starts to flow out of air bleeding plug (3) of
work equipment pump (2), tighten air bleeding plug (3).

Air bleeding plug (3): 34.3 – 44.1 N•m (25.30 – 32.53 lbf ft)

4. Start the engine and run it at low idle for at least five minutes.

From Hydraulic Cylinder

1. Start the engine and run it at low idle for at least five minutes.

2. While running the engine at low idle, repeat raising and lowering of the lift arm four to five times.
★ Do not operate the piston rod beyond a position 100 mm (3.94 in) in front of the stroke end to prevent relieving.

3. While running the engine at high idle, repeat raising and lowering of the lift arm four to five times.
★ Do not operate the piston rod beyond a position 100 mm (3.94 in) in front of the stroke end to prevent relieving.

4. Operate the piston rod to the stroke end at low idle to relieve it.

5. Repeat Steps 2 and 3 for the bucket and steering.

★ When a cylinder is replaced, this operation should be performed before connecting the piston rod.

30-104 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT

Releasing Residual Pressure in Hydraulic Circuit

Between Respective Hydraulic Cylinders and Control Valve
★ When disconnecting the pipes between respective hydraulic cylinders and the work equipment, release the residual
pressure in the circuit according to the following procedure.

1. Stop the engine.

2. Loosen the oil filler cap gradually to release the internal pressure of the hydraulic tank.

3. Set the work equipment lock lever to the Free position.

4. Turn the starting switch ON.

5. Release the residual pressure using the work equipment control lever.

From ECSS (Travel Damper) Circuit

WARNING! When disconnecting the piping of the ECSS

circuit (between the accumulator for the ECSS
and the work equipment control valve),
release the pressure of the accumulator for the
ECSS according to the following procedure.

1. Remove front frame left side cover (1).

2. Loosen locknut (4) of ECSS pressure relief plug (3) on work

equipment control valve (2).

3. Loosen adjustment plug (5) 1/2 – 1 turn to release the accumulator

pressure.

4. After releasing the residual pressure, tighten plug (5) and

locknut (4) securely in this order.
• Loosen locknut (4) to the maximum before tightening
plug (5).
• After tightening plug (5), tighten locknut (4).

Plug: 19.6 – 27.5 N•m (14.46 – 20.28 lbf ft)

Locknut: 19.6 – 27.5 N•m (14.46 – 20.28 lbf ft)

WA500-6 30-105 ➁
TESTING AND ADJUSTING WORK EQUIPMENT

Moving Machine When Removing Operator Cab

★ It might be necessary sometimes to remove the operator cab to move a machine into a maintenance shop or to move a
machine to a safe place after removing a damaged operator cab. In such cases, using the emergency parking brake release
switch allows you to move the machine.

★ In this situation, the emergency parking brake release switch is used instead of the parking brake switch used on the
machine.

★ The harness is prepared only for moving the machine into a maintenance shop or moving it from a work site to a safer
place. It should not be used for any purpose other than this.

WARNING! Lower the work equipment to the ground;

apply the parking brake; and put chocks under
the tires so that the machine does not move.

1. Remove operator cab assembly (1).

★ Refer to CAB AND ITS ATTACHMENTS: Operator’s Cab and
Floor Frame Assembly: Removal and CAB AND ITS
ATTACHMENTS: Operator’s Cab and Floor Frame
Assembly: Installation in the Disassembly and Assembly
section.

2. Remove fuse box cover (2).

3. Start the engine and set emergency parking brake release

switch (3) to the release side to enable the machine to move to a
maintenance shop or safe place.

WARNING! Remove the chocks to move the machine.

4. After moving the machine, return the emergency parking brake

release switch to the original position.

30-106 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT

Bucket Positioner
★ Measurement conditions:

Engine coolant temperature: . . . . . . . . . . . .Within operating range

Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range

Testing and Adjusting

1. Stop the engine and make sure that clearance (a) between bucket-
levelness detecting proximity switch (1) and detection bar (3), and
between maximum tilt-detecting proximity switch (2) and
detection bar (3) is within the standard value.
Standard clearance (a): . . . . . . . . . . . . . .3 – 5 mm (0.12 – 0.20 in)

2. Run the engine at high idle and check the operating position.
(Measure three times and obtain the average.)

Adjusting Clearance
1. Adjust switch nut (5) so that clearance (b) between the tip of
switch protector (4) and switch (1) and sensing surface (2) may
conform to the standard value. Then fix them to the adjusted
positions.
Standard clearance (b): . . . . . . . . . . .0.6 – 1.0 mm (0.02 – 0.04 in)

Switch nut: 14.7 – 19.6 N•m (10.84 – 14.46 lbf ft)

2. Use shims and the proximity switch bracket mounting bolt to

adjust clearance (a) between proximity switch (1), sensing
surface (2), and detection bar (3) to the standard range. Then fix
them to the adjusted positions.
Standard clearance (a): . . . . . . . . . . . . . 3 – 5 mm (0.12 – 0.20 in)
★ Using shims, adjust detection bar (3) so that clearance (a) conforms to the standard value along every stroke of the
detection bar.

WA500-6 30-107 ➁
TESTING AND ADJUSTING WORK EQUIPMENT

Adjusting Bucket-Levelness Detecting Proximity Switch

1. Start the engine and raise the bucket.

2. Activate bucket-levelness detecting proximity switch (1) while

operating the bucket at 1,500 rpm.

3. Lower the bucket to the ground.

4. Make sure the bucket angle is set in the range of 0° – 1° downward

to the ground. Repeat this three times and if the angle does not
conform to the above angle, adjust it as described in Step 5.

5. Loosen two mounting bolts of bucket-levelness detecting

proximity switch bracket (6) to slide bracket (6) installing position
and adjust it.

6. Confirm three times that the bucket angle is set in the range of 0° –
1° downward to the ground.

30-108 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT

Adjusting Maximum Tilt-Detecting Proximity Switch

1. Set height (c) of the pin center of the lift arm end to 1,000 mm
(39.37 in) from the ground surface.

2. Tilt the bucket to the maximum position.

3. Loosen two mounting bolts of maximum tilt-detecting proximity

switch bracket (7) to slide bracket (7) installing position and adjust
it.
• Set distance (d) from the end of detection bar (3) to the center
line of proximity switch (2).
Dimension: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 mm (1.97 in).

WA500-6 30-109 ➁
TESTING AND ADJUSTING WORK EQUIPMENT

Position-Detecting Lever
Testing

1. Make sure that clearance (a) between lift arm angle sensor (1) and
detection lever (2) is within the standard value.
Clearance (a): . . . . . . . . . . . . . . . . . . . 0.5 – 1 mm (0.02 – 0.04 in)

Adjusting

★ If clearance (a) does not conform to the standard value, adjust it

according to the following procedure.

1. Loosen bolt (3).

2. Adjust position of detection bar (2) so that clearance (a) between

lift arm angle sensor (1) and detection lever (2) becomes the
standard value

3. Tighten bolt (3).

30-110 ➁ WA500-6
TESTING AND ADJUSTING WORK EQUIPMENT

Checking Proximity Switch Operation Pilot Lamp

The proximity switch has a pilot lamp to indicate the operating
condition of the switch. Use this pilot lamp to adjust the proximity
switch.

★ A: Operation pilot lamp (Red)

Relative Position of
Operation Pilot
Proximity Switch Proximity Switch Sensing Surface and Remarks
Lamp
Sensing Object
Bucket-levelness Near ON
detecting proximity switch Operates when center
and maximum tilt- Far OFF of switch is near.
detecting proximity switch

WA500-6 30-111 ➁
TESTING AND ADJUSTING ELECTRICAL SYSTEM TROUBLESHOOTING

ELECTRICAL SYSTEM TROUBLESHOOTING

Procedure for Testing Diodes
★ Check an assembled-type diode (8 pins) and independent diode
(2 pins) in the following manner.

★ The conductive directions of the assembled-type diode are

indicated on the surface of the diode as shown in the figure.

★ The conductive directions of the single diode are indicated on the

surface of the diode as shown in the figure.

Using Digital-Type Circuit Tester

1. Switch the testing mode to diode range and confirm the indicated value.
★ Voltage of the battery inside is displayed with conventional circuit testers.

2. Put the red probe (+) of the test lead to the anode (P) and the black
probe (–) to the cathode (N) of the diode. Confirm the indicated
value.

3. Determine acceptability of the diode from the indicated value.

• Indicated value remains unchanged: Conduction is absent
(Failure)
• Indicated value changes: The diode has conductivity
(Normal)★
★ A value between 460 to 600 is indicated for silicon
diodes.

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TESTING AND ADJUSTING ELECTRICAL SYSTEM TROUBLESHOOTING

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.

A. Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of the diode.

B. 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 whether a specific diode is good by the way the pointer swings.
• With connection 2A above, the pointer does not move. It swings, however, when connection 2B is used.
• Normal (however, magnitude of the pointer’s move (indicating the resistance value) varies depending on the
given tester model and the measurement range selected).
• The pointer swings with both connections 2A and 2B:
• Defective (Internal short circuit)
• The pointer does not swing with both connections 2A and 2B:
• Defective (Internal wire break)

WA500-6 30-113 ➁
TESTING AND ADJUSTING ELECTRICAL SYSTEM TROUBLESHOOTING

Preparation Work for Troubleshooting Electrical System

★ When carrying out troubleshooting for an electric circuit related to the machine monitor, transmission controller, work
equipment controller, or KOMTRAX terminal, expose the related connectors according to the following procedure.

★ Unplug and plug the connectors of special lock types according to the following procedure.

Machine Monitor
1. Unplug the following connectors from cover (1).
• L58 connector: Parking brake switch
• L59 connector: ECSS switch
• L65 connector: Machine monitor mode selector switch 2
• L66 connector: Machine monitor mode selector switch 1
• L67 connector: Front working lamp switch
• L68 connector: Rear working lamp switch
• L69 connector: Load meter mode selector switch (if equipped)
• L70 connector: Load meter mode display switch (if equipped)
• L72 connector: Beacon lamp switch (if equipped)

★ Pull the switches out of the cover and unplug the connectors.
★ Do not insert your hand through the bottom of the cover and
try to forcibly unplug the connector. Forcibly unplugging a
connector or switch may damage it.

2. Remove interior covers (2).

3. Remove cover (1).

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TESTING AND ADJUSTING ELECTRICAL SYSTEM TROUBLESHOOTING
4. Remove bracket-mounting bolt (4) of machine monitor (3) and
reverse the machine monitor.
★ Be careful not to pull the wiring harness forcibly.

5. Connect diagnostic T-adapters to the following wiring connectors

of machine monitor (3).
• L51, L52, L53, L54, L55, L56, and L57 connectors

Transmission Controller
1. Remove covers (5) and (6) through the rear side of the operator
seat.

2. Connect diagnostic T-adapters to connectors L02, L03, and L04 of

transmission controller (7).
★ When it is difficult to install or remove the connectors, do it
after removing the transmission controller first.
★ Connectors are fixed with screws. Loosen the screws before
unplugging the connectors.
★ When the connectors are returned to the original position,
tighten the screw to the specified torque.

Screw: 2.82 N•m (24.96 lbf in)

WA500-6 30-115 ➁
TESTING AND ADJUSTING ELECTRICAL SYSTEM TROUBLESHOOTING

Work Equipment Controller

1. Remove covers (5) and (6) through the rear side of the operator
seat.

2. Connect diagnostic T-adapters to connectors L05, L06, and L07 of

work equipment controller (8).
★ When it is difficult to install or remove the connectors, do it
after removing the work equipment controller first.
★ Connectors are fixed with screws. Loosen the screws before
unplugging the connectors.
★ When the connectors are returned to the original position,
tighten the screw to the specified torque.

Screw: 2.82 N•m (24.96 lbf in)

KOMTRAX Terminal
1. Remove covers (5) and (6) through the rear side of the operator
seat.

2. Connect diagnostic T-adapter to connector L80 of KOMTRAX

terminal (9).
★ When it is difficult to plug or unplug the connectors, do it after
removing the KOMTRAX terminal.
★ Connectors are fixed with screws. Loosen the screws before
unplugging the connectors.
★ When the connectors are returned to the original position,
tighten the screw to the specified torque..

Screw: 2.2 – 2.8 N•m (19.47 – 24.78 lbf in)

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TESTING AND ADJUSTING KOMTRAX TERMINAL SYSTEM

KOMTRAX TERMINAL SYSTEM

★ Whether the KOMTRAX system is installed at the time of manufacture or retrofitted, you must do the following two
actions before you can use the system:

• Register the machine.

• Activate the KOMTRAX system.

Starting KOMTRAX Terminal Operations

If the KOMTRAX Terminal Has Been Installed at the Plant Before Shipment

★ If the KOMTRAX terminal has been installed at the plant before shipment (as standard equipment), implement the
following procedure.

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 will use a KOMTRAX client PC to register the machine.
• Refer to Global KOMTRAX Web Reference Manual (for Key Person) for the procedure.

★ The terminal is now ready to use.

If the KOMTRAX Terminal is Retrofitted

★ When retrofitting the KOMTRAX terminal after shipment (retrofitted machine), do the Station Opening Check in
Machine Side and the Application for the Start of Use procedures in this section.

Remark
During the communication and check, you should park the machine outside to enable frequent
communication with the ORBCOMM satellite. The station opening check cannot be completed indoors
where radio waves from the satellite are intercepted.

Station Opening Check in Machine Side

★ Complete Steps 3 to 5 within 60 seconds. If 60 seconds or more
elapse, begin with Step 1 again.

1. Turn OFF the starting switch and then, after making sure five
seconds have elapsed, proceed to the next step.

2. Visually check that check connectors 1 and 2 are connected.

• Check connector 1: CHK0
• Check connector 2: CHK1

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TESTING AND ADJUSTING KOMTRAX TERMINAL SYSTEM
3. When about five seconds have elapsed after the starting switch was
set to ACC, make sure that the 7-segment indicator lamp changes
to hyphen “–” on the KOMTRAX terminal.

4. Unplug inspection connector 1 and wait for about five seconds.

• Make sure that the connector is unplugged.

5. Replug inspection connector 1 and wait for about five seconds.

★ If the KOMTRAX terminal detects that the connector was
unplugged and replugged, the dot on the 7-segment indicator
lamp blinks a few times.

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TESTING AND ADJUSTING KOMTRAX TERMINAL SYSTEM
6. Make sure that the 7-segment indicator lamp is indicated normally
on the KOMTRAX terminal.
★ If so, the 7-segment indicator lamp indicates characters (d),
(0), and (–) repeatedly for 30 seconds after Step 5 has ended.
★ Those characters, even if displayed normally, change to a
character other than hyphen (–) after 30 seconds or more have
elapsed.
★ The display may change to a character other than (0) even
within 30 seconds.

• If [Normal] is indicated, proceed to the next step.

• If (–) remains displayed, do Steps 1 to 5 again.

7. Turn the starting switch to the START position for about five
seconds and make sure that the engine does not start.
• If the engine starts, repeat the procedure from Step 1.
• Do not return the starting switch to the OFF position.

8. Turn the starting switch from the ACC position to the START
position again and make sure that the engine starts.

9. Make sure that the KOMTRAX terminal’s indicator lamps are

normally turned on.
• Move on to the next step if the display is [Normal]. (It takes
from 90 seconds to 15 minutes before the display turns normal.)
• If [GPS position data detection trouble] is indicated, check if the GPS antenna or cable appears abnormal. If there is
an abnormality, repair it and start from Step 1 again.
• If [Reception trouble] is indicated, check if the communication antenna or cable appears abnormal. If there is an
abnormality, repair it then repeat from Step 1 again.
• If [GPS position data detection trouble and reception trouble] is indicated, check if the GPS antenna/cable or
communication antenna/cable appears abnormal. If there is an abnormality, repair it and start from Step 1 again.

WA500-6 30-119 ➁
TESTING AND ADJUSTING KOMTRAX TERMINAL SYSTEM
★ If [Network trouble] is indicated, check the display of [LED-
C4] (refer to KOMTRAX Terminal Indicator Lamps). If the
CAN is not recognized, check the CAN harness of the
KOMTRAX terminal. If there is any abnormality, repair it and
start from Step 1 again.
[A]: Normal
[B]: GPS position data detection trouble
[C]: Reception trouble
[D]: GPS position data detection trouble and reception trouble
[E]: Network trouble

10. Turn the starting switch OFF.

11. Make sure that the 7-segment indicator lamp is displayed normally
after five seconds have elapsed.
★ When [Normal] appears, station opening check is completed.
★ If [Abnormal] appears, station opening check does not end
normally. Perform the procedure from Step 1 again.
★ If station opening check ends normally, it should not be
rechecked.

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TESTING AND ADJUSTING KOMTRAX TERMINAL SYSTEM

Application for the Start of Use

★ Application for the start of use should be made only after the sign-up test is finished.

1. Notify the KOMTRAX operations administrator of the following

information about the machine that completed the station opening
check in the machine side.

A. Information (model, part number, and serial number) about

the machine that completed the station opening check in the
machine side

B. Part number and serial number of KOMTRAX terminal

C. Value of service meter when the KOMTRAX terminal was

installed (in 0.1 hours)

2. The KOMTRAX operations administrator will use a KOMTRAX

client PC to register the machine.
• Refer to Global KOMTRAX Web Reference Manual (for Key
Person) for the procedure.

★ The terminal is now ready for use.

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TESTING AND ADJUSTING KOMTRAX TERMINAL SYSTEM

KOMTRAX Terminal Indicator Lamps (if equipped)

LED Lamps for CPU

1. LED-C1 (State of R or ACC signal)

2. LED-C2 (Starting output state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)

7-Segment and Dot Displays for CPU

7. 7-Segment (Number of unsent mails)

8. Dot (GPS positioning state)

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TESTING AND ADJUSTING KOMTRAX TERMINAL SYSTEM
In the KOMTRAX system, information and processing details are displayed on the LED on the upper surface of the
KOMTRAX terminal. If a detect is suspected in the system, perform the following checks.

• Check antennas.

• Check 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.

Checking Antennas

★ Before checking the LED displays, check that there is no abnormality around the communication antenna and
GPS antenna.

• The communication antenna should not be off or damaged.

• The communication antenna cable should not be broken and is normally connected to the KOMTRAX terminal.

• The GPS antenna should not be off or damaged.

• The GPS antenna cable should not be broken and is normally connected to the KOMTRAX terminal.

Checking Terminal LED Displays

1. Meaning of CPU LED displays

★ The LED displays should be checked with the starting switch turned ON, starting switch at START, or with the
engine started.
No. LED Name/Function Display (*1) Description
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 switch 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

State of engine control ON Engine control signal: ON

2 LED-C2
signal OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
States of S-NET Fast blink Starting switch C signal: ON
3 LED-C3 connection 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)

State of CAN Fast blink CAN: Connected (with fuel sensor)

4 LED-C4
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
6 LED-C6 2-LED OFF Normal operation mode

★ *1: Blink types and blink times

Fast blink: . . . . . . . . . . . . . . . . . . . .Blinks in about 1-second cycle

Slow blink: . . . . . . . . . . . . . . . . . . . .Blinks in about 4-second cycle

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TESTING AND ADJUSTING KOMTRAX TERMINAL SYSTEM
2. Contents of 7-segment and dot displays for CPU
★ The LED display should be checked with the starting switch turned ON.
No. LED Name/Function Display (*2) Description
The number indicates the number of unsent mails (10 or
0 to 9 more unsent mails are indicated by “9”).
Number of displayed Light-on indicates that the machine is in the process of
unsent mails, capturing the satellite.
7 7-segment
satellite capture
state The number indicates the number of unsent mails (10 or
0 to 9 fast
more unsent mails are indicated by “9”).
blink
Fast blink indicates that the satellite is not captured.
GPS positioning was completed.
ON
GPS positioning (The position can be confirmed.) *3
8 Dot
status GPS positioning was not completed.
OFF
(The position cannot be confirmed.) *3

★ *2: Blink types and blink times

Fast blink: . . . . . . . . . . . . . . . . . . . .Blinks in about 1-second cycle

Slow blink: . . . . . . . . . . . . . . . . . . . .Blinks in about 4-second cycle

★ *3: Supplementary explanation of GPS positioning status

• One or more minutes may pass until GPS positioning is completed after the starting switch is turned ON even in an
outdoor service area.
• GPS positioning will fail in a weak-signal or non-service area.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

MACHINE MONITOR SYSTEM

Adjusting Replaced, Reassembled, or Added Sensor, Controller, Etc.
Items to Be Set
★ If any of the following components or parts are replaced, disassembled, or assembled, initialize the sensors, solenoids, etc.
using the machine monitor.

★ Adjust the items in alphabetical order (A) using the machine monitor.

Replaced, Disassembled, Assembled, or Added Component or Option Adjustment Item

Machine monitor A, B, C, K, L, M
Transmission main body D, E, F
Transmission controller A, B, D. E, F
Transmission ECMV solenoid D, E, F
Lift arm angle sensor G, K, L, M
Work equipment control valve I
Work equipment EPC solenoid I
Work equipment electric lever H
Work equipment controller A, B, G, H, I
Work equipment bucket horizontal proximity switch J
Bucket J, K, L, M
Lift arm B, G, J, K, L, M
Adding and removing an optional device B

Adjustment Item Contents of Adjustment Section No.

A Selection of model 12 (*1)
B Selection of option 10 (*1)
C Machine serial number input 11 (*1)
D Adjustment of transmission ECMV current 7-1 (*1)
E Reset of transmission initial learning 7-2 (*1)
F Transmission initial learning 7-2 (*1)
G Adjustment of work equipment controller lift arm angle 7-4 (*1)
H Adjustment of work equipment EPC lever detent position 7-5, 7-6, 7-7 (*1)
I Adjustment of work equipment EPC starting current 7-5, 7-6, 7-7, 7-8 (*1)
J Adjustment of bucket positioner — (*2)
K Adjustment of load meter lift arm angle 7-17, 7-18 (*1)
L No load calibration of load meter — (*3)
M Loaded calibration of load meter — (*3)

★ *1: Description No. in MACHINE MONITOR SYSTEM: Service Mode in this section

★ *2: See Work Equipment: Bucket Positioner: Testing and Adjusting and Work Equipment: Checking Proximity Switch
Operation Pilot Lamp in this section.

★ *3: See the Operation manual provided with your load meter.

WA500-6 30-125 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Adjustment for User’s Needs

If the user indicates a problem or requests a solution for a problem, use the machine monitor to change or adjust the items
shown in the following table.

Contents of Remarks or Request Adjustment Item

Want to change the display unit of the speedometer. N
Want to use the short ton for the load meter weight display unit. O
Want to turn off display of the economy lamp. P
Want to suppress hunting. Q
Want to change the gearshift travel speed in the auto-shift. Q
Fine control is not available in the lift arm raise/lower operation or the response in this
R
operation is poor.
Fine control is not available in the bucket tilt/dump operation or the shock dump effort is
S
weak.
Large shocks result when stopping the lift arm raise/lower or a substantial overrun occurs
T
at stopping.
Matching at loading to dump truck is poor. U
Travel speed indication is too fast/slow. V
Want to turn off the character display-based travel speed/engine speed indication. W
Want the power mode to turn on as the starting switch is turned on. (Power mode priority) X

Adjustment Item Contents of Adjustment Section No. (*)

N Optional setting and selection of speed unit 10
O Optional setting and selection of short ton switching 10
P Optional setting and selection of economy lamp display 10
Q Adjustment of sensor and adjustment of transmission L mode shift point 7-3
R Adjustment of sensor and change of lift arm lever pattern 7-13
S Adjustment of sensor and change of bucket lever pattern 7-14
T Adjustment of sensor and adjustment of lift arm lower stop modulation 7-15
Adjustment of sensor and adjustment of pump cutoff pressure in lift arm
U 7-16
raise
V Optional setting and change of tire size 10
Optional setting and change of travel speed/engine speed display on
W 10
character display and normal screen
X Optional setting and change of power mode priority 10

★ *1: Section No. in MACHINE MONITOR SYSTEM: Service Mode in this section.

★ *2: Change of the display unit of the speedometer as well as the weight is not available when the specification is prepared
for a country where the SI unit is employed.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Normal and Special Functions of Machine Monitor

The machine monitor is equipped with normal functions and special functions. Data items are displayed on the character
display in the middle of the machine monitor.

Depending on the internal setting of the machine monitor, the display items are divided into automatic display items and items
displayed when the machine monitor switches are operated.

Normal Functions: Operator Mode

Functions for which the content is normally displayed or which can be displayed and operated by the operator using the
switches.

★ See the Operation & Maintenance Manual for details of the Operator mode.

Special Functions: Service Mode

Functions which the serviceman can display and operate with the special switches to carry out inspection, maintenance, and
troubleshooting.

Operator Mode Table Service Mode Table

Section No. Section No.

Operator Mode Service Mode
** **
1 Service meter/clock display function (*1) 1 Switch to Service mode and screen display
Electrical system failure history display
2 Load meter function (if equipped) (*1) 2
function
Mechanical system failure history display
3 Odometer display function 3
function
4 Maintenance monitoring function 4 Real-time monitoring function
5 Telephone No. input function 5 Cylinder cutout function
6 Language selection function ¤ 6 No-injection cranking function
7 Monitor brightness adjustment function 7 Adjustment function
8 Time adjustment function (*1) 8 Maintenance monitoring function
Travel speed/engine speed display
9 9 Operation information display function
selecting function
Character display: Travel speed/engine
10 speed display/non-display selecting 10 Optional device selecting function
function (*2)
11 Action code display function 11 Machine serial number input function
12 Failure code display function 12 Model selection function
13 Initialize function
Setting of machine monitor when
Appendix
monitor is exchanged

★ **: The number in this column correlates with an item number in the Operator Mode or the Service Mode function
descriptions in this section.

★ *1: This display is not available when the load meter function is turned off through the OPT option in the Service mode.

★ *2: Not displayed if “Travel speed/Engine speed on character display” are turned off on the character display by selecting
the OPT option in the Service mode.

WA500-6 30-127 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Functions and Flow of Service Mode

Remark
Some items may not be used, depending on the setting and specification, although they are displayed on
the monitor (for details, see the text).

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

WA500-6 30-129 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

30-130 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Operator Mode
★ The Operator mode is described below.

★ For details of the Operator mode, see Section 10, Structure, Function and Maintenance Standard, or the Operation &
Maintenance Manual.

Remark
The number after the function description correlates to the number in the Section No. column in the
Operator Mode table located in Normal and Special Functions of Machine Monitor in this section.

Service Meter/Clock Display Function (1)

If the starting switch is turned ON, the service meter is displayed on the
top line.

Load Meter Function (if equipped) (2)

Press the [◊] switch on the ordinary Service Meter display screen to
display the load meter function.

★ For more information, see Explanation of Components: Meter

Display Portion: Load Meter (if equipped) in the Operation
section of the Operation & Maintenance Manual.

Odometer Display Function (3)

Press the [◊] switch from the ordinary Service Meter display screen to
display the odometer.

When the load meter option is selected, press the [<] switch to display
the odometer which succeeds the display of the load meter function.

★ For details, see Other Functions of Machine Monitor in the

Operation & Maintenance Manual.

WA500-6 30-131 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Maintenance Monitoring Function (4)

1. Filter, oil replacement time display (automatic display)
As the time approaches to replace the oil or filter, the machine
monitor automatically displays this information to alert the
operator.

2. Resetting replacement time (selection menu)

When maintenance operation for oil or a filter is completed, the
machine monitor allows you to reset the time interval through the
switch operation.

★ For details, see Other Functions of Machine Monitor in the

Operation & Maintenance Manual.

Telephone Number Input Function (5)

Telephone numbers are entered through the switch operation.
Modification or cancellation of the phone numbers in the machine
monitor is also available through the switch operation.

★ When action code [E03] is displayed, a phone number is displayed

along with [CALL].

★ For details, see Other Functions of Machine Monitor in the

Operation & Maintenance Manual.

Language Selection Function (6)

Switch operation allows you to select a display language for the
machine monitor.

★ The Service mode function is not included in the display selection

function because it is always displayed in English.

★ Available languages: English, Japanese, German, French, Italian,

Spanish, and Swedish.

★ For details, see Other Functions of Machine Monitor in the

Operation & Maintenance Manual.

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Monitor Brightness Adjustment Function (7)

Brightness of the machine monitor is adjustable in seven levels through
the switch operation.

★ Adjustment of brightness is available by two methods: adjustment

of the monitor alone and separate adjustment of the monitor and
liquid crystal.

★ For details, see Other Functions of Machine Monitor in the

Operation & Maintenance Manual.

Time Adjustment Function (8)

The time indicated by the clock of the machine monitor is adjustable.

★ For details, see Other Functions of Machine Monitor in the

Operation & Maintenance Manual.

★ This item can be changed only when the optional load meter
function is selected.

Travel Speed/Engine Speed Display Selecting

Function (9)
A unit to be used for the machine monitor speed display is selectable
from km/h and MPH. It is also possible to turn the display of the travel
speed and engine speed ON or OFF.

★ For details, see Other Functions of Machine Monitor in the

Operation & Maintenance Manual.

★ This function is available only when the RPM OPT option is

selected.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Travel Speed/Engine Speed Display/Non-Display

Selecting Function (10)
The travel speed or engine speed displayed on the character display of
machine monitor can be turned ON and OFF.

★ This function is available only when the RPM/SPEED option is

selected.

★ When the travel speed is displayed at the center of the machine

monitor, the engine speed is displayed on the character display.
When the engine speed is displayed at the center of the machine
monitor, the travel speed is displayed on the character display.

★ For details, see Other Functions of Machine Monitor in the

Operation & Maintenance Manual.

Action Code Display Function (11)

If trouble occurs, the machine monitor displays an action code
corresponding to the seriousness of the trouble to alert the operator to
take appropriate action.

★ The figure shows an example of the screen on which action code

[E03] and [CALL + Telephone number] are alternately displayed.

★ When action code [E01] or [E02] is displayed, [CALL +

Telephone number] is not displayed.

★ Action codes and actions alerted to operator

CALL +
Action Code Actions Recommended to Operator
Telephone Number
• Do necessary testing and/or servicing when the current work is completed or
E01 Not displayed
when the operator changes shift.
• 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.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Failure Code Display Function (12)

Pressing the [>] switch once while an action is displayed on the
machine monitor displays the failure code corresponding to the failure
currently warned.

★ The failure codes detected in the past are divided into failures of
the electrical system and the mechanical system and are recorded
as fault history. (For details, see Electrical System Failure History
Display Function (ELECTRIC FAULT) and Mechanical System
Failure History Display Function (MACHINE FAULT) in the
Service Mode section.)

★ When two or more failures are involved, pressing the [>] switch
displays further codes.

★ If the [>] switch is pressed again after it was pressed to display

every involved failure code, the Service Meter display screen is restored.

Pressing the [>] switch one more time displays the failure codes from the first.

If the [>] switch is not touched for 60 seconds, the Action Code display screen is automatically displayed.

★ The service code display function displays the following

information.

A: Failure code (location code + problem code)

B: Controller code:
• MON: Machine monitor
• TM: Transmission controller
• WRK: Work equipment controller
• ENG: Engine controller
C: The system where failure occurred

★ For details of a displayed failure code, see Failure Codes Table in

the Troubleshooting section.

★ If any switch operation is not done for 60 seconds or longer on the Failure Code display screen, the Action Code display
screen is automatically turned on.

WA500-6 30-135 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Service Mode
Remark
The number after the function description correlates to the number in the Section No. column in the Service
Mode table located in Normal and Special Functions of Machine Monitor.

Switching to Service Mode and Screen Display

Remark:
The service meter is displayed in English, regardless of language selection in the Operator mode.

When using the Service mode, carry out the following special operation to switch the screen display.

1. Checking screen display

Make sure that the machine monitor is set to the Operator mode and any of “Service meter,” “Action code,” or “Failure
code” is displayed on the screen.

2. Displaying ID Input initial screen

Hold down the [■] switch and [<] switch simultaneously for five seconds minimum to open the ID Input initial screen.

★ Holding down the two switches for five seconds or longer makes the entire screen blank. Once the screen is blank,
release the buttons.

3. Inputting and confirming ID

Use the buttons to input the ID.
• ID: 6491

A. Cursor (C) is positioned at the highest-order digit. Pressing the

[<] and [>] switches changes the value of this digit in the
range of 0 – 9.

B. Press the [◊] switch when the intended value appears in order
to select it.
★ The cursor moves to the 2nd digit.

C. Set the value in the same order and then press the [◊] switch.
• When you have entered a wrong value to a position
except the highest-order digit, move to the highest-order
digit using the [■] switch to repeat the procedure from
the beginning. In this case, values that have 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 the [■] switch. (*1).
★ (*1): When the cursor is located at the leftmost position,
pressing the switch restores the normal screen (Operator
mode).
★ When the cursor is at a location other than the leftmost
position, pressing the switch returns the cursor to the
leftmost position.
★ If a switch operation is not done for 60 seconds or more from the ID Input screen, the normal screen is
automatically turned on.

30-136 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
4. Displaying menu initial screen
★ After confirming the 4-digit ID, turn on the menu initial
screen of the Service mode.
★ Once entered and confirmed, an ID remains effective until the
starting switch is turned off.

5. Selecting Service mode menu

★ Pressing the [<] and [>] switches from the menu screen
displays the Service mode menus endlessly in the following
order.
★ The menus are displayed in the field indicated with the [*]
mark.
[1] ELECTRIC FAULT: Electrical system failure history
display function
[2] MACHINE FAULT: Mechanical system failure history
display function
[3] REAL-TIME MONITOR: Real-time monitoring function
[4] CYLINDER CUT-OUT: Engine reduced-cylinder
function
[5] NO INJECTION: No injection cranking function
[6] TUNING: Adjustment function
[7] MAINTENANCE MONITOR: Maintenance monitoring
function
[8] OPERATION INFO: Operating information 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 (function specialized for plant)

★ The menu is indicated in the parts of [*].

6. Completion of mode and function

Either of the following procedures ends a mode or function independent of the function being selected and the layer in
which it is used.

A. When the operation is to be continued using another mode or function: Press the [■] switch to return to the mode
screen or menu screen to be used next.

★ Note, however, that the [■] switch functions as an execution key on the [YES/NO] screen.
★ When the normal screen (Operator mode) is inadvertently turned on, repeat the above steps from Step 1 (input of
the ID is not necessary).

B. When ending an operation completely, turn the starting switch off from the current state.

WA500-6 30-137 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Electrical System Failure History Display Function (ELECTRIC FAULT) (2)

The machine monitor records the past failures in the electric system as
failure codes. The failure codes are displayed from the following
operations.

1. Selecting the menu

Select the ELECTRIC FAULT from the menu screen of the
Service mode.

★ [**] field displays total number of the failure history currently

recorded (up to 20 cases).

2. Displaying failure history

Press the [◊] button while the menu is selected to display the
recorded failure history.

3. Displayed problem data

The electric system problem data display function displays the
following information.
A: Record number
B: Failure code (Location code in four digits + Problem code in
two digits)
C: Number of occurrences (Number of occurrences of same code
in past)
D: Elapsed time 1 (Elapsed time on service meter from the first
occurrence)
E: Elapsed time 2 (Elapsed time on service meter from the last
occurrence)

★ The code of a failure currently occurring is indicated by flashing.

★ For details of a displayed failure code, see the Failure Codes Table in the Troubleshooting section.
★ Note that part of the information displayed from the electrical system problem data display function and the failure
code display function is not identical.
★ When the requested failure history is not recorded, [–] is indicated in the display space.

4. Switching failure history display

Pressing the [<] or [>] switch while a set of failure history is on the screen displays another set of recorded failure history.

30-138 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
5. Deleting individual failure history

A. Press the [◊] switch while the target failure history of deletion
is on the screen to turn on the CLEAR screen.

B. Select YES or NO using the [<] or [>] switch.

★ The selected cursor will start flashing.

• If YES is selected and the [■] switch is pressed, the
information is deleted.
• If NO is selected and the [■] switch is pressed,
deletion is cancelled and the Maintenance Interval
Change Item screen is restored.
★ By default, the cursor is set to NO (cancel) to prevent a
resetting error.
★ You cannot delete information about the currently
occurring failure.

6. Deleting all problem data

A. Press the [<] or [>] switch while the problem data is on the
screen to display the ALL CLEAR menu screen.

B. Press the [◊] switch to display the ALL CLEAR screen.

C. Select YES or NO using the [<] or [>] switch.

★ The selected cursor will start flashing.

• If YES is selected and the [■] switch is pressed, the
information is deleted.
• If NO is selected and the [■] switch is pressed,
deletion is cancelled and the Maintenance Interval
Change Item screen is restored.
★ By default, the cursor is set to NO (cancel) to prevent a
resetting error.
★ You cannot delete information about the currently
occurring failure.

WA500-6 30-139 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Mechanical System Failure History Display Function (MACHINE FAULT) (3)

The machine monitor retains the data for past problems in the mechanical system as failure codes. The failure codes are
displayed from the following operations.

1. Selecting the menu

★ Select MACHINE FAULT from the menu screen of the
Service mode.
★ [**] field displays total number of the failure history currently
recorded.

2. Displaying failure history

Press the [◊] switch while the menu is selected to display the
recorded failure history.

3. Displayed failure history

The mechanical system failure history display function displays
the following information.
A: Record number
B: Failure code (Location code in four digits + Problem code in
two digits)
C: Number of occurrences (Number of occurrences of same code
in past)
D: Elapsed time 1 (Elapsed time on service meter from the first
occurrence)
E: Elapsed time 2 (Elapsed time on service meter from the last
occurrence)

★ The code of a failure currently occurring is indicated by

flashing.
★ For details of a displayed failure code, see the Failure Codes
Table in the Troubleshooting section.
★ Note that part of the information displayed from the
mechanical system failure history display function and the
failure code display function is not identical.
★ When the requested failure history is not recorded, [–] is
indicated in the display space.

4. Switching failure history display

Pressing the [<] or [>] switch while a set of failure history is on the screen displays another set of recorded failure history.

5. Deleting failure history (Not available)

You cannot delete the failure history of the mechanical system.

30-140 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Real-Time Monitoring Function (REAL-TIME MONITOR) (4)

The machine monitor checks the state of the machine on a real-time basis by referencing signals from the sensors installed in
various parts of the machine.

The real-time monitoring function displays the following two types of information.

• 1-item independent display (for each controller)

• 2- item simultaneous display (code input)

1. Selecting the menu

Select REAL-TIME MONITOR from the menu screen of the
Service mode.

2. Displaying submenu
Press the [◊] switch while the menu is selected to display the
Submenu initial screen.

3. Selecting submenu
★ Press the [<] or [>] switch from the Submenu screen to display
the submenus endlessly in the following order.
★ The submenus are displayed in the field indicated with the [*]
mark.
[1] MONITOR PANEL: Machine monitor system
[2] TRANSMISSION: Transmission controller system
[3] BOOM: Work equipment controller system
[4] ENGINE: Engine controller system
[4] 2 ITEMS: 2-item display

WA500-6 30-141 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
4. Setting the 1-item individual monitoring

A. Select the target controller system of monitoring from the

Submenu screen.

B. Press the [◊] switch while the submenu is selected to display

the MONITOR PANEL screen.

C. Press the [<] or [>] switch to select a monitoring item.

★ The monitoring items are scrolled according to the
internally set order.
★ Holding down the [◊] switch turns on high-speed
scrolling.
★ Holding and cancelling the monitoring data:
Pressing the [◊] switch while the monitoring is in
progress holds the monitoring data and the [◊] mark starts
flashing. Pressing the [◊] switch again restores the active
state.

D. Display data for 1-item individual monitoring

The 1-item Individual Monitoring screen displays the
following information.
A: Item display
B: Monitoring codes (5 digits)
1: Monitoring data (including the unit used)

★ See the Real-Time Monitoring Codes Tables for details.

5. Setting 2-items simultaneous monitoring

A. Select 2 ITEMS from the Submenu screen.

B. Press the [◊] switch while the submenu is selected to display the
Monitoring Code Input screen.

30-142 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
i. This cursor (C) is located at the highest-order digit.
Pressing the [<] or [>] switch changes the value of this
digit in the range of 0 – 9.

ii. Press the [◊] switch when the intended value appears in
order to select it as the set value.
★ The cursor moves to the 2nd position.

iii. Set the value in the same order and then press the
[◊] switch.
★ When you have entered a wrong value in a position
except the highest-order digit, you can move the
cursor to the highest-order digit by using the
[■] switch and repeating the procedure from the
beginning. In this case, values that have been entered
remain as they are until modified. When the cursor is
at the highest-order digit, it can move to the higher
layer by using the [■] switch.

C. As both monitoring codes are confirmed, the 2 ITEMS screen

will be turned on.
★ Holding and cancelling the monitoring data
Pressing the [◊] switch while the monitoring is in
progress holds the monitoring data and the [◊] mark starts
flashing. Pressing the [◊] switch again restores the active
state.

D. Display data for 2-items simultaneous monitoring

★ 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)
★ See the Real-Time Monitoring Codes Tables for details.

WA500-6 30-143 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Real-Time Monitoring Codes Tables

Monitor Panel [Mechanical Monitor System]

Remark
Table on this page corresponds to table on facing page.
MONITOR PANEL [Mechanical Monitor System]
Monitoring Monitoring Items Display Item Data Display Range
No.
Codes (*1) (*2) (*3)
1 20200 Part number of monitoring software VERSION Arabic numerals
2 20221 Application version VERSION (APP) Arabic numerals
3 20222 Data version VERSION (DATA) Arabic numerals

4 01001 Engine speed ENG SPEED 0 – 3000

5 40000 Travel speed SPEED 0 – 50

6 04202 Fuel level FUEL SENSOR 0 – 100

7 04207 Fuel level FUEL SENSOR 0.00 – 5.00

8 04103 Engine coolant temperature COOLANT TEMP -40 – 210

9 40100 Torque converter oil temperature TC OIL TEMP 24 – 131

10 40101 Torque converter oil temperature TC OIL TEMP 0.00 – 5.00

11 04401 Hydraulic oil temperature HYD TEMP 24 – 131

12 04404 Hydraulic oil temperature HYD TEMP 0.00 – 5.00

13 30202 Rear brake oil temperature R BRAKE OIL 24 – 131

14 30205 Rear brake oil temperature R BRAKE OIL 0.00 – 5.00

15 04302 Charge level ALTERNATOR R 0.00 – 30.00

16 40200 Small lamp voltage SMALL LAMP 0.00 – 30.00
17 40300 Battery electrolyte level A BATTERY A 0.00 – 30.00
18 40301 Battery electrolyte level B BATTERY B 0.00 – 30.00

19 06001 Lift arm angle BOOM ANG -90 – 90

20 06003 Lift arm angle BOOM ANG 0.00 – 5.00

30-144 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

MONITOR PANEL [Mechanical Monitor System]

Unit Remarks
No. Display Contents in Normal State
(*4) (*5)
1 Depends on software part number Status display
2 Depends on application version Status display
3 Depends on data version Status display
Low idle: 800 ±25 rpm
High idle: 2000 ±50 rpm (P-mode)
4 1900 ±50 rpm (E-mode) rpm
Torque converter stall: 1800 ±100 rpm (P-mode)
1730 ±100 rpm (E-mode)
F1/R1: 6.7/7.3 km/h (4.2/4.5 mph) ±5% (P-mode, Torque converter)
F2/R2: 11.7/12.8 km/h (7.3/8.0 mph) ±5% (P-mode, Torque converter)
5 km/h (mph)
F3/R3: 20.3/22.0 km/h (12.6/13.7 mph) ±5% (P-mode, Torque converter)
F4/R4: 33.8/37.0 km/h (21.0/23.0 mph) ±5% (P-mode, Torque converter)
6 0 – 100% %
Gauge FULL (100%, 10 Ω): 0.32 V At disconnection or hot short
Gauge 1/2 (50%, 32 Ω): 0.88 V in sensor: Gauge EMPTY
7 V
Caution (61.3 Ω): 1.45 V At grounding fault in sensor:
Gauge EMPTY (0%, 85 Ω): 1.81 V Gauge FULL
Coolant temperature:
Max. 100°C (212°F)
8 Depends on machine status (°C) °C (°F)
Data acquired from engine
controller
9 Depends on machine status (°C) °C (°F) Overheat 120°C (248°F)
At disconnection or hot short
Start of gauge red zone: 120°C (248°F): 1.62 V in sensor: Gauge MIN
10 V
80°C (176°F): 2.91 V At grounding fault in sensor:
Gauge MAX
Oil temperature of hydraulic
11 Depends on machine status (°C) °C (°F)
tank Max. 100°C (212°F)
At disconnection or hot short
Start of gauge red zone: 120°C (248°F): 1.62 V in sensor: Gauge MIN
12 V
80°C (176°F): 2.91 V At grounding fault in sensor:
Gauge MAX
13 Depends on machine status (°C) °C
120°C (248°F): 1.62 V
14 V
80°C (176°F): 2.91 V
15 Depends on machine status (0.0 to 30 V) V
16 Depends on machine status (0.0 to 30 V) V
17 Min. 2 V V Only for optional setting
18 — V Not used in this machine.
STD lift arm: Highest lift arm: 46.8 ±2.0 deg
Lowest lift arm: -42.3 ±3.0 deg
19 Degree (°)
Hi lift arm: Highest lift arm: 49.3 ±2.0 deg
Lowest lift arm: -40.5 ±3.0 deg
STD lift arm: Highest lift arm: 3.80 ±0.3 V
Lowest lift arm: 1.33 ±0.5 V
20 V
Hi lift arm: Highest lift arm: 3.87 ±0.3 V
Lowest lift arm: 1.38 ±0.5 V

WA500-6 30-145 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

MONITOR PANEL [Mechanical Monitor System]

Monitoring Monitoring Items Display Item Data Display Range
No.
Codes (*1) (*2) (*3)

21 40400 Lift arm bottom pressure BOOM BTM PRESS 0.00 – 50.00

22 40402 Lift arm bottom pressure BOOM BTM PRESS 0.00 – 5.00

23 40500 Lift arm head pressure BOOM HEAD PRESS 0.00 – 50.00

24 40501 Lift arm head pressure BOOM HEAD PRESS 0.00 – 5.00

25 40600 Calibration pressure CAL PRESS 0.00 – 50.00

26 40800 Load meter calculated weight MES LOAD 0.00 – 50.00
27 30802 Rotary switch setting state SW1, SW2, SW3 F, F, F
28 30904 DIP switch setting state SW5-1, SW5-2 ON/OFF, ON/OFF
29 30905 DIP switch setting state SW5-3, SW5-4 ON/OFF, ON/OFF
30 30906 DIP switch setting state SW6-1, SW6-2 ON/OFF, ON/OFF
31 30907 DIP switch setting state SW6-3, SW6-4 ON/OFF, ON/OFF
32 40900 Input signal D_IN_0-7 D-IN--0------7 See attached table
33 40901 Input signal D_IN_8-15 D-IN--8------15 See attached table
34 40902 Input signal D_IN_16-23 D-IN--16------23 See attached table
35 40903 Input signal D_IN_24-31 D-IN--24------31 See attached table
36 40904 Input signal D_IN_32-39 D-IN--32------39 See attached table
37 40925 Output signal D_OUT_0-3 D-OUT--0--3 See attached table

*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 usable characters is restricted.

*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the range.

*4: SI units alone are employed whenever a unit is needed.

*5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and item name may
be displayed on the machine monitor.

30-146 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

MONITOR PANEL [Mechanical Monitor System]

Unit Remarks
No. Display Contents in Normal State
(*4) (*5)
Rated loading, high idle, lift arm control lever
21 Depends on machine status. MPa (psi) full, arm horizontal:
Approx. 18 MPa (2610.68 psi)
0 MPa: 0.5 V
10 MPa: 1.3 V
22 V
20 MPa: 1.1 V
50 MPa: 4.5 V
Only for optional setting of load meter
(Arm horizontal: Rated loading, high idle, lift
23 Depends on machine status. MPa (psi)
arm control lever full:
Approx. 0.5 MPa (72.5 psi)
0 MPa: 0.5 V
10 MPa: 1.3 V
24 V Only for optional setting of load meter
20 MPa: 1.1 V
50 MPa: 4.5 V
25 — MPa Not used in this machine.
26 Load weight (t) ton Only for optional setting of load meter
27 Status display Not used in this machine.
28 Status display Not used in this machine.
29 Status display Not used in this machine.
30 Status display Not used in this machine.
31 Status display Not used in this machine.
32 Status display
33 Status display
34 Status display
35 Status display
36 Status display
37 Status display

WA500-6 30-147 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
MON [Mechanical Monitor System]

MON [Mechanical Monitor System]

Input/
Monitoring Description of ON/OFF Switch
No. Output Display Item
Codes (Display: when ON; 1, when OFF; 0)
Signal
D-IN-0 Head lamp Lighting of head lamp = ON (24 V)/OFF (OPEN)
D-IN-1 Starting motor ACC Starting switch Acc = ON (24 V)/OFF (OPEN)
D-IN-2 Starting switch C Starting switch START = ON (24 V)/OFF (OPEN)
D-IN-3 — —
Auto grease A
D-IN-4 D-IN-5
1 40900 D-IN-4 (Applicable to a machine equipped
with optional auto grease) Operation OFF ON
Failed OFF OFF
Auto grease B
D-IN-5 (Applicable to a machine equipped Tank empty ON OFF
with optional auto grease) Failed ON ON
D-IN-6 — —
D-IN-7 — —
D-IN-8 — —
D-IN-9 — —
Load meter mode selector switch
(A/B)
D-IN-10 Pressing of switch = ON (24 V)/OFF (OPEN)
(Applicable to a machine equipped
with optional load meter)
Load meter mode selector switch
(+/–)
2 40901 D-IN-11 Pressing of switch = ON (24 V)/OFF (OPEN)
(Applicable to a machine equipped
with optional load meter)
Lighting of turn signal right lamp = ON (GND)/OFF
D-IN-12 Turn signal right
(OPEN)
Lighting of turn signal left lamp = ON (GND)/OFF
D-IN-13 Turn signal left
(OPEN)
D-IN-14 [◊] switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-15 [■] switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-16 Brake oil pressure (front) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17 Brake oil pressure (rear) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-18 — —
D-IN-19 — —

3 40902 D-IN-20 Clogged air cleaner No clogging = ON (GND)/OFF (OPEN)

D-IN-21 — —
Parking brake emergency release
D-IN-22 Pressing of switch = ON (24 V)/OFF (OPEN)
switch
Load meter total weight display
D-IN-23 Pressing of switch = ON (GND)/OFF (OPEN)
selector switch

30-148 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

MON [Mechanical Monitor System]

Input/
Monitoring Description of ON/OFF Switch
No. Output Display Item
Codes (Display: when ON; 1, when OFF; 0)
Signal
D-IN-24 Transmission filter clogging No clogging = ON (GND)/OFF (OPEN)
D-IN-25 — —
Parking brake operation = ON (GND)/OFF
D-IN-26 Parking brake
(OPEN)
D-IN-27 Engine coolant level Normal coolant level = ON (GND)/OFF (OPEN)

4 40903 D-IN-28 — —
D-IN-29 Engine oil level Normal oil level = ON (GND)/OFF (OPEN)
Operation of emergency steering
motor (Applicable to a machine Emergency steering operation = ON (GND)/OFF
D-IN-30
equipped with the optional (OPEN)
emergency steering)
D-IN-31 — —
Load meter subtotal switch
D-IN-32 Pressing of switch = ON (GND)/OFF (OPEN)
(Load meter specifications)
Load meter cancel switch
D-IN-33 Pressing of switch = ON (GND)/OFF (OPEN)
(Load meter specifications)
D-IN-34 High beam (dimmer switch) High beam = ON (GND)/OFF (OPEN)
5 40904 D-IN-35 — —
D-IN-36 Service switch ON = ON(GND)/OFF(OPEN)
D-IN-37 > switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-38 < switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-39 — —
D-OUT-0 Alarm buzzer Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1 — —
6 40952
D-OUT-2 — —
D-OUT-3 — —

WA500-6 30-149 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
Transmission [Transmission Controller System]

Remark
Table on this page corresponds to table on facing page.

TRANSMISSION [Transmission Controller System]

Monitoring Monitoring Items Display Item Data Display Range
No.
Codes (*1) (*2) (*3)
1 20201 Transmission controller ROM part number VERSION Arabic numerals
2 20223 Application version VERSION APP 20223
3 20224 Data version VERSION DATA 20224

4 41600 Selection of engine mode ENGINE MODE Arabic numerals

5 41400 Fan pump EPC current value (Command) FAN EPC DIR 0 – 1000

6 93400 Fan reverse switch input FAN REVERSE SW Arabic numerals

7 41501 Torque converter inlet oil temperature T/C IN OIL TEMP —

8 41502 Torque converter inlet oil temperature T/C IN OIL TEMP —
9 93500 Torque converter input shaft speed T/C SPEED:IN —
10 93501 Torque converter output shaft torque T/C TORQUE:OUT —
11 31200 Transmission input shaft speed T/M SPEED IN 0 – 32767

12 31400 Transmission output shaft speed T/M SPEED:OUT 0 – 32767

13 31404 Transmission output shaft speed 2 T/M SPEED:OUT2 —

14 41203 Transmission cutoff operation setting T/M CUT SET 0.00 – 5.00

15 41201 Transmission cutoff (left brake) pressure T/M CUT OFF P 0.00 – 5.00

16 41202 Transmission cutoff (left brake) pressure T/M CUT OFF P 0.00 – 5.00

17 93700 Torque converter speed ratio TC SPEED RATIO 0 – 100

18 93600 Transmission oil temperature T/M OIL TEMP 0 – 150

19 93601 Transmission oil temperature sensor input voltage T/M OIL TEMP 0.00 – 5.00

20 92400 Modulation clutch oil pressure input MOD/C PRESS 0.00 – 50.00
21 92401 Modulation clutch oil pressure input voltage MOD/C PRESS 0.00 – 5.00
22 92500 Modulation clutch calorific value MOD/C Q 0 – 25.5
23 92501 Modulation clutch calorific rate MOD/C q 0 – 2.55
Throttle lock switch (pressed up)
24 95500 THROT LOCK A Arabic numerals
(RPM set switch)

30-150 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

TRANSMISSION [Transmission controller system]

Unit Remarks
No. Display Contents in Normal State
(*4) (*5)
1 Depends on software part number Status display
2 Depends on software version Status display
3 Depends on software version Status display
0: Power mode
4 Status display
2: Economy mode
0 – 1000 [mA]
Engine speed below 500 rpm = 677 mA
5 During cranking (Terminal C operation) = 850 mA mA
During fan reverse switching = 850 mA
During fan reverse operation = 0 mA
1: ON (CLOSE)
6 Status display
0: OFF
7 — °C Not used in this machine.
8 — V Not used in this machine.
9 — rpm Not used in this machine.
10 — Nm Not used in this machine.
11 0 – 32767 [min-1] rpm
0 – 32767 [min-1]
0 km/h = 0 rpm
10 km/h (6 mph) = 788 rpm
12 rpm
20 km/h (12 mph) = 1376 rpm
30 km/h (19 mph) = 2063 rpm
40 km/h (25 mph) = 2751 rpm
13 — rpm Not used in this machine.
0.00 – 5.00 MPa
14 MPa (psi) Cutoff set operation changes the displayed value.
(0.00 – 725.19 psi)
As foot brake is released: 0.00 ±0.1 MPa
0.00 – 5.00 MPa
15 MPa (psi) Foot brake pressed: Brake pressing changes the
(0.00 – 725.19 psi)
displayed value.
As foot brake is released: 1.00 ± 0.1 V
16 0.00 – 5.00 [V] V Foot brake pressed: Brake pressing changes the
displayed value.
17 0 – 100 [%] %
18 0 – 150°C (0 – 302°F) °C (°F)
0.00 – 5.00 [V]
4.72 V = 0°C (0°F)
4.33 V = 30°C (86°F)
19 V
3.55 V = 60°C (140°F)
2.20 V = 100°C (212°F)
1.61 V = 120°C (248°F)
20 — MPa Not used in this machine.
21 — V Not used in this machine.
22 — 2 Not used in this machine.
100 J/cm
23 — 0.1 kW/cm2 Not used in this machine.
0: PRM set switch OFF
24 Status display
1: PRM set switch ON

WA500-6 30-151 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

TRANSMISSION [Transmission Controller System]

Monitoring Monitoring Items Display Item Data Display Range
No.
Codes (*1) (*2) (*3)
Throttle lock switch (pressed downward)
25 95501 THROT LOCK B Arabic numerals
(RPM set auto-deceleration switch)
26 95400 Throttle correction command output THROTTLE MOD -100 – 100
27 44200 Throttle opening upper limit output THROT LIMIT UP 0 – 100.0
28 44201 Throttle opening lower limit output THROT LIMIT LO 0 – 100.0

29 93801 Accelerator mode THROTTLE MODE Arabic numerals

30 94000 Traction setting input value TRACTION DIAL —

31 94001 Traction setting input voltage TRACTION DIAL —

32 95000 Lockup selector switch input signal LOCK UP SW Arabic numerals

33 31602 1st ECMV current value (Command) ECMV 1 DIR 0 – 1000

34 31603 2nd ECMV current value (Command) ECMV 2 DIR 0 – 1000
35 31604 3rd ECMV current value (Command) ECMV 3 DIR 0 – 1000
36 31605 4th ECMV current value (Command) ECMV 4 DIR 0 – 1000
37 31608 F (forward) ECMV current value (Command) ECMV F DIR 0 – 1000
Lockup clutch ECMV current value
38 31609 ECMV LU DIR 0 – 1000
(Command)
Modulation clutch ECMV current value
39 31640 ECMV MOD/C DIR —
(Command)
40 31606 R (reverse) ECMV current value (Command) ECMV R DIR 0 – 1000
ECSS (travel damper) solenoid valve current
41 93300 ECSS V DIR 0 – 1000
value (Command)
0 – 2.55
42 41802 1st fill time FILL TIME 1 (When fill is not
provided: 0)
0 – 2.55
43 41803 2nd fill time FILL TIME 2 (When fill is not
provided: 0)
0 – 2.55
44 41804 3rd fill time FILL TIME 3 (When fill is not
provided: 0)
0 – 2.55
45 41805 4th fill time FILL TIME 4 (When fill is not
provided: 0)
0 – 2.55
46 41808 F (forward) fill time FILL TIME F (When fill is not
provided: 0)
0 – 2.55
47 41806 R (reverse) fill time FILL TIME R (When fill is not
provided: 0)
48 40905 Input signal D_IN_0-7 D-IN--0------7 See attached table
49 40906 Input signal D_IN_8-15 D-IN--8-----15 See attached table
50 40907 Input signal D_IN_16-23 D-IN-16-----23 See attached table

30-152 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

TRANSMISSION [Transmission Controller System]

Unit Remarks
No. Display Contents in Normal State
(*4) (*5)
0: PRM set auto deceleration switch OFF
25 Status display
1: PRM set auto deceleration switch ON
26 –100 – 100 [%] %
27 0.0 – 100.0 [%] %
28 0.0 – 100.0 [%] %
Depends on accelerator pedal operation.
Accelerator pedal released = 0
29 Accelerator pedal partial pressing (release side) = 1 Status display
Accelerator pedal partial pressing (pressing side) = 2
Accelerator pedal full pressing = 3
30 — % Not used in this machine.
31 — V Not used in this machine.
0: Lockup selector switch OFF
32 Status display
1: Lockup selector switch ON
33 0 – 1000 [mA] mA
34 0 – 1000 [mA] mA
35 0 – 1000 [mA] mA
36 0 – 1000 [mA] mA
37 0 – 1000 [mA] mA

38 0 – 1000 [mA] mA

39 — mA Not used in this machine.

40 0 – 1000 [mA] mA

41 0 – 1000 [mA] mA

42 0 – 2.55 [sec], When fill is not provided: 0 sec

43 0 – 2.55 [sec], When fill is not provided: 0 sec

44 0 – 2.55 [sec], When fill is not provided: 0 sec

45 0 – 2.55 [sec], When fill is not provided: 0 sec

46 0 – 2.55 [sec], When fill is not provided: 0 sec

47 0 – 2.55 [sec], When fill is not provided: 0 sec

48 Status display
49 Status display
50 Status display

WA500-6 30-153 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

TRANSMISSION [Transmission Controller System]

Monitoring Monitoring Items Display Item Data Display Range
No.
Codes (*1) (*2) (*3)
51 40908 Input signal D_IN_24-31 D-IN-24-----31 See attached table
52 40942 Input signal D_IN_32-39 D-IN-32-----39 See attached table
53 40949 Output signal D_OUT_0-7 D-OUT-0------7 See attached table
54 40950 Output signal D_OUT_8-15 D-OUT-8-----15 See attached table
55 40951 Output signal D_OUT_16-23 D-OUT-16----23 See attached table

56 94100 Clutch trigger initial learning flag TRIG FR1234 0/1 (ON/OFF)

30-154 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

TRANSMISSION [Transmission Controller System]

Unit Remarks
No. Display Contents in Normal State
(*4) (*5)
51 Status display
52 Status display
53 Status display
54 Status display Not used in this machine.
55 Status display Not used in this machine.
0: ON
56 Status display
1: OFF

*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 usable characters is restricted.

*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the range.

*4: SI units alone are employed whenever a unit is needed.

*5: An item that does not allow monitoring is indicated as “Not used in this machine” although its code and item name
may be displayed on the machine monitor.

WA500-6 30-155 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
Transmission [Transmission Controller System]

TRANSMISSION [Transmission Controller System]

Input/
Monitoring Description of ON/OFF Switch
No. Output Display Item
Code (Display: when ON; 1, when OFF; 2)
Signal
Engine mode selector switch
D-IN-0 Engine mode selector switch
(Power mode) = ON (GND)/OFF (OPEN)
Joystick shift-up switch = ON (GND)/OFF
D-IN-1 Joystick steering shift-up switch
(OPEN)
Joystick shift-down switch = ON (GND)/
D-IN-2 Joystick steering shift-down switch
OFF (OPEN)
Air conditioner compressor operation = ON
D-IN-3 Air conditioner compressor operation
(GND)/OFF (OPEN)
1 40905
D-IN-4 Shift mode L
Shift mode Manual L H
D-IN-4 0 1 1
D-IN-5 Shift mode L
D-IN-5 0 0 1
Joystick steering ON/OFF switch or right
Joystick steering ON/OFF switch or
D-IN-6 FNR ON/OFF switch
right FNR ON/OFF switch
= ON (24 V)/OFF (OPEN)
D-IN-7 Terminal C signal Starting switch = ON (24 V)/OFF (OPEN)
D-IN-8 Transmission cut-off switch Starting switch = ON (24 V)/OFF (OPEN)
Pressing of switch = ON (GND)/OFF
D-IN-9 Transmission cut-off set switch
(OPEN)
Pressing of switch = ON (GND)/OFF
D-IN-10 Kick-down switch
(OPEN)
Pressing of switch = ON (GND)/OFF
D-IN-11 Shift hold switch
(OPEN)
2 40906
D-IN-12 — —
Pressing of switch = ON (GND)/OFF
D-IN-13 RPM set idle-up/down selector switch (idle-up)
(OPEN)
Pressing of switch = ON (GND)/OFF
D-IN-14 RPM set idle-up/down switch (idle-down)
(OPEN)
Pressing left brake pedal = ON (GND)/OFF
D-IN-15 Throttle lock release left brake pedal switch
(OPEN)
• Gear shift lever 1st (1st speed)
D-IN-16 Gear shift lever 1st (1st speed)
= ON (24 V)/OFF (OPEN)
• Gear shift lever 2nd (2nd speed)
D-IN-17 Gear shift lever 2nd (2nd speed)
= ON (24 V)/OFF (OPEN)
• Gear shift lever 3rd (3rd speed)
D-IN-18 Gear shift lever 3rd (3rd speed)
= ON (24 V)/OFF (OPEN)
• Gear shift lever 4th (4th speed)
D-IN-19 Gear shift lever 4th (4th speed)
= ON (24 V)/OFF (OPEN)
3 40907
• FNR (directional) lever F (Forward)
D-IN-20 FNR (directional) lever F (Forward)
= ON (24 V)/OFF (OPEN)
• FNR (directional) lever N (Neutral)
D-IN-21 FNR (directional) lever N (Neutral)
= ON (24 V)/OFF (OPEN)
• FNR (directional) lever R (Reverse)
D-IN-22 FNR (directional) lever R (Reverse)
= ON (24 V)/OFF (OPEN)
Parking brakeON (24 V)/OFF (OPEN)
D-IN-23 Parking brake signal
[Travel] [Parking]

30-156 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

TRANSMISSION [Transmission Controller System]

Input/
Monitoring Description of ON/OFF Switch
No. Output Display Item
Code (Display: when ON; 1, when OFF; 2)
Signal
Joystick steering FNR (directional) switch
Joystick steering FNR (directional) switch F
F (forward) or right FNR (directional)
D-IN-24 (forward) or right FNR (directional) switch F
switch F (forward) = ON (GND)/OFF
(forward)
(OPEN)
ECMV fill switch F (forward) = ON (GND)/
D-IN-25 ECMV fill switch F (forward)
OFF (OPEN)
ECMV fill switch R (reverse)
D-IN-26 ECMV fill switch R (reverse)
= ON (GND)/OFF (OPEN)
ECMV fill switch 1st
D-IN-27 ECMV fill switch 1st
= ON (GND)/OFF (OPEN)
4 40908
ECMV fill switch 2nd
D-IN-28 ECMV fill switch 2nd
= ON (GND)/OFF (OPEN)
ECMV fill switch 3rd
D-IN-29 ECMV fill switch 3rd
= ON (GND)/OFF (OPEN)
ECMV fill switch 4th
D-IN-30 ECMV fill switch 4th
= ON (GND)/OFF (OPEN)
Joystick steering FNR (directional) switch
Joystick steering FNR (directional) switch R
R (reverse) or right FNR (directional)
D-IN-31 (reverse) or right FNR (directional) switch R
switch R (reverse) = ON (GND)/OFF
(reverse)
(OPEN)
Joystick steering FNR (directional) switch N Joystick steering FNR (directional) switch
D-IN-32 (neutral) or right FNR (directional) switch N N (neutral) or right FNR (directional) switch
(neutral) N (neutral) = ON (GND)/OFF (OPEN)
D-IN-33 — —
D-IN-34 — —
5 40942 D-IN-35 — —
D-IN-36 — —
D-IN-37 — —
D-IN-38 — —
D-IN-39 — —
D-OUT-0 — —
D-OUT-1 — —
D-OUT-2 — —
D-OUT-3 Fan reverse solenoid Output ON = ON (24 V)/OFF (OPEN)
6 40949 D-OUT-4 Fan neutral solenoid (if equipped) Output ON = ON (24 V)/OFF (OPEN)
Low temperature bypass solenoid (if
D-OUT-5 Output ON = ON (24 V)/OFF (OPEN)
equipped)
D-OUT-6 — —
D-OUT-7 — —

WA500-6 30-157 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

WRK [Work Equipment Controller System]

WRK [Work Equipment Controller System]

Monitoring Monitoring Items Display Item Data Display Range
No.
Codes (*1) (*2) (*3)
XXXXRYYY [3rd – 10th
digits of part No. are
Work equipment controller software displayed]
1 20202 VERSION
version Example: When the number
is 7831-46-R110 →
“3146R110”
2 20225 Application version VERSION APP Arabic numerals
3 20226 Data version VERSION DATA Arabic numerals

4 94700 Loader pump pressure PUMP PRESS 0.00 – 50.00

5 94701 Loader pump pressure PUMP PRESS 0.00 – 5.00

6 94500 Loader pump EPC current (Command) PUMP EPC DIR 0 – 1000

7 94600 Pump delivery flow rate PUMP FLOW 0 – 264

8 06002 Lift arm angle BOOM ANG -180.0 – +180.0

9 06005 Lift arm angle BOOM ANG 0.00 – 5.00

10 94400 Frame angle FRAME ANGLE -180.0 – +180.0

0 – 256000
11 42100 Lift arm lever operation frequency BOOM LVR
(In a thousand of times)

12 42000 Lever potentiometer voltage lift arm 1 BOOM POT1 0.00 – 5.00

13 42001 Lever potentiometer voltage lift arm 2 BOOM POT2 0.00 – 5.00

0 – 256000
14 42101 Bucket lever operation frequency BUCKET LVR
(In a thousand of times)

15 42002 Lever potentiometer voltage bucket 1 BOOM POT1 0.00 – 5.00

30-158 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

WRK [Work Equipment Controller System]

Unit Remarks
No. Display Contents in Normal State
(*4) (*5)

1 Depends on software part No. —

2 Depends on application version No. Status display

3 Depends on data version No. Status display
Work equipment neutral: 2.0 ±2.0 MPa (290.08 ±290.08 psi)
4 MPa (psi)
Work equipment relieved: 34.0 ±2.0 MPa (4931.28 ±290.08 psi)
Work equipment neutral: 0.70 ±0.2 V
5 V
Work equipment relieved: 3.22 ±0.2 V
Low idle (800 rpm): 700 ±30 mA
High idle (Min. 1,420 rpm): 200 ±10 mA
6 mA
Work equipment relieved: 700 ±10 mA
Engine stop (below 500 rpm): 900 ±10 mA
Work equipment neutral: 170 CC/R
7 cc/r
Work equipment relieved: 23 ±10 CC/R
STD lift arm
Highest lift arm: 47.0 ±2.0 deg
Lowest lift arm: -43.0 ±3.0 deg
8 Degree (°)
Hi lift arm
Highest lift arm: 50.0 ±2.0 deg
Lowest lift arm: -43.0 ±3.0 deg
STD lift arm
Highest lift arm: 3.80 ±0.3 V
Lowest lift arm: 1.31 ±0.5 V
9 V
Hi lift arm
Highest lift arm: 3.89 ±0.3 V
Lowest lift arm: 1.31 ±0.5 V
10 No relevant function in WA500-5 Degree (°)

11 Depends on lever operation frequency. —

Neutral 2.50 V ±0.10 V

RAISE (Before detent) 3.89 V ±0.25 V
12 RAISE (Detent position) 4.11 V ±0.25 V V
LOWER (Before detent) 1.11 V ±0.25 V
FLOAT (Detent position) 0.89 V ±0.25 V
Neutral 2.50 V± 0.10 V
RAISE (Before detent) 1.11 V ±0.25 V
13 RAISE (Detent position) 0.89 V ±0.25 V V
LOWER (Before detent) 3.89 V ±0.25 V
FLOAT (Detent position) 4.11 V ±0.25 V

14 Depends on lever operation frequency. —

Neutral 2.50 V ±0.10 V

TILT (Before detent) 3.89 V ±0.25 V
15 V
TILT (Detent position) 4.11 V ±0.25 V
Full dump 0.89 V ±0.20 V

WA500-6 30-159 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

WRK [Work Equipment Controller System]

Monitoring Monitoring Items Display Item Data Display Range
No.
Codes (*1) (*2) (*3)

16 42003 Lever potentiometer voltage bucket 2 BUCKET POT2 0.00 – 5.00

17 41900 Lift arm raise EPC current (Command) RAISE EPC DIR 0 – 1000

18 41901 Lift arm lower EPC current (Command) LOWER EPC DIR 0 – 1000

19 41902 Bucket tilt EPC current (Command) TILT EPC DIR 0 – 1000

20 41903 Bucket dump EPC current (Command) DUMP EPC DIR 0 – 1000

21 41908 AJSS EPC current (Command) AJSS EPC DIR —

22 41904 AJSS right EPC current (Command) J/S EPC DIR RH 0 – 1000

23 41905 AJSS left EPC current (Command) J/S EPC DIR LH 0 – 1000

24 42004 Lever potentiometer voltage AJSS 1 J/S POT1 0.00 – 5.00

25 42005 Lever potentiometer voltage AJSS 2 J/S POT2 0.00 – 5.00

3-spool valve 1, ECMV and current value

26 41906 3RD EPC1 DIR 0 – 1000
(Command)
3-spool valve 2, ECMV and current value
27 41907 3RD EPC2 DIR 0 – 1000
(Command)
0 – 256000
28 42102 3-spool valve lever operation frequency 3RD LVR
(In a thousand of times)

29 42006 Lever potentiometer voltage 3-spool valve 1 3RD POT1 0.00 – 5.00

30 42007 Lever potentiometer voltage 3-spool valve 2 3RD POT2 0.00 – 5.00

31 94300 AJSS lever operation angle AJSS LEVER —

32 94301 AJSS lever potentiometer voltage AJSS LEVER —
33 94401 AJSS frame potentiometer voltage FRAME ANGLE —
34 94800 AJSS steering deviation angle S/T DEFLECTION —

35 94900 Digging-in-progress flag WORK FLAG ON/OFF

36 40910 Input signal D_IN_0-7 D-IN--0------7 See attached table

37 40911 Input signal D_IN_8-15 D-IN--8-----15 See attached table
38 40912 Input signal D_IN_16-23 D-IN-16-----23 See attached table
39 40913 Input signal D_IN_24-31 D-IN-24-----31 See attached table

30-160 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

WRK [Work equipment controller system]

Unit Remarks
No. Display contents in normal state
(*4) (*5)
Neutral 2.50 V ±0.10 V
TILT (Before detent) 1.11 V ±0.25 V
16 V
TILT (Detent position) 0.89 V ±0.25 V
Full dump 4.11 V ±0.20 V
Neutral 0 ±10 mA
17 mA
Max. 896 ±10 mA
Neutral ±10 mA
18 Before detent: 640 ±10 mA mA
Float position: 1000 ±10 mA
Neutral 0 ±10 mA
19 mA
Max. 930 ±10 mA
Neutral 0 ±10 mA
20 mA
Max. 848 ±10 mA
21 — mA Not used in this machine.
Neutral 0 ±10 mA
22 1 mA
Max. 850 ±10 mA
Neutral 0 ±10 mA
23 1 mA
Max. 850 ±10 mA
Neutral 2.50 V ±0.10 V
24 Full steering to right 1.34 V ±0.25 V V
Full steering to left 3.66 V ±0.25 V
Neutral 2.50 V ± 0.10 V
25 Full steering to right 1.34 V ±0.25 V V
Full steering to left 3.66 V ±0.25 V
Neutral 0 ±10 mA
26 1 mA
Max. 960 ±10 mA
Neutral 0 ±10 mA
27 1 mA
Max. 960 ±10 mA

28 Depends on lever operation frequency. —

Neutral: 2.50 V ±0.10 V

29 Retract: 4.11 V ±0.20 V 0.01 V
Extract: 0.89 V ±0.20 V
Neutral: 2.50 V ±0.10 V
30 Retract: 0.89 V ±0.20 V 0.01 V
Extract: 4.11 V ±0.20 V
31 — Degree (°) Not used in this machine.
32 — V Not used in this machine.
33 — V Not used in this machine.
34 — Degree (°) Not used in this machine.
Digging: ON
35 Status display
Others: OFF
36 Status display
37 Status display
38 Status display
39 Status display

WA500-6 30-161 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

WRK [Work Equipment Controller System]

Monitoring Monitoring Items Display Item Data Display Range
No.
Codes (*1) (*2) (*3)
40 40961 Input signal D_IN_32-39 D-IN-32-----39 —
41 40952 Output signal D_OUT_0-7 D-OUT-0------7 See attached table
42 40953 Output signal D_OUT_8-15 D-OUT-8-----15 —
43 40954 Output signal D_OUT_16-23 D-OUT-16----23 See attached table

30-162 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

WRK [Work Equipment Controller System]

Unit Remarks
No. Display Contents in Normal State
(*4) (*5)
Status display Not used in this machine.
Status display
Status display Not used in this machine.
Status display

*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 usable characters is restricted.

*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the range.

*4: SI units alone are employed whenever a unit is needed.

*5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and item name may
be displayed on the machine monitor.

WA500-6 30-163 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

WRK [Work Equipment Controller System]

WRK [Work Equipment Controller System]

Input/
Monitoring
No. Output Display Item Description of ON/OFF Switch
Codes
Signal
Pressing of switch ON = ON (24 V)/OFF
D-IN-0 Semi-automatic digging lock mode switch
(OPEN)
Pressing of switch ON = ON (24 V)/OFF
D-IN-1 Semi-automatic digging loose mode switch
(OPEN)
Pressing of switch ON = ON (24 V)/OFF
1 40910 D-IN-2 Joystick Hi/Lo selector switch
(OPEN)
D-IN-3 — —
D-IN-4 — —
D-IN-5 — —
D-IN-6 — —
Bucket dump ON = ON (24 V)/OFF
D-IN-8 Bucket full stroke proximity switch
(OPEN)
Bucket horizontal ON = ON (24 V)/OFF
D-IN-9 Bucket tilt horizontal proximity switch
(OPEN)
Remote positioner bucket angle set switch Remote positioner bucket angle set switch
D-IN-10
(facing upward) (facing upward) = ON (GND)/OFF (OPEN)
2 40911 Remote positioner bucket angle set switch Remote positioner bucket angle set switch
D-IN-11
(facing downward) (facing upward) = ON (GND)/OFF (OPEN)
D-IN-12 — —
D-IN-13 — —
D-IN-14 — —
D-IN-15 — —
Work equipment neutral lock switch
D-IN-16 Work equipment neutral lock switch (Working position) ON = (24 V)/OFF
(OPEN)
D-IN-17 Starting motor C terminal signal Starting switch = ON (24 V)/OFF (OPEN)
D-IN-18 — —
3 40912 D-IN-19 — —
D-IN-20 — —
D-IN-21 — —
D-IN-22 — —
D-IN-23 — —
D-IN-24 — —
D-IN-25 — —
D-IN-26 — —
D-IN-27 — —

4 40913 Remote positioner raise/lower set switch Remote positioner raise/lower set switch
D-IN-28
(RAISE) (RAISE) = ON (GND)/OFF (OPEN)
Remote positioner raise/lower set switch Remote positioner raise/lower set switch
D-IN-29
(LOWER) (LOWER) = ON (GND)/OFF (OPEN)
D-IN-30 — —
D-IN-31 — —

30-164 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

WRK [Work Equipment Controller System]

Input/
Monitoring
No. Output Display Item Description of ON/OFF Switch
Codes
Signal
D-OUT-0 Work equipment neutral lock solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1 Lift arm raise detent solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-2 Lift arm float detent solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-3 Bucket tilt detent solenoid Output ON = ON (24 V)/OFF (OPEN)
5 40952
D-OUT-4 — —
D-OUT-5 — —
D-OUT-6 — —
D-OUT-7 — —
D-OUT-8 Joystick steering cut relay Output ON = ON (24 V)/OFF (OPEN)
D-OUT-9 — —
D-OUT-10 — —
D-OUT-11 — —
6 40953
D-OUT-12 — —
D-OUT-13 — —
D-OUT-14 — —
D-OUT-15 — —
D-OUT-16 — —
D-OUT-17 — —
D-OUT-18 Remote positioner top indicator ON Output ON = ON (24 V)/OFF (OPEN)
D-OUT-19 Remote positioner bottom indicator ON Output ON = ON (24 V)/OFF (OPEN)
7 40954
D-OUT-20 Safety relay operation Output ON = ON (24 V)/OFF (OPEN)
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —

WA500-6 30-165 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
ENG [Engine Controller System]

ENG [Engine controller system]

Data Display
Monitoring Monitoring Items Display Item Unit Remarks
No. Range
Code (*1) (*2) (*4) (*5)
(*3)
Status
1 20400 Hardware serial No. ECM S/N Arabic numerals
display
POWER
2 03200 Battery voltage 0.0 – 480.0 V
SUPPLY
3 01002 Engine speed ENG SPEED 0 – 4000 rpm
COOLANT
4 04104 Engine coolant temperature -40 – 210 °C
TEMP
Engine coolant temperature COOLANT
5 04105 0.00 – 5.00 V
sensor voltage TEMP
6 37200 Engine oil pressure sensor ENG OIL PRESS -99.9 – 999.9 kPa
Engine oil pressure sensor
7 37201 ENG OIL PRESS 0.00 – 5.00 V
voltage
Not equipped on
8 42700 Engine oil temperature ENG OIL TEMP -40 – 210 °C WA500-6; always
displayed 600°C
Not equipped on
Engine oil temperature sensor
9 42702 ENG OIL TEMP 0.00 – 5.00 V WA500-6; always
voltage
displayed 0.00 V
10 36400 Common rail pressure RAIL PRESS 0 – 400 MPa
Common rail pressure sensor
11 36402 RAIL PRESS 0.00 – 5.00 V
voltage
AMBIENT
12 37400 Atmospheric pressure -99.9 – 999.9 kPa
PRESS
Atmospheric pressure sensor AMBIENT
13 37402 0.00 – 5.00 V
voltage PRESS
Not equipped on
14 18400 Air intake temperature INTAKE TEMP -50 – 200 °C WA500-6; always
displayed 25°C
Not equipped on
Air intake temperature sensor
15 18401 INTAKE TEMP 0.00 – 5.00 V WA500-6; always
voltage
displayed 0.00 V
16 04204 Fuel temperature FUEL TEMP -40 – 210 °C
17 14201 Fuel temperature sensor voltage FUEL TEMP 0.00 – 5.00 V
18 18500 Boost temperature CHG TEMP -50 – 200 °C
19 18501 Boost temperature sensor voltage CHG TEMP 0.00 – 5.00 V
20 36500 Boost pressure CHG PRESS-A -99.9 – 999.9 kPa
21 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 – 5.00 V
Not equipped all
22 17900 EGR valve differential pressure EGR DIF PRESS -99.9 – 999.9 kPa models; always
displayed 0.0 kPa

30-166 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

ENG [Engine controller system]

Data Display
Monitoring Monitoring Items Display Item Unit Remarks
No. Range
Code (*1) (*2) (*4) (*5)
(*3)
Not equipped all
EGR valve differential pressure
23 17901 EGR DIF PRESS 0.00 – 5.00 V models; always
sensor voltage
displayed 0.00 V
EGR IN PRESS-
24 18000 EGR valve inlet pressure -99.9 – 999.9 kPa
A
EGR valve inlet pressure sensor EGR IN PRESS-
25 18002 0.00 – 5.00 V
voltage A
EGR VALVE
26 18100 EGR valve position 0.00 – 99.99 mm
POS
EGR VALVE
27 18101 EGR valve position sensor voltage 0.00 – 5.00 V
POS
OUTPUT
28 18700 Engine output torque -24000 – 24000 Nm
TORQUE
29 36700 Equivalent torque TORQUE RATIO 0 – 100 %
FINAL
30 31706 Final accelerator position 0 – 100 %
THROTTLE
31 37300 Momentary fuel consumption FUEL RATE 0.0 – 999.9 l/h
Final injection volume command INJECT
32 18600 0 – 1000 mg
(in weight) COMMAND
Final injection timing command
33 36300 INJECT TIMING -180.0 – 180.0 CA
TFIN
34 31701 Position of accelerator pedal THROTTLE POS 0 – 100 %
35 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 – 5.00 V
36 18200 Bypass valve position BPS VALVE POS 0.00 – 99.99 mm
Bypass valve position sensor
37 18202 BPS VALVE POS 0.00 – 5.00 V
voltage
Status
38 18300 Idle validation signal IVS 1 ON/OFF
display
Status
39 18301 Idle validation signal IVS 2 ON/OFF
display
Engine controller internal
40 18900 ECM IN TEMP -40 – 210 °C
temperature
Final common rail pressure PRESS
41 36200 0 – 400 MPa
command PFIN COMMAND
PCV valve close timing
42 17201 PCV TIMING 180.0 – 180.0 CA
(BTDC standard)
Status
43 17500 Selection of engine mode POWER MODE 0–4
display
Incoming value is
Name of selected model displayed as is. Status
44 00400 MACHINE ID (H)
(upper 8 digits) (Lower 8 digits of display
16 characters)

WA500-6 30-167 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

ENG [Engine controller system]

Data Display
Monitoring Monitoring Items Display Item Unit Remarks
No. Range
Code (*1) (*2) (*4) (*5)
(*3)
Incoming value is
Name of selected model displayed as is. Status
45 00401 MACHINE ID (L)
(lower 8 digits) (Lower 8 digits of display
16 characters)
Incoming value is
Status
46 20216 Build version BUILD VER displayed as is.
display
(8 characters)
Incoming value is
Status
47 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.

*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the range.

*4: SI units alone are employed whenever a unit is needed.

*5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and item name may
be displayed on the machine monitor.

30-168 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Cylinder Cutout Function (CYLINDER CUT-OUT) (5)

The engine reduced-cylinder function is used to set the injector of one or more cylinders electrically to the no-injection state
and to turn on reduced-cylinder operation. When any engine cylinder is suspected of abnormal output (combustion), use this
approach to pinpoint the failed cylinder.

1. Selecting the menu

Display the CYLINDER CUT-OUT screen from the menu screen
of the Service mode.

2. Displaying submenu
Press the [◊] switch while the menu is selected to display the
submenu.

★ The cylinder No. and engine speed (N): rpm are displayed on
the upper line and the specified injection rate (Q): mg/stroke is
displayed on the lower line.

3. Selecting a cylinder to be reduced

Using the [<] or [>] switch, select a cylinder to be reduced (from
No. 1 – No. 6 cylinder) and then confirm this cylinder using the
[◊] switch.

★ The cylinder to be reduced is selectable while the engine is

running.
★ Any number of cylinders can be reduced – a single unit or two
or more units.
• [>] switch: Advances the cursor rightward
• [<] switch: Advances the cursor leftward
• [◊] switch: Confirms the cylinder to be reduced (the
cursor starts flashing after the confirmation)
• [■] switch: Restores the CYLINDER CUT-OUT screen

★ As the reduced-cylinder command is issued from the engine

controller to the cylinder to be reduced, the bottom of the
stopped cylinder number turns black.

WA500-6 30-169 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
4. Determining which cylinder is abnormal
★ When a normal cylinder is cut out:
The value (Q) increases and (N) is decreased by the quantity which is not injected. (They do not change, however, in
the constant engine speed control mode.) The amount that (Q) and (N) change depends on the load condition.
★ When an abnormal cylinder is cut out:
The values of (Q) and (N) do not change because the fuel has not been injected in the cutout cylinder since before it
was cut out.

5. Cancelling a reduced cylinder

Using the [<] or [>] switch, select the currently stopped cylinder
and then press the [◊] switch to cancel the reduced-cylinder
command from the engine controller. The black display will
disappear.

No-Injection Cranking Function (NO INJECTION) (6)

The machine monitor is equipped with a function capable of lubricating
the engine through no-injection cranking. When a machine has been
stored for a long time, this function is used to lubricate the engine prior
to its restart in order to prevent wear or damage caused by lack of oil.

The no-injection cranking must be set up while the engine is stopped.

1. Selecting menu
Display the NO INJECTION screen from the menu screen of the
Service mode.

2. Pressing the [◊] switch sets up the no-injection cranking.

★ If the starting switch is turned to the START position while
this screen is displayed, no injection cranking starts.
★ If this screen does not appear as the [◊] switch is pressed, you
should suspect a communication error.

30-170 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
★ If the no-injection cranking is selected as the engine is
running, the Engine Stop Instruction screen appears.
• In such a case, stop the engine once and then do the setup
again.

Adjustment Function (TUNING) (7)

The machine monitor implements the initial setting after disassembly or replacement of the transmission, or after replacement
or addition of a sensor, EPC valve, or controller. Through the initial setting, the machine monitor corrects and adjusts the
installation error or manufacturing variations of individual parts.

★ Adjustment function

No. Adjustment Item

7-1 Adjustment of transmission ECMV current
7-2 Setting of transmission initial learning
7-3 Adjustment of transmission L-mode shift point
7-4 Adjustment of lift arm angle sensor (Raise) (for EPC lever)
7-5 Adjustment of lift arm raise lever and variations in the dead zone of EPC
7-6 Adjustment of lift arm lower (float) lever and variations in the dead zone of EPC
7-7 Adjustment of bucket tilt lever and variations in the dead zone of EPC
7-8 Adjustment of bucket dump EPC starting current
7-9 Adjustment of 3-spool valve EPC cylinder extraction lever and variations in the dead zone of EPC (*1)
7-10 Adjustment of the 3-spool valve EPC cylinder retraction lever and variations in the dead zone of EPC (*1)
7-11 Adjustment of joystick steering right lever and variations at EPC starting point (*1)
7-12 Adjustment of joystick steering left lever and variations at EPC starting point (*1)
7-13 Modification of lift arm lever pattern
7-14 Modification of bucket lever pattern
7-15 Adjustment of lift arm lower stop modulation
7-16 Adjustment of pump cutoff pressure in lift arm raise
7-17 Adjustment of lift arm angle sensor (raise) (Machine with load meter)
7-18 Adjustment of lift arm angle sensor (lower) (Machine with load meter)
7-19 Modification of AJSS oil pressure command table pattern (*1)
7-20 Adjustment of speed limit (Machine with lockup clutch)

(*1): This item is not used.

WA500-6 30-171 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
Adjustment of Transmission ECMV Current (7-1)

1. Preparations for transmission ECMV current adjustment

A. Display the REAL-TIME MONITOR from the menu screen

of the Service mode.

B. Press the [◊] switch to display the submenu and then select
TRANSMISSION using the [<] or [>] switch
(TRANSMISSION screen).

C. Press the [◊] switch to confirm the real-time monitoring of the

transmission controller.
★ As the selection is confirmed, the application program
version of the transmission controller is displayed.
[20223]: . . . . . . . . . . . . . . . . . . . . . . ID number of display item
[********]: . . . . . . . . . . . . . . . Display of data (program version)

D. Use the [<] or [>] switch, move the cursor to the T/M OIL
TEMP screen.
[93600]: . . . ID number of transmission control oil temperature
[[********]: . . . . . Display of transmission control oil temperature

30-172 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
2. Conformation of transmission oil temperature control

A. Start the engine; press the brake pedal fully; and release the parking brake.

B. Set the transmission shift mode to Manual; set the FNR (directional) lever, joystick steering FNR (directional) switch,
or right FNR (directional) switch to F (forward); and shift lever or switch to 4th.

C. Make sure from Step 1 that the transmission controlled oil temperature is 70 – 80°C (158 – 176°F). If it is out of this
range, stall the torque converter and adjust the temperature to 70 – 80°C.

D. Return the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) to
N (neutral) and maintain it in that position. After three minutes, make sure the oil temperature is still in the 70 – 80°C
(158 – 176°F) range.

E. Let the oil move through the transmission by operating the FNR (directional) lever or joystick steering FNR
(directional) switch, right FNR (directional) switch, or gear shift lever or switch as shown in the following table.

Operating Order 1 2 3 4
Gear speed N2 F2 F1 F2
Min. Min. Min. Min.
Holding time
2 sec. 2 sec. 2 sec. 2 sec.

Operating Order 5 6 7 8
Gear speed F3 F4 F3 F2
Min. Min. Min. Min.
Holding time
2 sec. 2 sec. 2 sec. 2 sec.

Operating Order 9 10 11
Gear speed N2 R2 N2
Min. Min. Min.
Holding time
2 sec. 2 sec. 2 sec.

★ When doing this operation, the engine must be set to low idle, manual switch to ON, and lockup switch to OFF.
★ Make sure the machine is normal (failure is not detected).
★ When stalling the torque converter, be careful that it does not overheat.

3. Adjustment of transmission ECMV current

★ There are six types of correction targets: F (forward), R (reverse), 1st, 2nd, 3rd, and 4th. As the engine is started,
correction of all of these clutches is started automatically.
★ Since the learning operation requires the specified oil temperature, the oil temperature must be adjusted to the 70 –
80°C (158 – 176°F) range.

A. Turn on the starting switch (engine is not started) and then display T/M OIL TEMP. Refer to Step 1 (Preparations for
transmission ECMV current adjustment).

B. Make sure that the transmission controlled oil temperature is in the 70 – 80°C (158 – 176°F) range when the engine is
set to low idle; accelerator pedal to OFF; FNR (directional) lever, joystick steering FNR (directional) switch, or right
FNR (directional) switch to N (neutral); and parking brake to ON.

WA500-6 30-173 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
C. Display the TUNING from the menu screen of the Service
mode.

D. Hold down the [◊] switch for a minimum of five seconds to

display the 01: TM TRIGGER screen.

E. Using the [<] or [>] switch from the submenu, select 02:
ECMV TUNING.

F. Press the [◊] switch to confirm the adjustment item.

G. Using the [◊] switch, select AUTO from the Automatic

Correction (AUTO) and Manual Correction (MANUAL)
selection screen to confirm the automatic correction.

30-174 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
★ Selecting ECMV TUNING AUTO displays IP in the
character display, automatically starting transmission
ECMV current adjustment.

Operating Order 1 2 3 4
IP “IP F-1” “IP F-2” “IP F-3” “IP F-4”
ECMV/ F/1st F/2nd F/3rd F/4th
frequency time time time time

Operating Order 5 6 7 8
“IP R- “IP R- “IP R- “IP R-
IP
1” 2” 3” 4”
ECMV/ R/1st R/2nd R/3rd R/4th
frequency time time time time

Operating Order 9 10 11 12
IP “IP 1-1” “IP 1-2” “IP 1-3” “IP 1-4”
ECMV/ 1st/1st 1st/2nd 1st/3rd 1st/4th
frequency time time time time

Operating Order 13 14 15 16
IP “IP 2-1” “IP 2-2” “IP 2-3” “IP 2-4”
2nd/
ECMV/ 2nd/1st 2nd/3rd 2nd/4th
2nd
frequency time time time
time

Operating Order 17 18 19 20
IP “IP 3-1” “IP 3-2” “IP 3-3” “IP 3-4”
ECMV/ 3rd/1st 3rd/2nd 3rd/3rd 3rd/4th
frequency time time time time

Operating Order 21 22 23 24
IP “IP 4-1” “IP 4-2” “IP 4-3” “IP 4-4”
ECMV/ 4th/1st 4th/2nd 4th/3rd 4th/4th
frequency time time time time

H. If the correction is normally completed, OK is displayed in the

character display.

WA500-6 30-175 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
I. If the correction does not end normally, the code for an
abnormal end is indicated. (The figure to the right shows an
example of an operation in which the 1st time correction of
the 3rd position has ended abnormally).

★ Codes for abnormal end

Reason Code
Deviation from correction condition 1
Absence of fill 2
In excess of correction value 3

★ If abnormal end code “1” (NG1: Deviation from correction condition) is displayed, set the condition again by
referring to Step 1 and repeating the correction.
★ If abnormal end code “2” (NG2: Absence of fill) is displayed, implement troubleshooting of the failure codes
15STLH and DXHTKA. If the state is normal, repeat the operation starting from Step 1 and repeat the correction.
(The value of T depends on the applicable gear speed.)
★ If abnormal end code “3” (NG3: In excess of correction value) is displayed, execute the troubleshooting of
failure code 15STL1. After making sure that the condition is normal, implement Step 1 again. (The value of T
depends on the applicable gear speed.)

J. If the operation ended normally, turn the starting switch off. The corrected value will be stored on the transmission
controller after three seconds.
★ When it is necessary to turn on the starting switch immediately after the adjustment, keep the starting switch, just
in case, at the OFF position for a minimum of 10 seconds and then turn it on.

Setting of Transmission Initial Learning (7-2)

When initializing all the past initial trigger learning data stored on the transmission controller, use the following procedure.

1. Reset initial learning

A. Turn the starting switch on. (Engine does not start.)

B. Set the FNR (directional) lever, joystick steering FNR

(directional) switch, or right FNR (directional) switch to
N (neutral).

C. Display the TUNING screen from the menu screen of the

Service mode.

30-176 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
D. Press and hold the [◊] switch for a minimum of five seconds to
display the 01: TM TRIGGER screen.

E. Press the [◊] switch to confirm the adjustment item. As the

item is confirmed, the Initial Learning reset screen appears.
★ If the initial learning is not done, INITIAL STATUS is
displayed.

★ When the initial learning is completed, TUNED is

displayed.

i. When TUNED is displayed, press the [◊] switch to

display the Initial Learning reset screen.

ii. Press the [<] or [>] switch from the Initial Learning reset
screen to move the cursor to the YES position and then
press the [■] switch to reset the initial learning.

iii. When suspending the reset operation, select NO from the

Initial Learning reset screen or press the [■] switch on the
TUNED screen.

2. Preparations for transmission initial learning

A. Display the REAL-TIME MONITOR from the menu screen

of the Service mode.

WA500-6 30-177 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
B. Press the [◊] switch to display the submenu; select 2 ITEMS
using the [<] or [>] switch; and then confirm the selection
using the [◊] switch. (SEL ITEMS 1, 2 screen).

C. From the SEL ITEMS 1, 2 screen, enter ID number 93600 of

the transmission control oil temperature and ID number 94100
for displaying the trigger learning.
★ Refer to Step 5 in MACHINE MONITOR SYSTEM:
Service Mode: Real-Time Monitoring Function (REAL-
TIME MONITOR).

D. Using the [◊] switch, confirm the 2 ITEMS display of the

transmission control oil temperature and the trigger learning
display.
★ Content of the trigger learning is displayed for each of F,
R, 1st, 2nd, 3rd, and 4th clutch in the figure.
• 0: Learning not done yet
• 1: Learning completed

3. Implementation of transmission initial learning

★ Before starting the transmission initial learning, be sure to
implement the Adjustment of Transmission ECMV Current
procedure and Step 1 in the Setting of Transmission Initial
Learning procedure. Then start the initial learning according
to the following procedure.

★ Implement the gearshift operation using actual travel, bench travel, or while pressing the wheel brake.

WARNING! When actual travel is used for the operation,

be sure to choose a spacious area while
paying reasonable care to the environment.

★ When executing the operation, the engine must be set to low idle, the manual switch to ON, and the lockup switch to
OFF.

A. Start the engine; press the brake pedal fully; and then release the parking brake.

B. Set the transmission shift mode to Manual; set the FNR (directional) lever, joystick steering FNR (directional) switch,
or right FNR (directional) switch to F (forward); and set the shift lever or switch to 4th.

30-178 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
C. Make sure that the transmission control oil temperature is 70 – 80°C (158 – 176°F); refer to Step 2 (Preparations for
transmission initial learning). If it is out of this range, stall the torque converter and adjust the temperature to 70 –
80°C.
★ If the initial learning is performed while the oil temperature is out of the specified range, time lags and gear shift
shocks can result.

D. Perform the initial learning by operating the FNR (directional) lever, joystick steering FNR (directional) switch, right
FNR (directional) switch, or gear shift lever or switch in the following manner.

Operating Order 1 2 3 4
Gear speed N2 F2 F1 F2
Min. 6 Min. 6 Min. 6 Min. 4
Holding time
sec. sec. sec. sec.

Operating Order 5 6 7 8
Gear speed F3 F4 F3 F2
Min. 4 Min. 4 Min. 4 Min. 4
Holding time
sec. sec. sec. sec.

Operating Order 9 10 11
Gear speed N2 R2 N2

• Hold the gear shift lever in each gear speed for more than the specified time.
★ If the gear shift lever is operated before the specified time is reached, the initial learning is not completed
(TUNED is not displayed).

4. Conformation of completion of transmission initial learning

A. Referring to Step 2 (Preparations for transmission initial learning), make sure 111111 is marked on ID number 94100,
indicating that the initial learning is completed.

B. Press the [■] switch to end confirmation of the initial learning.

Adjustment of Transmission L-Mode Shift Point (7-3)

This function is used for modifying the shift point when the shift mode switch is at the L position, by adding a correction
amount.

★ The factory default setting of the correction amount must be 0.

★ The shift point depends on the engine mode. When this function is used, however, the same correction value is applied
independent of the engine mode.

★ Some of the shift points being adjusted with the shift point adjustment function may not include the following shift
patterns.

• The shift point that is used when the hunting prevention function is turned on.
• The shift down point that is used when the accelerator is set to idle.

★ After a shift point adjustment is done, confirmation on the machine must be done.

WA500-6 30-179 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
1. Clearing an adjusted shift point

A. Display the TUNING screen from the menu screen of the

Service mode.

B. Hold down the [◊] switch for a minimum of five seconds to

display the 01: TM TRIGGER screen.

C. Using the [<] or [>] switch, select the 04: SHIFT rpm screen
from the submenu.

D. Press the [◊] switch to confirm the selection.

★ As the selection is confirmed, 0: ALL CLEAR is
displayed in the lower space.

E. Press the [◊] switch to confirm ALL CLEAR.

★ As all the stored values are cleared, the screen returns to
the shift point adjustment item.
★ If the [■] switch is pressed instead of the [◊] switch, the
stored value is not cleared and the screen returns to the
adjustment items.

30-180 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
2. Adjusting a shift point
★ This operation allows you to change a gear shift travel speed when L auto-shift mode is selected.
★ Gear shift patterns are changed as shown in the following table.

No. Gear Shift Pattern to be Changed

0 ALL CLEAR
1 F2T/C → F3T/C
2 F3 T/C → F4 T/C
3 F4T/C → F3T/C
4 F3 T/C → F2 T/C
5 F3L/U ON
6 F3L/U OFF
7 F4L/U ON
8 F4L/U OFF

T/C: Torque converter travel

L/U: Lockup travel (only for lockup specification)

★ Gear shift pattern change procedure

As an example of a gear shift pattern change, this procedure describes how to change the gear shift travel speed
pattern from F2T/C to F3T/C. (The same procedure is used for the other gear shift patterns, too.)

A. Select the 04: SHIFT rpm screen using the [◊] switch and then
select 01: F2T/C → F3T/C using the [<] or [>] switch.

B. Press the [◊] switch to confirm the selection.

★ As the selection is confirmed, the Shift Point Adjusting
Value input screen appears. This screen displays the
currently entered shift point adjusting value.
★ Adjusting Value input screen when Adjusting value = 0

C. Press the [<] or [>] switch to select a desired adjusting value.

★ When adjusting a shift point, 50 rpm of the transmission
output shaft speed is used as a unit.
★ Adjusting the transmission output shaft speed by 50 rpm
changes the travel speed by approximately 0.759 km/h
(0.472 mph).
★ Selecting +50 rpm increases the speed by approximately
0.7 km/h (0.43 mph).
★ Selecting -50 rpm decreases the speed by approximately 0.7 km/h (0.43 mph).

WA500-6 30-181 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
D. After selecting a desired setting data, press the [■] switch to
end the setup procedure.

Adjustment of Lift Arm Angle Sensor (Raise) (7-4)

★ For EPC lever function

This procedure is used for adjusting the lift arm angle of the work
equipment.

1. Display the TUNING screen from the menu screen of the Service
mode.

2. Hold down the [◊] switch for a minimum of five seconds to display
the 01: TM TRIGGER screen.

3. Using the [<] or [>] switch, move the cursor to the 05: RAISE
ANGLE item.

30-182 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
4. Press the [◊] switch to confirm the selection.
★ As the selection is confirmed, the RAISE ANGLE screen is
displayed.

5. Press the [◊] switch while the lift arm is being raised to the upper
limit (cylinder stroke end).
★ The buzzer sounds twice to indicate the completion of the
setting.
★ A 1-second beep indicates that the set lift arm angle voltage
does not conform to the specified value. In this case,
adjustment does not start.

6. Press the [■] switch to end the adjustment mode.

★ If the [■] switch is pressed while the calibration is continued,
the calibration currently taking place will be stopped even if it is not completed.

7. When the adjustment does not end successfully, check the lift arm angle sensor voltage from the real-time monitor.

8. Adjust the lift arm angle sensor mounting position so that the voltage displayed on the real-time monitor falls within the
following range and then do the sensor adjustment again.

★ Lift arm length by lift arm specification

Lift Arm Voltage

Lift Arm Position
Specification Range

A Upper limit position 3.80 ±0.3 V

(Stroke end of raised
B cylinder) 3.87 ±0.3 V

★ Lift arm length by machine model

Machine
A B
Model
3250 mm 3636 mm
WA500-6
(127.95 in) (143.15 in)

Adjustment of Lift Arm Raise Lever and Variations in the Dead Zone of EPC (7-5)

1. Adjusting variation correcting calibration of lift arm raise EPC lever

This adjustment is needed when the electric (EPC) work
equipment lever is used or when the work equipment controller
was replaced.

WARNING! Before starting the adjustment, lower the lift

arm to the ground and stop the engine.

A. Display the TUNING screen from the menu screen of the

Service mode.

WA500-6 30-183 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
B. Hold down the [◊] switch for a minimum of five seconds to
display the 01: TM TRIGGER screen.

C. Using the [<] or [>] switch, move the cursor to the 06: RAISE
EPC item.

D. Raise the lift arm EPC lever to a position just before the raise
detent position and maintain the lever at this position.
★ Be careful that the raise detent operation does not start.

E. Pressing the [◊] switch turns on the reading of lever voltage

and then stores the read voltage, replacing the currently stored
standard value.
★ The setting is complete as the 06: RAISE EPC screen is
restored after the buzzer beeps (buzzer beeps twice).
★ If the lever output voltage at this point is below the
standard value (off the design range), pressing the [◊]
switch sounds the buzzer for one second and the screen
remains unchanged as [◊] = SET, as shown in the figure.
In this case, the adjustment is cancelled and the 06:
RAISE EPC screen is restored.
★ If the [■] switch is pressed at this point, correction of
variations in the work equipment EPC lever detent
position is stopped even if it is not completed.

2. Adjusting lift arm raise EPC starting current

★ Start the engine prior to the setup operation.

A. Display the TUNING screen from the menu screen of the

Service mode.

30-184 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
B. Hold down the [◊] switch for a minimum of five seconds to
display the 01: TM TRIGGER screen.

C. Using the [<] or [>] switch, move the cursor to the 06: RAISE
EPC item.

D. Lower the lift arm by dumping the bucket and then lift the
front wheel.

E. Start raising the lift arm gradually while setting the engine to
high idle (the machine body is lowered).

F. Return the lever through fine operation. As the lift arm is

stopped, maintain the lever at that position (front wheel is
floated).

G. Pressing the [◊] switch turns on reading of the commanded

value of EPC and then stores the difference between it and the
standard value as the offset value.
★ The setting is complete as the 06: RAISE EPC screen is
restored after the buzzer beeps (buzzer beeps twice).
★ If the [◊] switch is pressed when the lever is at neutral, the
adjusted value is cleared. In this case, the 06: RAISE EPC
screen is restored after the buzzer beeps (buzzer beeps
twice).

Adjustment of Lift Arm Lower (float) Lever and Variations in the Dead Zone of EPC (7-6)

1. Adjusting variation correcting calibration of lift arm lower (float) EPC lever
★ This adjustment is required when the electric (EPC) work
equipment lever is used or when the work equipment
controller was replaced.

WARNING! Before starting the adjustment, lower the lift

arm to the ground and stop the engine.

A. Display the TUNING screen from the menu screen of the

Service mode.

WA500-6 30-185 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
B. Hold down the [◊] switch for a minimum of five seconds to
display the 01: TM TRIGGER screen.

C. Using the [<] or [>] switch, move the cursor to the 07:
LOWER EPC item.

D. Stop the lift arm EPC lever in a position just before the float
detent position and maintain the lever at this position.
★ Be careful that the float detent operation does not turn on.

E. Pressing the [◊] switch turns on reading of lever voltage and

then stores the read voltage, replacing the currently stored
standard value.
★ The setting is complete as the 07: LOWER EPC screen is
restored after the buzzer beeps twice.
★ If the lever output voltage at this point is below the
standard value (off the design range), pressing the
[◊] switch sounds the buzzer for one second and the
screen remains unchanged as [◊] = SET, as shown in the
figure. In this case, the adjustment is cancelled and the
07: LOWER EPC screen is restored.
★ If the [■] switch is pressed at this point, correction of
variations in the work equipment EPC lever detent
position is stopped even if it is not completed.

2. Adjusting lift arm lower EPC starting current

★ Start the engine prior to the setup operation.

A. Display the TUNING screen from the menu screen of the

Service mode.

30-186 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
B. Hold down the [◊] switch for a minimum of five seconds to
display the 01: TM TRIGGER screen.

C. Using the [<] or [>] switch, move the cursor to the 07:
LOWER EPC item.

D. Set the lift arm roughly horizontal without applying any load.

E. Start lowering the lift arm gradually while maintaining the

engine at high idle.

F. Return the lever through fine operation. As the lift arm is

stopped, maintain the lever at that position.

G. Pressing the [◊] switch turns on reading of the commanded

value of EPC and then stores the difference between it and the
standard value as the offset value.
★ The setting is complete as the 07: LOWER EPC screen is
restored after the buzzer beeps twice.
★ If the [◊] switch is pressed when the lever is at neutral, the
adjusted value is cleared. In this case, the 07: LOWER
EPC screen is restored after the buzzer beeps twice.

Adjustment of Bucket Tilt Lever and Variations in the Dead Zone of EPC (7-7)

1. Adjusting variation correcting calibration of bucket tilt EPC lever

★ This adjustment is required when the electric (EPC) work
equipment lever is used or when the work equipment
controller was replaced.

WARNING! Before starting the adjustment, lower the lift

arm to the ground and stop the engine.

A. Display the TUNING screen from the menu screen of the

Service mode.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
B. Hold down the [◊] switch for a minimum of five seconds to
display the 01: TM TRIGGER screen.

C. Using the [<] or [>] switch, move the cursor to the 08: TILT
EPC item.

D. Stop the bucket tilt lever in a position just before the tilt detent
position and maintain the lever at this position.
★ Be careful that the tilt detent operation does not get turned
on.

E. Pressing the [◊] switch turns on reading of lever voltage and

then stores the read voltage, replacing the currently stored
standard value.
★ The setting is complete as the 08: TILT EPC screen is
restored after the buzzer beeps twice.
★ If the lever output voltage at this point is below the
standard value (off the design range), pressing the
[◊] switch sounds the buzzer for one second and the
screen remains unchanged as [◊] = SET, as shown in the
figure. In this case, the adjustment is cancelled and 08:
TILT EPC screen is restored.
★ If the [■] switch is pressed at this point, correction of
variations in the work equipment EPC lever detent
position is stopped even if it is not completed.

2. Adjusting bucket tilt EPC starting current

★ Start the engine prior to the setup operation.

A. Display the TUNING screen from the menu screen of the

Service mode.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
B. Hold down the [◊] switch for a minimum of five seconds to
display the 01: TM TRIGGER screen.

C. Using the [<] or [>] switch, move the cursor to the 08: TILT
EPC item.

D. Lower the lift arm by dumping the bucket and then lift the
front wheel.

E. Start lowering the bucket gradually while maintaining the

engine at high idle (the machine body is lowered).

F. Return the lever through fine operation. As the bucket is

stopped, maintain the lever at that position.

G. Pressing the [◊] switch turns on reading of the commanded

value of EPC and then stores the difference between it and the
standard value as the offset value.
★ The setting is complete as the 08: TILT EPC screen is
restored after the buzzer beeps twice.
★ If the [◊] switch is pressed when the lever is at neutral, the
adjusted value is cleared. In this case, the 08: TILT EPC
screen is restored after the buzzer beeps twice.

Adjustment of Bucket Dump EPC Starting Current (7-8)

★ Start the engine prior to the setup operation.

1. Display the TUNING screen from the menu screen of the Service
mode.

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2. Hold down the [◊] switch for a minimum of five seconds to display
the 01: TM TRIGGER screen.

3. Using the [<] or [>] switch, move the cursor to the 09: DUMP EPC
item.

4. Set the bucket roughly horizontal without applying any load.

5. Start dumping the bucket gradually while maintaining the engine

at high idle.

6. Return the lever through fine operation. As the bucket is stopped,

maintain the lever at that position.

7. Pressing the [◊] switch turns on reading of the commanded value

of EPC and then stores the difference between it and the standard
value as the offset value.
★ The setting is complete as the 09: DUMP EPC screen is
restored after the buzzer beeps twice.
★ If the [◊] switch is pressed when the lever is at neutral, the
adjusted value is cleared. In this case, the 09: DUMP EPC
screen is restored after the buzzer beeps twice.

Adjustment of 3-Spool Valve EPC Cylinder Extraction Lever and Variations in the Dead Zone of EPC (7-9)

★ This item is not used.

Adjustment of 3-Spool Valve EPC Cylinder Retraction Lever and Variations in the Dead Zone of EPC (7-10)

★ This item is not used.

Adjustment of Joystick steering Right Lever and Variations at EPC Starting Point (7-11)

★ This item is not used.

Adjustment of Joystick Steering Left Lever and Variations at EPC Starting Point (7-12)

★ This item is not used.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
Modification of Lift Arm Lever Pattern (7-13)

This function is used to modify the fine-controllability and response of the lift arm by changing the data on the EPC output
current to the lift arm lever stroke.

Characteristics of Tables 1 – 5 are summarized in the following table (factory-set table: 3).

★ Table number and function

Table
Function General
No.
In the lowering operation, the lift arm is lowered at approximately 70% the speed of the
Fine control
1 floating speed. (Floating speed remains the same.)
priority
In the raising operation, speed change becomes more drastic as the stroke grows larger.
In the lowering operation, the lift arm is lowered at approximately 85% the speed of the
Fine control
2 floating speed. (Floating speed remains the same.)
priority
In the raising operation, controllability at fewer strokes is enhanced.
This table allows compatibility between controllability and response in both the raise and
3 Standard
lower operations.
Response
4 Fewer and faster lever strokes enhance the response.
priority
Response is further improved because the lever strokes are fewer and faster than that of
Response No. 4.
5
priority This table allows a greater speed change at fewer strokes than others. If reasonable care is
not exercised, there may be substantial shocks when stopping.

★ Normally, change to Tables No. 2 to No. 4 is made. When selecting the No. 1 or No. 5 table, thorough preliminary
performance check and operator evaluation are required.

★ The maximum lowering speed is not available from the data of Tables No. 1 and No. 2. When measuring the lift arm
lowering speed, Tables No. 3 – No. 5 must be used.

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1. Display the TUNING screen from the menu screen of the Service
mode.

2. Hold down the [◊] switch for a minimum of five seconds to display
the 01: TM TRIGGER screen.

3. Using the [<] or [>] switch, move the cursor to the 14: BOOM
TABLE item.

4. Press the [◊] switch to confirm the selection.

★ As the selection is confirmed, the Lift Arm Lever Table
adjustment screen is displayed.

5. Select a desired table from No. 1 – No. 5 by using the [<] or [>]
switch.

6. Press the [■] switch to confirm the adjustment.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
Modification of Bucket Lever Pattern (7-14)

This function is used to modify the fine controllability, response, and shock dump of the bucket by changing the data on the
EPC output current to the bucket lever stroke.

Characteristics of Tables 1 – 3 are summarized in the following table (factory-set table: 2).

★ Table number and function

Table
Function General
No.
Fine control
1 In the dump and tilt operation, controllability at fewer strokes is enhanced.
priority
This table allows compatibility between controllability and response in both the dump and tilt
2 Standard
operations.
Fewer and faster lever strokes enhance the response.
Response
3 This table makes it easier to dump a load by swinging the bucket as well as shock dump and
priority
leveling of load at the tilt end.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
1. Display the TUNING screen from the menu screen of the Service
mode.

2. Hold down the [◊] switch for a minimum of five seconds to display
the 01: TM TRIGGER screen.

3. Using the [<] or [>] switch, move the cursor to the 15: BUCKET
TBL item.

4. Press the [◊] switch to confirm the selection.

★ As the selection is confirmed, the bucket lever adjustment
screen is displayed.

5. Select a desired table from No. 1 – No. 3 by using the [<] or [>]
switch.

6. Press the [■] switch to confirm the adjustment.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
Adjustment of Lift Arm Lower Stop Modulation (7-15)

★ When the lift arm lever is operated for a sudden stop, this function modifies the speed reduction rate of the stop
modulation, which is prepared for alleviating shocks resulting from stopping, by applying the stop modulation to the EPC
output current.

★ The modulation used for an automatic stop with the remote positioner or due to kickout does not depend on this data.

★ Before using this function to modify the modulation, you must do the Adjustment of Lift Arm Lever Pattern (7-13)
procedure and perform the operator’s evaluation.

★ The stop modulation function acts the same way in both the raise and lower directions.

★ The data at delivery is set to 100% of the standard.

Modulation
State Remarks
Quantity
The stop modulation is not
Stopping shocks can result if
activated. The lift arm is
0% the operator does not
stopped without delaying to
exercise reasonable care.
the lever stroke.
It allows compatibility
100% between delay in response at —
stop and stopping shocks.
The lift arm overruns the
It alleviates stopping shocks
target stop position because
that can result from
200% its stopping is delayed even
operator’s sudden stop
when the lever is set at
operation.
neutral.

1. Display the TUNING screen from the menu screen of the Service
mode.

2. Hold down the [◊] switch for a minimum of five seconds to display
the 01: TM TRIGGER screen.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
3. Using the [<] or [>] switch, move the cursor to the 16: LOWER
STOP item.

4. Press the [◊] switch to confirm the selection.

5. As the selection is confirmed, the LOWER STOP screen appears.

6. Select a desired table from 0, 100, and 200 by using the [<] or [>]
switch.

7. Press the [■] switch to confirm the adjustment.

Adjustment of Pump Cutoff Pressure in Lift Arm Raise (7-16)

This function modifies matching of the travel speed and work equipment speed at dump approach and hopper charge by
changing the condition of the lift arm bottom pressure, which is used as a pump flow rate-restricting condition when lifting a
given load.

The following lists the pump flow rate-restricting conditions applicable to a load-lifting operation.

★ If the lift arm is operated under the following initial conditions, its speed is restricted to approximately 70% and the
remaining torque is used for the travel.

• Lift arm angle > 0° (Horizontal)

• Bucket tilt end-detecting proximity switch signal = Present (Tilt end-detection available)
• Lift arm bottom pressure > 20 MPa (2901 psi)

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
★ Modifying the lift arm bottom pressure changes the matching as shown in the table.

• The following data shows, when the machine is loaded, the time required for the lift arm to reach the lift arm top
when the raise operation is started simultaneously with start of the machine and the travel distance at that time.
• Decreasing the currently set pressure activates the cutoff earlier, thereby lengthening the lift arm rising time as well as
extending the travel distance.

Lift Arm F1 F2
Working Bottom Pressure
Mode during Rising Distance Time Distance Time
(MPa (psi)
10 (1450) 16.5 11 25.1 11.2
Economy 20 (2901) 15.5 10.7 24.7 10.7
25 (3626) 15 10.2 24.5 10.6
10 (1450) 17.8 10.7 26.7 11.1
Power 20 (2901) 16.3 10.3 24.4 10.5
25 (3626) 15.3 9.8 24.2 10.2

★ The pressure at delivery is 20 MPa (2901 psi).

★ Modifying the set value changes the lift arm rising time.

★ When measuring the lift arm rising time for troubleshooting purposes, be sure to return the current setting to 20 MPa
(2901 psi).

1. Display the TUNING screen from the menu screen of the Service
mode.

2. Hold down the [◊] switch for a minimum of five seconds to display
the 01: TM TRIGGER screen.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
3. Using the [<] or [>] switch, move the cursor to the 17: PUMP CUT
item.

4. Press the [◊] switch to confirm the selection.

★ As the selection is confirmed, the pump cutoff pressure
adjustment screen is displayed.

5. Select a desired pressure in the range of 5 – 45 MPa by using the

[<] or [>] switch.

6. Press the [■] switch to confirm the adjustment.

Adjustment of Lift Arm Angle Sensor (raise) (machine with load meter) (7-17)

1. Display the TUNING screen from the menu screen of the Service
mode.

2. Hold down the [◊] switch for a minimum of five seconds to display
the 01: TM TRIGGER screen.

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3. Using the [<] or [>] switch, move the cursor to the 18: RAISE
ANGLE item.

4. Press the [◊] switch to confirm the selection.

★ As the selection is confirmed, the RAISE ANGLE screen
appears.

5. Press the [◊] switch after raising the lift arm to the upper limit
position (cylinder stroke end).
★ The buzzer beeps twice to indicate the completion of the
setting.
★ A 1-second beep indicates that the set lift arm angle voltage
does not conform to the specified value. In this case,
adjustment does not start.

6. Press the [◊] switch to end the adjustment mode.

★ If the [■] switch is pressed while the calibration is continued,
the calibration currently underway will be stopped even if it is not completed.

7. When the adjustment does not end successfully, check the lift arm angle sensor voltage from the real-time monitoring.
• Adjust the lift arm angle sensor mounting position so that the voltage displayed on the real-time monitoring falls
within the following range and then do the sensor adjustment again.

Lift Arm Position Voltage Range

Upper limit position
0.5 – 4.5 V
(Stroke end of raised cylinder)

Adjustment of Lift Arm Angle Sensor (lower) (machine with load meter) (7-18)

1. Display the TUNING screen from the menu screen of the Service
mode.

WA500-6 30-199 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
2. Hold down the [◊] switch for a minimum of five seconds to display
the 01: TM TRIGGER screen.

3. Using the [<] or [>] switch, move the cursor to the 19: LOWER
ANGLE item.

4. Press the [◊] switch to confirm the selection.

★ As the selection is confirmed, the LOWER ANGLE screen
appears.

5. Press the [◊] switch after lowering the lift arm to the lower limit
position (cylinder stroke end).
★ The buzzer beeps twice to indicate completion of the setting.
★ A 1-second beep indicates that the set lift arm angle voltage
does not conform to the specified value. In this case,
adjustment does not start.

6. Press the [■] switch twice to end the adjustment mode.

★ If the [■] switch is pressed while the calibration is continued,
the calibration currently underway is stopped even if it is not
completed.

7. When the adjustment does not end successfully, check the lift arm angle sensor voltage from the real-time monitoring.
★ Adjust the lift arm angle sensor mounting position so that the voltage displayed on the real-time monitoring falls
within the following range and then do the sensor adjustment again.

Lift Arm Position Voltage Range

Lower limit position
0.5 – 4.5 V
(Stroke end of lowered cylinder)

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
Modification of AJSS Oil Pressure Command Table Pattern (7-19)

★ This item is not used.

Adjustment of Speed Limit (machine with lockup clutch) (7-20)

This speed limit adjusting function is used to enhance fuel consumption in the forward 4th lockup travel.

• First select the maximum travel speed (selected from three levels). Then set the upper limit of the throttle opening for
F (forward), 4th, and L/U (lockup) to limit the maximum travel speed.

★ The throttle opening is limited to 90%, when delivered.

• Select a restricted throttle opening from 80%, 90%, and 100% (no restriction).

★ The state in which F (forward), 4th, and L/U (lockup) are selected is the state in which F4 gear shift is completed and L/U
is at the holding pressure.

★ When gear shift to a speed other than F4 is started or when L/U is cancelled, the upper limit value of this control becomes
100% (no restriction).

★ Setting at delivery is 90%.

1. Display the TUNING screen from the menu screen of the Service
mode.

2. Hold down the [◊] switch for a minimum of five seconds to display
the 01: TM TRIGGER screen.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
3. Using the [<] or [>] switch, move the cursor to the 22: SPEED
LIMIT item.

4. Press the [◊] switch to confirm the selection.

5. As the selection is confirmed, the Maximum Speed Limit

adjustment screen is displayed.

6. After making sure that 90% is displayed for the limit value, press
the [■] switch to restore the original screen.

7. When the displayed limit value is not 90%, select 90% using the
[<] or [>] switch and then press the [◊] switch to confirm the
setting change.

Maintenance Monitoring Function (MAINTENANCE MONITOR) (8)

The maintenance function provides the following capabilities for the maintenance of filters and oils.

• Change of maintenance interval time

• Selection between enabling or disabling timer by item

• Setting of a default value

• Selection between enabling or disabling timer for items

1. Changing maintenance interval time

A. Display the MAINTENANCE MONITOR screen from the

menu screen of the Service mode.

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B. Press the [◊] switch to display the 41: FUEL P FILT screen.
★ The lower, left side of the display indicates the time
remaining up to the replacement.
★ The lower, right side of the display indicates the
cumulative replacement frequencies.

C. From the following table, choose the item for which the
maintenance interval is to be changed and use the [<] or
[>] switch to select it.

★ List of Maintenance Items

Indication of Items on the Replacement

Item ID No.
Character Display Interval Time (H)
Fuel pre-filter 41 FUEL P FILT 500
Engine oil 01 ENG OIL 500
Engine oil filter 02 ENG OIL FILTER 500
Transmission oil filter 13 TRANSM FILTER 500
Fuel filter 03 FUEL FILT 1000
Transmission oil 12 TRANSM OIL 1000
Corrosion resistor 06 CORR-RESISTER 1000
Hydraulic tank breather element 05 HYD BREATHER 2000
Axle oil 15 AXLE OIL 2000
Hydraulic oil filter 04 HYD FILT 2000
Hydraulic oil 10 HYD OIL 2000

D. Use the [◊] switch to confirm the target items of the interval
change.

E. Maintenance interval time change procedure

i. This cursor is located at the highest-order digit. Pressing

the [<] or [>] switch changes the value of this digit in the
range of 0 – 9.

ii. Press the [◊] switch when the intended value appears to
select it as the set value.
★ The cursor moves to the 2nd digit.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
iii. Set the values up to the lowest-order digit in the same
manner and then press the [◊] switch.
★ When the input interval time is within the setting
range, the screen changes to the Check screen.
★ When the entered interval time is out of the setting
range, the entered interval time does not replace the
current value and the Input screen is restored.
★ The shortest interval time value is 50 hours.
• When you have entered a wrong value in a position
(except the highest-order digit), move to the highest-
order digit using the [■] switch and repeat the
procedure from the beginning. 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 the [■] switch.

F. Use the [<] or [>] switch to select YES or NO.

★ The selected cursor starts flashing.
• If YES is selected and the [■] switch is pressed, the
information is deleted.
• If NO is selected and the [■] switch is pressed,
deletion is cancelled and the Maintenance Interval
Change Item screen is restored.
★ By default, the cursor is set to NO (cancel) to prevent a
resetting error.
★ When an interval time is changed, the timer remaining
time is changed in the following manner:
Timer remaining time = Interval time being set - Elapsed
time from the last replacement

2. Selection between enabling or disabling timer by item

A. Pressing the [<] or [>] switch from Step 1C, the Interval Time
Change screen displays the Selection Between Enabling or
Disabling Timer by Item screen.
★ When “Timer by item” is enabled, the order of display is
ON → OFF.

★ When “Timer by item” is disabled, the order of display

becomes OFF → ON.
★ The default display is ON.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
B. Press the [◊] switch from this state.
★ If “Timer by item” is disabled, OFF is displayed in the
upper column.

★ If “Timer by item” is enabled, ON is displayed in the upper

column.

C. Use the [<] or [>] switch to select YES or NO.

★ The selected cursor starts flashing.
• If YES is selected and the [■] switch is pressed, the
information is deleted.
• If NO is selected and the [■] switch is pressed,
deletion is cancelled and the Maintenance Interval
Change Item screen is restored.
★ If the timer which has been stopped is activated, the
interval time set before the timer was stopped is applied.
The timer remaining time is reset. The number of resets
before the timer was stopped is applied.

3. Changing set default value.

A. Press the [◊] switch from the MAINTENANCE MONITOR

screen of the Service mode to display the 01: ENG OIL
screen.

B. Use the [<] or [>] switch to select the INITIALIZE screen.

C. Press the [◊] switch from this state.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
D. Use the [<] or [>] switch to select YES or NO.
★ The selected cursor starts flashing.
• If YES is selected and the [■] switch is pressed, the
change is enabled.
• If NO is selected and the [■] switch is pressed, the
change is not implemented and the maintenance
monitoring screen is restored.
★ 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.

Timer remaining time = Default value - Elapsed time

since the last replacement.

★ Executing the default value setting does not affect the reset frequency. It remains the same as before this operation
was executed.
★ Set enable for enable or disable of individual items.

4. Selection between timer stop for all items and enable by item

A. Press the [◊] switch from the MAINTENANCE MONITOR

screen of the Service mode to display the 01: ENG OIL
screen.

B. Use the [<] or [>] switch to select the ALL ITEMS OFF OR
ON screen.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
C. Press the [◊] switch to display the ALL ITEMS → OFF screen.

D. Press the [<] or [>] switch when selecting the ALL ITEMS →
ON screen.

E. Press the [◊] switch from the ALL ITEMS → OFF screen or
the ALL ITEMS → ON screen.
★ When the [◊] switch is pressed from the ALL ITEMS →
OFF screen, OFF is displayed in the upper space.

★ When the [◊] switch is pressed from the ALL ITEMS →

ON screen, ON is displayed in the upper space.

F. Use the [<] or [>] switch to select YES or NO.

★ The selected cursor starts flashing.
• If YES is selected and the [■] switch is pressed, the
information is deleted.
• If NO is selected and the [■] switch is pressed,
deletion is cancelled and the Maintenance Interval
Change Item screen is restored.

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TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
G. As the timer stop for all items is executed:
★ The timer function for all items is stopped and the MAINTENANCE MONITOR screen is restored.
★ Setting for individual items is also disabled.
★ If cancelled, the operation is cancelled and the MAINTENANCE MONITOR screen is restored.

H. When timer enable for all items is executed:

★ Interval time being set for all items is executed to the set value before being disabled, independent of whether or
not it is enabled or disabled for a specific item.
★ The timer remaining time is reset. (The reset frequency remains the same as before the resetting.)
★ The MAINTENANCE MONITOR screen is restored.
★ Setting for individual items is also enabled.
★ If cancelled, the operation is cancelled and the MAINTENANCE MONITOR screen is restored.

Operating Information Display Function (OPERATION INFO) (9)

This is a fuel consumption-related function and displays the following information:

• Fuel consumption ratio and average fuel consumption

• Cumulative fuel consumption and travel distance

• Cumulative fuel consumption and elapsed time

• Loaded volume and loading frequency (This display is available only if a load meter is installed.)

1. Selecting menu
Display the OPERATION INFO screen from the menu screen of
the Service mode.

2. Press the [◊] switch to display the Fuel Consumption Ratio and
Average Fuel Consumption screen.

3. Use the [<] or [>] switch to select the item to be displayed (A to D

in this step) on the Fuel Consumption Ratio and Average Fuel
Consumption screen.

A. Fuel Consumption Ratio and Average Fuel Consumption

screen
★ The upper column displays fuel consumption [L/km or
L/mile] per 1 km (or 1 mile) from the last resetting.
• Above value is computed from the fuel consumption
ratio and travel distance (odometer distance).
• Counting is stopped at 99999.9, the upper limit.
★ The lower column displays the average fuel consumption
[L/h] from the last resetting.
• Counting is stopped at 99999.9, the upper limit.
★ Calculation is done only for the duration in which the engine is running.

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B. Cumulative fuel consumption and travel distance
★ The upper column displays the cumulative fuel
consumption [L] from the last resetting.
• Counting is stopped at 99999.9, the upper limit.
★ The lower column displays the travel distance [km or
mile] from the last resetting.
• The unit km or mile is selected depending on that
used on the odometer.
• Counting is stopped at 99999.9, the upper limit.
★ Calculation is done only for the duration in which the
engine is running.

C. Cumulative fuel consumption and elapsed time

★ The upper column displays the cumulative fuel
consumption [L] from the last resetting.
• Counting is stopped at 99999.9, the upper limit.
★ The lower column displays the elapsed time [h] from the
last resetting.
• Counting is stopped at 99999.9, the upper limit.
★ Calculation is done only for the duration in which the
engine is running.

D. Loaded volume and loading frequency screen

★ The upper column displays the loaded volume [ton] from
the last resetting.
• Counting is stopped at 999999.9, the upper limit.
★ Short ton or metric ton depends on optional setting.
★ The lower column displays the loading frequency from
the last resetting.
• Counting starts stopped at 65000, the upper limit.
★ Calculation is done only for the duration in which the
engine is run and the optional device is used.

4. Deleting display data

★ Data on screens 3A to 3D allow deletion.
• Select a desired item and then delete it using the [◊] switch.
• Use the [■] switch when canceling deletion of data.

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5. Setting gain correction
★ Gain correction means the function of correcting gain to
cumulative fuel consumption.
★ Gain correction is available only from the Fuel Consumption
Ratio and Average Fuel Consumption screen.

A. After deleting data (RESET screen), press the [<] or [>]

switch to display the current set value.

B. Pressing the [◊] switch displays the correction screen.

★ Default value: 0.0%
★ This setting allows you to correct the cumulative fuel
consumption in the range of -50.0 to +50.0.

C. Move the cursor to [+] or [–].

D. Pressing the [<] or [>] switch alternately displays [+] and [–].

E. Press the [◊] switch to confirm [+] or [–].

★ The cursor moves to the highest-order digit of the set value.

F. Pressing the [<] or [>] switch changes the value of this digit in the range of 0 – 9.

G. Press the [◊] switch when the intended value appears in order to select it as the set value.
★ The cursor moves to the 2nd digit.

H. Set the values up to the lowest digit in the same manner and
then press the [◊] switch to confirm.
★ As the selection is confirmed, the preceding screen is
restored.
★ If the [■] switch is pressed before you finish entering the
selection, the cursor moves to the [+] and [–] position. In
this case, the value remains unchanged. Pressing the [■]
switch again restores the preceding screen.
★ If the value is not in the -50 to +50 range, pressing the [◊]
switch at the lowest digit just moves the cursor to the [+]
and [–] position and the value remains as it is.

30-210 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Optional Device Selecting Function (OPTIONAL SELECT) (10)

Use this procedure for setting an option.

★ 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. The option is now effective.

★ 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 Item
Item Default Description
English No.
Select A or B according to the lift arm
specifications.
Lift arm model LIFT BOOM 1 A
• Lift arm length = 3,250 mm: A
• Lift arm length = 3,636 mm: B
Auto grease AUTO GREASE 2 None When an option is provided, select ADD.
Battery electrolyte level sensor BAT LIQUID 3 None When an option is provided, select ADD.
Transmission filter clogging
TRANSM CLOG 4 None When an option is provided, select ADD.
sensor
Printer PRINTER 5 None When an option is provided, select ADD.
Normally, 0% shall be maintained without
Tire size TIRE SIZE 6 0
modifying current setting.
Only in specification which can display in mile,
Switching to short ton SHORT TON 7 None select ADD to display in short ton; select NO to
display in metric ton.
Only in specification which can display in mile,
Travel speed unit SPEED (UNIT) 8 MPH
MPH and km/h are selectable.
Engine speed or travel speed
Normally, ADD shall be maintained without
display on character display RPM/SPEED 10 Provided
modifying current setting.
and normal screen
Load meter LOAD METER 11 None When an option is provided, select ADD.
Emergency steering EMERG S/T 13 Provided When an option is not provided, select NO ADD.
When joystick steering or right FNR switch is
installed, the setting applicable to each shall be
Joystick steering or right FNR implemented.
(directional) switch, or both are J/S-FNR SW 14 NON • Set NON only for steering wheel.
absent • Set J/S for joystick steering.
• Set FNR SW for the right FNR (directional)
switch.
Normally, ADD shall be maintained without
Display of economy lamp ECO LAMP Provided
modifying current setting.
ECSS (Travel damper) E.C.S.S. 20 None When an option is provided, select ADD.
Automatic reversing fan AUTO RE FAN 21 None Set NO ADD and never change.
Torque converter lockup LOCK UP 22 None When an option is provided, select ADD.
Normally, NO ADD shall be maintained without
4th gear prohibition FORBID 4TH 23 None
modifying current setting.
Throttle lock THROT LOCK 24 None When an option is provided, select ADD.

WA500-6 30-211 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Display in Item
Item Default Description
English No.
When an option is provided, select ADD.
Power mode priority P-MODE PRI 25 None (Setting available: Power mode is introduced as
starting switch is turned on)
Very cold region specification COLD SPEC 26 None NO ADD; this must not be changed.
EPC 3-spool lever EPC 3RD 31 None When an option is provided, select ADD.
EPC lever EPC LEVER 32 Provided When an option is provided, select ADD.

1. Display the OPTIONAL SELECT screen from the menu screen of

the Service mode.

2. Hold down the [◊] switch for 5 seconds or longer.

3. The 1: LIFT BOOM screen appears.

★ If the [■] switch is pressed, the screen returns to the
OPTIONAL SELECT screen.
★ For optional setting, be sure to change or select the relevant
items from the 1: LIFT BOOM screen. Also set each item
sequentially on the next 2: AUTO GREASE screen and after.

30-212 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Setting Options

1. Changing or settling lift arm model option selection

★ Pressing the [◊] switch from the 1: LIFT BOOM screen interchanges A and B.
★ As A and B are interchanged, a sound (beep) indicating acceptance of the operation is generated.
• Select the lift arm length for A and B from the following.

Machine Model A B
3250 mm 3636 mm
WA500-6
(128 in) (143 in)

WA500-6 30-213 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM
2. Option setting/not setting selection
★ Among the items included in the list of installed optional
devices and their setting, the option setting/not setting
selection applies to the following items.
★ If the options are not selected, the Option Non-Selection
screen (NO ADD) is displayed.

★ If the options are selected, the Option Selected screen (ADD)

is displayed.
★ The [◊] switch allows the alternate display of the Option Non-
Selection screen and the Option-Selected screen.

3. Setting tire deflection option

★ Select the tire deflection option from the list of installed
optional devices and their setting.
★ Pressing the [◊] switch sequentially displays [@@]% in the
following order.
★ The display progresses from +00 through -10. Pressing the
[◊] switch at this point returns the display to +00.
Order No.1 No.2 No.3 No.4 No.5 No.6 No.7
@@ +00 +02 +04 +06 +08 +10 +12

Order No.8 No.9 No.10 No.11 No.12 No.13 No.14

@@ –02 –4 –6 –8 –10 –12 +00

★ As the display is switched, a sound (beep) (indicating acceptance of the operation) is generated.

4. Storing option selection

A. If the option selection was changed, 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.)

B. The specified option selection is enabled as the starting switch is turned on.
★ Whenever an option selection is made, turn off the starting switch once and then turn it on again in
approximately 15 seconds.

30-214 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Machine Serial Number Input Function (MACHINE No. SET) (11)

1. Display the MACHINE No. SET screen from the menu screen of
the Service mode.

2. Press the [◊] switch to display the MACHINE No. screen.

3. Enter the serial number according to the following procedure.

★ The cursor is positioned at the highest-order digit.

A. Pressing the [<] or [>] switch increases or decreases the value

at the cursor position. Select a desired value using these
switches.

B. Press the [◊] switch to confirm the selection.

★ The cursor moves to the digit situated immediately on the
right hand.

C. Set the values up to the lowest digit in the same manner and
then press the [◊] switch to confirm.
★ As the selection is confirmed, the preceding screen is
restored.
★ Pressing the [■] switch while entry is taking place moves
the cursor to the highest-order digit. In this case, repeat
the entry from the highest-order digit.
★ If the [■] switch is pressed while the cursor is at the
highest-order digit, the preceding screen is restored.

WA500-6 30-215 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Model Selection Function (MACHINE WA500) (12)

★ The machine model select function allows you to change the setting of the machine model on the monitor.

★ Select a model first after initializing the machine monitor.

★ Selecting a model resets the optional setting. If a model is selected, perform all the optional settings in sequence from the
beginning.

1. Implementing the model change

A. Display the MACHINE screen from the menu screen of the

Service mode.
★ The currently selected machine model is displayed on the
lower line.

B. Hold down the [◊] switch for five seconds to display the
Model Selection screen.

C. Use the [<] and [>] switch to select the machine model.
★ Press the [■] switch to stop the model selection.
★ As the operation is stopped, a sound (beep) (indicating
acceptance of the operation) is generated, restoring the
MACHINE screen.

D. Use the [◊] switch to confirm the selected model.

★ As the selection is confirmed, a sound (beep) (indicating
acceptance of the operation) is generated, restoring the
MACHINE screen.
★ Check that the desired machine model is displayed on the
MACHINE screen.

2. Storing model change

A. When the model change is 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.)

B. The model selected when the starting switch is turned on is validated.

★ Whenever a model change is done, turn off the starting switch once and then turn it on again in approximately
15 seconds.

30-216 ➁ WA500-6
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

Initialize Function (INITIALIZE) (13)

This function is used only in the factory. It is not used for service
purposes.

Appendix
Refer to Service News for the following items:

• Setting of service meter when machine monitor is exchanged.

• Setting of odometer when machine monitor is exchanged.

WA500-6 30-217 ➁
TESTING AND ADJUSTING MACHINE MONITOR SYSTEM

MEMORANDUM

30-218 ➁ WA500-6
TESTING AND ADJUSTING PM CLINIC INSPECTION TABLES

PM CLINIC INSPECTION TABLES

WA500-6 Serial No. A92001 and up

WARNING! When measuring the transfer clutch control pressure, carry out the measurement at a place where
the machine can travel safely at a speed of more than 10 km/h (6 mph).

Machine serial No. #

Hours inspection Engine serial No. SAA6D140E-5#

Work Order No. Date of Service Service Meter Inspector

Interview with Operator and Walk-around Inspection

Ambient temperature
Problems before inspection:
Max. °C (°F)
1. Min. °C (°F)
2. Altitude: m (yd)
3.
4.
Maximum coolant temperature (During operation) Maximum HST oil temperature (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

• W = White
• G = Green
• R = Red
★ Before starting the inspection, check that the machine does not move when the directional lever is placed in position.

★ If the machine is cold, warm it up fully.

Standard Value Service Limit Measurement

Item Condition Unit Good Bad
for New Machine Value Result
Engine at low idle 650 – 700 650 – 700
Engine at high idle 2,100 – 2,200 2,100 – 2,200
Engine at high idle and torque
1,740 – 1,940 1,640 – 2,040
converter stalled
Engine speed rpm
Engine at high idle and work
2,000 – 2,200 1,900 – 2,300
equipment relieved
Torque converter stalled + Work
1,700 – 1,900 1,500 – 2,100
equipment relieved
Blow-by Engine at high idle and torque kPa Max. 2.94 3.92
Engine

pressure converter stalled (psi) (0.43) (0.57)

SAE0W30EOS Min. 0.34 0.21
SAE5W40EOS Engine at high idle
Lubricating oil MPa (49.31) (30.46)
SAE10W30DH
pressure (psi)
SAE15W40DH Min. 0.10 0.08
SAE30DH Engine at low idle
(14.50) (11.60)
Engine at high idle and torque kPa Min. 116 89
Boost pressure
converter stalled (psi) (16.82) (12.91)
• Engine at high idle and torque
Exhaust °C Max. 650 700
converter stalled
temperature (°F) (Max. 1202) (1292)
• Outside temperature: 20°C (68°F)

WA500-6 30-219 ➁
TESTING AND ADJUSTING PM CLINIC INSPECTION TABLES

Standard Value Service Limit Measurement

Item Condition Unit Good Bad
for New Machine Value Result
* When shifting transmission gear to forward/reverse position, apply brake securely.
Engine at high 3.19 – 3.48 3.19 – 3.48
Main relief idle (462.67 – 504.73) (462.67 – 504.73)
pressure Engine at low • Torque converter 3.49 – 3.79 3.49 – 3.79
idle oil pressure: (506.18 – 549.69) (506.18 – 549.69)
Torque Within operating
Engine at high range 0.44 – 0.84 0.44 – 0.84
converter inlet
idle • Transmission: (63.82 – 121.83) (63.82 – 121.83)
pressure
Torque Neutral
Engine at high 0.29 – 0.49 0.29 – 0.49
converter outlet
TransmissiOn valve

idle (42.06 – 71.07) (42.06 – 71.07)

pressure
3.04 – 3.44 3.04 – 3.44
1st
MPa (440.91 – 498.93) (440.91 – 498.93)
(psi) 3.08 – 3.48 3.08 – 3.48
2nd
(446.72 – 504.73) (446.72 – 504.73)
• Torque converter
oil pressure: 3.08 – 3.48 3.08 – 3.48
3rd
Within operating (446.72 – 504.73) (446.72 – 504.73)
ECMV output range 2.99 – 3.39 2.99 – 3.39
4th
(clutch) pressure • Engine at high (433.66 – 491.68) (433.66 – 491.68)
idle 1.71 – 2.01 1.71 – 2.01
Lockup • Manual switch: (248.01 – 291.53) (248.01 – 291.53)
ON
3.18 – 3.58 3.18 – 3.58
F
(461.22 – 519.24) (461.22 – 519.24)
3.14 – 3.54 3.14 – 3.54
R
(455.42 – 513.43) (455.42 – 513.43)

Standard Value Service Limit Measurement

Item Condition Unit Good Bad
for New Machine Value Result
* Secure frame with frame lock bar.
Steering

24.5 – 25.5 23.5 – 25.5

Steering relief MPa
Engine at high idle (3553.43 – (3553.43 –
pressure (psi)
3698.46) 3698.46)
• Torque converter As brake is 3.38 – 3.68 3.38 – 3.68
oil temperature: released (490.23 – 533.74) (490.23 – 533.74)
Parking brake Within operating MPa
inlet pressure range When brake (psi) Min. 0.14 Min. 0.14
• Engine at low operated (Min. 20.31) (Min. 20.31)
idle
• Tire inflation pressure: Specified
pressure
Parking brake Holds in Holds in
• Test on flat and dry paved slope of —
performance position position
1/5 (11° 20').
• Set machine in operating state.
Parking brake mm 3.1 – 3.3 2.77
Brake

disc thickness (in) (0.12 – 0.13) (0.11)

Measure when
brake oil
Charge cut-in 5.88 – 6.37 5.39 – 6.86
• Hydraulic oil pressure
pressure (852.82 – 923.89) (781.75 – 994.96)
temperature: warning lamp
Within operating goes off.
range Measure when
• Engine at low MPa
brake oil 9.8 – 10.78 9.31 – 11.27
Charge cut-out idle (psi)
pressure starts (1421.37 – (1350.30 –
pressure
lowering after 1563.51) 1634.58)
rising.
• Hydraulic oil temperature: Within
Brake oil 4.9 – 5.59 4.7 – 5.78
operating range
pressure (710.68 – 810.76) (681.68 – 838.32)
• Engine at low idle

30-220 ➁ WA500-6
TESTING AND ADJUSTING PM CLINIC INSPECTION TABLES

Standard Value Service Limit Measurement

Item Condition Unit Good Bad
for New Machine Value Result
• Engine: Stopped
Drop in brake • Measure lowering of oil pressure kPa Max. 0.49 Max. 0.49
pressure from 4.9 MPa (710.68 psi) in (psi) (Max. 0.071) (Max. 0.071)
5 minutes.
• Tire inflation pressure: Specified
pressure
• Test on flat, level, straight, and dry
paved road.
Brake

• Braking initial speed: 20 km/h,

Wheel brake m Max. 4 Max. 4
Delay in pressing pedal: Max 0.1
performance (ft) (Max. 13.12) (Max. 13.12)
sec
• Brake pedal pressing force:
Specified force, 294 ±29.4 N•m
(lbf ft)
• Measure braking distance.
Wear of wheel mm 0 Max. 5.5
Measure with disc wear indicator.
brake disc (in) (0) (Max. 0.22)
Work
32.8 – 34.8 31.8 – 34.8
equipment Bucket circuit
(4757.24 – (4612.20 –
valve relief relieved
5047.31) 5047.31)
pressure
MPa
Work • P-mode (psi)
equipment Hydraulic oil Work equipment
1.27 – 1.47 1.17 – 1.57
valve LS temperature: control lever
(184.20 – 213.21) (169.69 – 227.71)
differential Within moved halfway
pressure operating
Work equipment

range Rising time 6.7 – 7.5 Max. 8.9

Lift arm speed • Engine at
high idle Lowering time 3.7 – 4.7 Max. 5.4
Bucket full stroke Sec 2.2 – 2.8 Max. 3.4
Bucket tilt back time
speed Bucket at level
1.5 – 2.1 Max. 2.6
time
• Hydraulic oil Bucket cylinder Max. 20 Max. 20
temperature:
mm/
Hydraulic drift Within
15 min.
of work operating Max. 40 Max. 40
Lift cylinder (in/
equipment range (Max. 1.57) (Max. 1.57)
15 min)
• Engine:
Stopped
Visual check of Front axle
There must not be excessive metal
Axle

differential —
Rear axle powder.
drain plug

WA500-6 30-221 ➁
TESTING AND ADJUSTING PM CLINIC INSPECTION TABLES
Memo

30-222 ➁ WA500-6
 40 TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 40-17

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-19
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 40-20
Precautions when Handling Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20
Handling Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-25
Points to Remember when Troubleshooting Electrical Circuits . . . . . . . . . . . . . . . . . . . 40-26
ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27
Classification by Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27
Classification by Color and Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27
How to Read Electric Wire Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28
Type, Symbol, and Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-29
HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
Categories and Method of Using Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . 40-33
Troubleshooting Individual Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-34
Chart Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-36
Chart Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-36
Troubleshooting Individual Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-37
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . 40-39
X-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-39
SWP-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
M-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-43
S-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-45
MIC-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
AMP040-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-49
AMP070-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-51
L-Type Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
PA-Type Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
Bendix (MS) Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
F-Type Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
KES1 (Automobile) Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55
Connectors for Relay (Socket-Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-57
HD30 Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
DT Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
DTM Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66
DTHD Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66
DRC26 Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
T-BRANCH BOX and T-BRANCH ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
MODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72

WA500-6 40-1 ➁
TROUBLESHOOTING TABLE OF CONTENTS

INFORMATION CONTAINED IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . 40-76

TROUBLESHOOTING BY FAILURE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-78
Failure Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-78
FUSE BOX AND SLOW-BLOW FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91
Connection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91
Fuse Box A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91
Fuse Box B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91
Slow-Blow Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-92
FAILURE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-93
1500LO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-94
TORQFLOW Transmission: Double Meshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-94
15BONX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-96
Transmission Filter: Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-96
15SAL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-98
ECMV F Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . . . . 40-98
15SALH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100
ECMV F Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . . . 40-100
15SBL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-102
ECMV R Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . . . 40-102
15SBLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-104
ECMV R Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . . . 40-104
15SEL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-106
ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . . 40-106
15SELH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-108
ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . . 40-108
15SFL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110
ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON . . . . . . . . . . . 40-110
15SFLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . 40-112
15SGL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-114
ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . 40-114
15GLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-116
ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . 40-116
15SHL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-118
ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . 40-118
15SHLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120
ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . 40-120
2F00MA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-122
Parking Brake: Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-122
2G42ZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-124
Front Accumulator: Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-124
2G43ZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-126
Rear Accumulator: Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-126
44K0L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-128
Bucket Positioner: ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-128
AA1ANX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130
Air Cleaner: Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130
AB00L6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-132
Alternator: Signal Disagrees with Operating State of Engine . . . . . . . . . . . . . . . . . . . . 40-132

40-2 ➁ WA500-6
TROUBLESHOOTING TABLE OF CONTENTS

AB00MA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-134
Alternator: Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-134
B@BAZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-136
Engine: Low Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-136
B@BAZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-138
Engine Oil: Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-138
B@BCNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140
Engine: Coolant: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140
B@BCZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-142
Engine: Coolant: Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-142
B@C7NS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-144
Brake: Brake Oil: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-144
b@CENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146
Torque Converter Oil: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146
B@CENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-148
Torque Converter Oil: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-148
B@GAZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150
Battery Electrolyte: Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150
B@HANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-152
Hydraulic Oil: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-152
CA111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-154
Abnormality in Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-154
CA115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-157
Engine Ne or Bkup Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-157
CA122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-158
Charge Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-158
CA123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160
Charge Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160
CA131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-162
Throttle Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-162
CA132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-164
Throttle Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-164
CA135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-166
Engine Oil Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-166
CA141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-168
Engine Oil Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-168
CA144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170
Coolant Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170
CA145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-172
Coolant Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-172
CA153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-174
Charge Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-174
CA154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-176
Charge Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-176
CA187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-177
Sensor Power Supply 2 Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-177
CA221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-178
Atmospheric Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-178
CA222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180

WA500-6 40-3 ➁
TROUBLESHOOTING TABLE OF CONTENTS

Atmospheric Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180

CA227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-182
Sensor Power Supply 2 High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-182
CA234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-184
Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-184
CA238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-186
Ne Speed Sensor Power Supply Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-186
CA263 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-188
Fuel Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-188
CA265 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190
Fuel Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190
CA271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-192
PCV1 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-192
CA272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-194
PCV1 Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-194
CA273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-196
PCV2 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-196
CA274 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-198
PCV2 Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-198
CA322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200
Injector #1 (L/B #1) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200
CA323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-202
Injector #5 (L/B #5) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-202
CA324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-204
Injector #3 (L/B #3) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-204
CA325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-206
Injector #6 (L/B #6) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-206
CA331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-208
Injector #2 (L/B #2) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-208
CA332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210
Injector #4 (L/B #4) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210
CA342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-212
Calibration Code Data Inconsistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-212
CA351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-213
Injectors Drive Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-213
CA352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216
Sensor Power Supply 1 Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216
CA386 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218
Sensor Power Supply 1 High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218
CA431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220
Idle Validation Switch Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220
CA432 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
Idle Validation Action Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
CA441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-223
Battery Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-223
CA442 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224
Battery Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224
CA449 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-225
Common Rail Pressure High Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-225

40-4 ➁ WA500-6
TROUBLESHOOTING TABLE OF CONTENTS

CA451 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-226
Common Rail Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-226
CA452 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228
Common Rail Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228
CA553 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-229
Common Rail Pressure High Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-229
CA554 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230
Common Rail Pressure In-Range Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230
CA559 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-232
Supply Pump Pressure Very Low Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-232
Checksheet for No-Pressure Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-234
CA689 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236
Engine Ne Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236
CA731 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238
Engine Bkup Speed Sensor Phase Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238
CA757 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-239
All Continuous Data Lost Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-239
CA778 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240
Engine Bkup Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240
CA1228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242
EGR Valve Servo Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242
CA1625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-243
EGR Valve Servo Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-243
CA1626 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-244
Bypass Valve Solenoid Current High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-244
CA1627 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-246
Bypass Valve Solenoid Drive Circuit Disconnection Error . . . . . . . . . . . . . . . . . . . . . 40-246
CA1628 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-247
Bypass Valve Servo Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-247
CA1629 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248
Bypass Valve Servo Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248
CA1631 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250
Bypass Valve Lift Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250
CA1632 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-252
Bypass Valve Lift Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-252
CA1633 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-253
KOMNET Datalink Timeout Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-253
CA1642 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254
EGR Inlet Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254
CA1653 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-256
EGR Inlet Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-256
CA2185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258
Throttle Sensor Supply Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258
CA2186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260
Throttle Sensor Power Supply Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260
CA2249 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-261
Supply Pump Pressure Very Low Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-261
CA2271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262
EGR Valve Lift Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262

WA500-6 40-5 ➁
TROUBLESHOOTING TABLE OF CONTENTS

CA2272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-264
EGR Valve Lift Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-264
CA2351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-266
EGR Valve Solenoid Operation Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-266
CA2352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-268
EGR Valve Solenoid Operation Disconnection Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-268
CA2555 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-269
Intake Heater Relay Disconnection Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-269
CA2556 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-270
Intake Heater Relay Short Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-270
D160KZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272
Backup Lamp Relay: Disconnection or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272
D191KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-274
Joystick Steering Neutral Safety Relay: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . 40-274
D191KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-276
Joystick Steering Neutral Safety Relay: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-276
D192KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-278
ECSS Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-278
D192KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-279
ECSS Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-279
D192KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-280
ECSS Solenoid Relay: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . . 40-280
D193KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-282
Joystick Steering Solenoid Cut Relay: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 40-282
D193KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-284
Joystick Steering Solenoid Cut Relay: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-284
D193KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-286
Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line . . . . . . . 40-286
D5ZHKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-288
Terminal C Signal: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-288
D5ZHKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-292
Terminal C Signal: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-292
D5ZHKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-294
Terminal C Signal: Disconnection or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-294
D5ZHL6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298
Terminal C Signal: Signal Does Not Match Engine Running or Stopped State . . . . . . 40-298
DA80L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-300
Auto-Grease Controller: ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-300
DAF3KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302
Machine Monitor: Low Source Voltage (input) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302
DAF5KP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-304
Machine Monitor: Low Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-304
DAFRKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-308
Machine Monitor: CAN Defective Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-308
DAQ0KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-310
Transmission Controller: Low Source Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-310
DAQ0KT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-312
Transmission Controller: Abnormality in Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 40-312
DAQ2KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-314

40-6 ➁ WA500-6
TROUBLESHOOTING TABLE OF CONTENTS

Transmission Controller Load Power Supply Line: Low Source Voltage (input) . . . . 40-314
DAQ9KQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-316
Transmission Controller: Disagreement of Model Selection Signals . . . . . . . . . . . . . . 40-316
DAQRKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-318
Transmission Controller: CAN Defective Communication . . . . . . . . . . . . . . . . . . . . . . 40-318
DAQRMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-320
Transmission Controller Option Setting: Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . 40-320
DB2RKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-322
Engine Controller: CAN Defective Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-322
DB90KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-324
Work Equipment Controller: Low Source Voltage (input) . . . . . . . . . . . . . . . . . . . . . . 40-324
DB90KT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-326
Work Equipment Controller: Abnormality in Controller . . . . . . . . . . . . . . . . . . . . . . . 40-326
DB92KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-328
Work Equipment Controller Load Power Supply Line: Low Source Voltage (input) . 40-328
DD95KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-330
Work Equipment Controller Power Supply Output: Out-of-Input Signal Range . . . . . 40-330
DB99KQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-332
Work Equipment Controller: Disagreement of Model Selection Signals . . . . . . . . . . . 40-332
DB9RKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-334
Work Equipment Controller: CAN Defective Communication . . . . . . . . . . . . . . . . . . 40-334
DB9RMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-336
Work Equipment Controller Option Setting: Malfunction . . . . . . . . . . . . . . . . . . . . . . 40-336
DB9RMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-338
Work Equipment Controller: CAN Communication Defective Operation . . . . . . . . . . 40-338
DD15LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-340
Switch (Panel Switch 1 n): Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-340
DD16LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-342
Switch (Panel Switch 2 ‡): Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-342
DD17LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-344
Switch (Panel Switch 3 <): Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-344
DD18LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-346
Switch (Panel Switch 4 >): Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-346
DD1ALD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-348
Remote Positioner Raise/Lower Set Switch (raise): Switch is Kept Pressed for Long Time . .
40-348
DD1BLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-350
Remote Positioner Raise/Lower Set Switch (lower): Switch is Kept Pressed for Long Time .
40-350
DD1CLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-352
Load Meter Subtotal Switch: Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . 40-352
DD1FLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-354
Load Meter Mode Selector Switch (A/B): Switch is Kept Pressed for Long Time . . . 40-354
DD1GLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-356
Load Meter Mode Selector Switch (+/-): Switch is Kept Pressed for Long Time . . . . 40-356
DD1HLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-358
Load Meter Display Selector Switch: Switch is Kept Pressed for Long Time . . . . . . . 40-358
DDA7L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-360
RPM Set ON/OFF Switch: ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . . . . . . . . . 40-360

WA500-6 40-7 ➁
TROUBLESHOOTING TABLE OF CONTENTS

DDA8KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-362
RPM Set Idle UP/DOWN Selector Switch (idle UP): Short Circuit . . . . . . . . . . . . . . . 40-362
DDA9KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-364
RPM Set Idle UP/DOWN Selector Switch (idle DOWN): Short Circuit . . . . . . . . . . . 40-364
DDB6L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-366
Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . 40-366
DDD1LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-370
Remote Positioner Bucket Angle Set Switch: Switch is Kept Pressed for Long Time . 40-370
DDE5MA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-372
Emergency Steering Drive Switch: Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-372
DDK3KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-374
Right FNR Switch: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-374
DDK3KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-377
Right FNR Switch: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-377
DDK4KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-380
Joystick Steering FNR Switch: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-380
DDK4KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-383
Joystick Steering FNR Switch: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-383
DDK5L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-386
Joystick Steering with Shift UP/DOWN Switch: ON/OFF Signals Disagree . . . . . . . . 40-386
DDK6KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-388
FNR Lever Switch: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-388
DDK6KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-391
FNR Lever Switch: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-391
DDT0L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-394
Shift Mode Selector Switch: ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . . . . . . . . 40-394
DDT4LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-396
Transmission Cutoff Set Switch: Switch is Kept Pressed for Long Time . . . . . . . . . . . 40-396
DDW9LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-398
Kickdown Switch: Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . . . . . . . . 40-398
DDWLLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-400
Hold Switch: Switch is Kept Pressed Down for Long Time . . . . . . . . . . . . . . . . . . . . . 40-400
DDY0LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-402
Load Meter Cancel Switch: Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-402
DF10KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-404
Transmission Shift Lever Switch: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-404
DF10KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-407
Transmission Shift Lever Switch: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-407
DGF1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-410
Transmission Oil Temperature Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 40-410
DGF1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-412
Transmission Oil Temperature Sensor: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-412
DGH2KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-414
Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . . . . . . 40-414
DGR2KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-416
Rear Brake Oil Temperature Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-416
DGR2KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-418
Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . . . . . . . . 40-418
DGT1KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-420

40-8 ➁ WA500-6
TROUBLESHOOTING TABLE OF CONTENTS

Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range . . . . . . . . . . . . 40-420

DH21KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-422
Work Equipment Pump Oil Pressure Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . 40-422
DH21KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-424
Work Equipment Pump Oil Pressure Sensor: Short Circuit . . . . . . . . . . . . . . . . . . . . . 40-424
DHPCKX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-426
Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range . . . . . . . . . . . 40-426
DHPDKX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-428
Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . 40-428
DHT1KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-430
Left Brake Pressure Sensor: Out-of-Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-430
DHT2L6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-432
Transmission Filter Clogging Sensor: Signal Disagrees with Operating and Stopped States of
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-432
DK59KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-434
Lift Arm EPC Lever Potentiometer (Main): Disconnection . . . . . . . . . . . . . . . . . . . . . 40-434
DK59KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-437
Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line . . 40-437
DK59L8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-440
Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree . . . . . . . . . . . . . 40-440
DK5AKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-444
Lift Arm EPC Lever Potentiometer (Sub): Disconnection . . . . . . . . . . . . . . . . . . . . . . 40-444
DK5AKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-447
Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne . . . 40-447
DK5BKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-450
Bucket EPC Lever Potentiometer (Main): Disconnection . . . . . . . . . . . . . . . . . . . . . . . 40-450
DK5BKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-453
Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line . . . . 40-453
DK5BL8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-456
Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree . . . . . . . . . . . . . . 40-456
DK5CKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-459
Bucket EPC Lever Potentiometer (Sub): Disconnection . . . . . . . . . . . . . . . . . . . . . . . . 40-459
DK5CKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-462
Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line . . . . . 40-462
DK5DKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-465
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Disconnection . . . . . 40-465
DK5DKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-468
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Short Circuit with Power Sup-
ply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-468
DK5DL8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-470
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Analog Signals Disagree 40-
470
DK5EKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-474
3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Disconnection . . . . . . . 40-474
DK5EKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-476
3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Short Circuit with Power Supply
Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-476
DK5FKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-478
Joystick Steering EPC Lever Potentiometer (Main): Disconnection . . . . . . . . . . . . . . . 40-478

WA500-6 40-9 ➁
TROUBLESHOOTING TABLE OF CONTENTS

DK5FKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-480
Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line . .
40-480
DK5GKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-482
Joystick Steering EPC Lever Potentiometer (Sub): Disconnection . . . . . . . . . . . . . . . . 40-482
DK5GKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-484
Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line 40-
484
DK5FL8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-486
Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree . . . . . . 40-486
DKA0KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-490
Lift Arm Angle Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-490
DKA0KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-492
Lift Arm Angle Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-492
DKA0KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-496
Lift Arm Angle Sensor: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . 40-496
DKA0L0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-498
Lift Arm Angle Sensor: Double Meshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-498
DLF1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-500
Transmission Input Shaft Speed Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . 40-500
DLF1LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-502
Transmission Input Shaft Speed Sensor: Speed Signals Disagree . . . . . . . . . . . . . . . . 40-502
DLT4KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-504
Transmission Input Shaft Speed Sensor: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-504
DLT4KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-506
Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . 40-506
DT20KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-508
Transmission Cutoff Indicator Lamp: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-508
DUM1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-510
Remote Positioner Raise Set Indicator Lamp: Short Circuit . . . . . . . . . . . . . . . . . . . . . 40-510
DUM2KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-512
Remote Positioner Lower Set Indicator Lamp: Short Circuit . . . . . . . . . . . . . . . . . . . . 40-512
DV00KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-514
Alarm Buzzer: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-514
DW4PKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-516
Lift Arm Raise EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-516
DW4PKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-518
Lift Arm Raise EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-518
DW4PKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-520
Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . 40-520
DW4QKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-522
Lift Arm Lower EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-522
DW4QKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-524
Lift Arm Lower EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-524
DW4QKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-526
Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . 40-526
DW4RKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-528
Bucket Tilt EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-528
DW4RKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-530

40-10 ➁ WA500-6
TROUBLESHOOTING TABLE OF CONTENTS

Bucket Tilt EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-530

DW4RKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-532
Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . 40-532
DW4SKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-534
Buck Dump EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-534
DW4SKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-536
Bucket Dump EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-536
DW4SKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-538
Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-538
DW7BKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-540
Fan Reverse Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-540
DW7BKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-542
Fan Reverse Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-542
DW7BKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-544
Fan Reverse Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . . 40-544
DW7DKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-546
Hydraulic Drive Fan Neutral Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 40-546
DW7DKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-547
Hydraulic Drive Fan Neutral Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-547
DW7DKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-548
Hydraulic Drive Fan Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . 40-548
DWM1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-550
Work Equipment Neutral Lock Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . 40-550
DWM1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-552
Work Equipment Neutral Lock Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . 40-552
DWM1KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-554
Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line . . . . 40-554
DWN6KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-556
Lift Arm Raise Magnet Detent Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . 40-556
DWN6KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-558
Lift Arm Raise Magnet Detent Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . 40-558
DWN6KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-560
Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line . . . . 40-560
DWN7KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-562
Lift Arm Float Magnet Detent Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . 40-562
DWN7KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-564
Lift Arm Float Magnet Detent Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-564
DWN7KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-566
Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line . . . . . 40-566
DWN8KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-568
Bucket Tilt Magnet Detent Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-568
DWN8KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-570
Bucket Tilt Magnet Detent Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-570
DWN8KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-572
Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source . . . . . . . . . . . . . 40-572
DX16KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-574
Fan Pump EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-574
DX16KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-575
Fan Pump EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-575

WA500-6 40-11 ➁
TROUBLESHOOTING TABLE OF CONTENTS

DX16KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-576
Fan Pump EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . 40-576
DXA1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-577
Pump PC-EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-577
DXA1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-578
Pump PC-EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-578
DXH1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-580
Lockup ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-580
DXH1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-582
Lockup ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-582
DXH1KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-584
Lockup ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . 40-584
DXH4KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-586
1st Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-586
DXH4KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-588
1st Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-588
DXH4KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-590
1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-590
DXH5KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-592
2nd Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-592
DXH5KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-594
2nd Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-594
DXH5KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-596
2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-596
DXH6KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-598
3rd Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-598
DXH6KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-600
3rd Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-600
DXH6KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-602
3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-602
DXH7KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-604
R Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-604
DXH7KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-606
R Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-606
DXH7KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-608
R Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . 40-608
DXH8KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-610
F Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-610
DXH8KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-612
F Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-612
DXH8KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-614
F Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . 40-614
DXHHKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-616
4th Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-616
DXHHKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-618
4th Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-618
DXHHKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-620
4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-620
DXHJKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-622

40-12 ➁ WA500-6
TROUBLESHOOTING TABLE OF CONTENTS

3-Spool Valve Extract EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-622

DXHJKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-623
3-Spool Valve Extract EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-623
DXHJKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-624
3-Spool Valve Extract EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . 40-624
DXHKKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-626
3-Spool Valve Retract EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-626
DXHKKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-627
3-Spool Valve Retract EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-627
DXHKKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-628
3-Spool Valve Retract EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . 40-628
DXHLKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-630
Joystick Steering Right EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 40-630
DXHLKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-632
Joystick Steering Right EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-632
DXHLKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-635
Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line . . . . . . 40-635
DXHMKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-638
Joystick Steering Left EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-638
DXHMKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-640
Joystick Steering Left EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-640
DXHMKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-643
Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . 40-643
TROUBLESHOOTING: E-MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-646
Troubleshooting Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-646
Information in Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-646
E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-648
Engine Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-648
E-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-653
Wiper Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-653
E-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-657
Windshield Washer Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-657
E-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-660
Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off . 40-
660
E-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-668
Working Lamp Does Not Light Up or Go Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-668
E-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-673
Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off . . . . . . . . . . . . . . . . 40-673
E-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-679
Brake Lamp Does Not Light or It Keeps Lighting Up . . . . . . . . . . . . . . . . . . . . . . . . . 40-679
E-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-682
Backup Lamp Does Not Light or It Keeps Lighting Up . . . . . . . . . . . . . . . . . . . . . . . . 40-682
E-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-684
Backup Buzzer Does Not Sound or It Keeps Sounding . . . . . . . . . . . . . . . . . . . . . . . . 40-684
E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-686
Horn Does Not Sound or It Keeps Sounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-686
E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-690
Alarm Buzzer Does Not Sound or It Keeps Sounding . . . . . . . . . . . . . . . . . . . . . . . . . 40-690

WA500-6 40-13 ➁
TROUBLESHOOTING TABLE OF CONTENTS

E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-692
Air Conditioner Does Not Operate or Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-692
E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-695
KOMTRAX System Does Not Work Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-695
Lamp Display Section of KOMTRAX Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . 40-697
TROUBLESHOOTING: H-MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-698
Troubleshooting Hydraulic and Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 40-698
Using Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-698
Failure Codes and Causes Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-700
H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-704
Machine Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-704
H-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-706
Torque Converter Lockup is Not Switched OFF (Engine Stalls) . . . . . . . . . . . . . . . . . 40-706
H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-707
Torque Converter Lockup is Not Switched ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-707
H-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-708
Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not
Shifted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-708
H-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-712
Large Shocks When Starting and Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-712
H-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-716
Large Time Lag When Starting and Shifting Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-716
H-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-720
Torque Converter Oil Temperature is High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-720
H-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-721
Steering Does Not Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-721
H-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-722
Steering Does Not Turn (Joystick Steering, if equipped) . . . . . . . . . . . . . . . . . . . . . . . 40-722
H-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-723
Steering Response is Poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-723
H-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-724
Steering Turning Response is Poor (Joystick Steering, if Equipped) . . . . . . . . . . . . . . 40-724
H-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-725
Steering is Heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-725
H-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-726
When Machine Turns, It Shakes or Jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-726
H-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-727
When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped) . . . . . . . . . 40-727
H-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-728
Wheel Brake Does Not Work or Does Not Work Well . . . . . . . . . . . . . . . . . . . . . . . . . 40-728
H-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-729
Wheel Brake is Not Released or It Drags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-729
H-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-730
Parking Brake Does Not Work or Does Not Work Well . . . . . . . . . . . . . . . . . . . . . . . . 40-730
H-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-731
Parking Brake is Not Released or It Drags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-731
H-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-732
Lift Arm Does Not Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-732
H-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-733

40-14 ➁ WA500-6
TROUBLESHOOTING TABLE OF CONTENTS

Lift Arm is Low or Rising Force is Insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-733

H-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-734
When Rising, Lift Arm Starts to Move Slowly at a Specific Height . . . . . . . . . . . . . . . 40-734
H-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-734
Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats) . . . . . . . . . . . . . . . . . . 40-734
H-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-734
Hydraulic Drifts of the Lift Arm Occur Often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-734
H-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-735
Lift Arm Wobbles During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-735
H-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-736
Bucket Does Not Tilt Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-736
H-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-737
Bucket Speed is Low or Tilting-Back Force Is Insufficient . . . . . . . . . . . . . . . . . . . . . 40-737
H-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-738
Bucket Starts to Operate Slowly in the Midst of Tilting Back . . . . . . . . . . . . . . . . . . . 40-738
H-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-738
Bucket Cylinder Cannot Hold Down the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-738
H-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-738
Hydraulic Drifts of the Bucket Occur Often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-738
H-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-739
Bucket Wobbles During Travel with Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-739
H-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-739
During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls . . . 40-739
H-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-739
Large Shocks When Work Equipment Starts and Stops . . . . . . . . . . . . . . . . . . . . . . . . 40-739
H-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-739
When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves . . 40-739
H-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-740
ECSS Does Not Operate; Pitching and Bouncing Occur . . . . . . . . . . . . . . . . . . . . . . . 40-740

WA500-6 40-15 ➁
TROUBLESHOOTING TABLE OF CONTENTS

MEMORANDUM

40-16 ➁ WA500-6
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.

WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals. Do not allow any unauthorized person to come near the machine.

WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns. Wait for the engine to cool down before starting to troubleshoot.

WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

WARNING! When disconnecting wiring, always disconnect the negative (-) terminal of the battery
first.

WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant, or
air, always release the internal pressure first. When installing measuring equipment, be
sure to connect it properly.

The purpose of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.

When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However, a
short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure
that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
• It will waste man hours, parts, or oil and grease.
• It can also result in a loss of confidence by the user or operator.

For this reason, when carrying out troubleshooting, it is necessary to do a thorough investigation first and to carry out
troubleshooting in accordance with the fixed procedure.

2. Points to ask the user or operator.

A. Have any other problems occurred other than the problem that has been reported?

B. Was there anything strange about the machine before the failure occurred?

C. Did the failure occur suddenly, or were there problems with the machine before this?

D. Under what conditions did the failure occur?

E. Had any repairs been carried out before the failure? When were these repairs carried out?

F. Has the same kind of failure occurred before?

WA500-6 40-17 ➁
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
3. Check before troubleshooting.

A. Check the oil level.

B. Check for any external leakage of oil from the piping or hydraulic equipment.

C. Check the travel of the control levers.

D. Check the stroke of the control valve spool.

E. Other maintenance items can be checked externally, so check any item that is considered necessary.

4. Confirming the failure.

A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.

B. When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.

5. Troubleshooting

A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to pinpoint the position of the failure.

B. The basic procedure for troubleshooting is as follows.

i. Start from the simple points.

ii. Start from the most likely points.

iii. Investigate other related parts or information.

6. Measures to remove root cause of failure.

A. Even if the failure is repaired but the root cause of the failure is not repaired, the same failure will occur again.

B. To prevent this, always investigate why the problem occurred then remove the root cause.

40-18 ➁ WA500-6
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

WA500-6 40-19 ➁
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period and to prevent failures or other troubles before they occur,
correct operation, maintenance, 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 contains sections on handling electrical equipment and handling hydraulic equipment (particularly
hydraulic oil).

Precautions when Handling Electrical Equipment

1. Handling High-Voltage Circuits

A. If the machine is equipped with an electronically-controlled

engine, high voltage is used to control fuel injection, (110 -
130 V) for the fuel injector drive.
• Never handle the engine wiring harness while the engine
is running or tamper with or modify this circuit.
★ Severe injury may result due to the high voltage and
amps in the circuit.
• Always use caution when working around this
circuit.

2. Handling Wiring Harnesses and Connectors

Wiring harnesses consist of wiring connecting one component to
another component, connectors used for connecting and
disconnecting one wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted in boxes or
cases, wiring harnesses are more likely to be affected by the direct
effects of rain, water, heat, or vibration.
Furthermore, during inspection and repair operations they are
frequently removed and reinstalled so they are likely to suffer
deformation or damage.
★ It is necessary to be extremely careful when handling wiring
harnesses.

3. Main Failures Occurring in Wiring Harness

A. Faulty contact of connectors (faulty contact between male and

female)
★ Problems with faulty contact are likely to occur for
several reasons:
• The male connector is not properly inserted into the
female connector.
• One, or both, of the connectors is deformed.
• The position of the connectors is not correctly
aligned.
• There is corrosion or oxidation of the contact
surfaces.

40-20 ➁ WA500-6
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
B. Defective compression or soldering of connectors
The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.

C. Disconnections in wiring
• Crimping compression of the connectors to the wire may
be loosened.
• Soldering may be damaged.
• Wiring may be broken.
★ Possible causes:
• Wiring held and tugged and the connectors pulled
apart.
• Components lifted with a crane with the wiring still
connected.
• Heavy object hit the wiring.

D. High pressure water entering a connector

The connector is designed to make it difficult for water to
enter (drip-proof structure).
★ If high-pressure water is sprayed directly on the
connector, water may enter the connector depending on
the direction of the water jet.
★ If water does enter, it is difficult for it to be drained.
If water gets into the connector, the water will short-
circuit the pins.
• If any water gets in, immediately dry the connector or
take other appropriate action before passing electricity
through it.

E. Oil, grease, or dirt stuck to connector

If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and female pins,
the oil will not let the electricity pass; this will cause a defective
contact.
• If there is oil, grease, or dirt stuck to the connector, wipe it
off with a dry cloth or blow dry with air, and spray it with a
contact restorer.
• When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
• If there is water or oil present, it will increase the
contamination of the points. Clean with air until all
water and oil have been removed.

WA500-6 40-21 ➁
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
4. Removing, Installing, and Drying Connectors and Wiring
Harnesses

A. Unplugging connectors

i. Hold the connectors when disconnecting.

• When unplugging the connectors, hold the
connectors and not the wires.
• For connectors held by a screw, loosen the screw
fully then hold the male connectors in one hand and
the female connectors in the other hand and pull
apart.
• For connectors which have a lock stopper, press
down the stopper with your thumb and pull the
connectors apart.
★ Never try to pull connectors apart with one hand.

ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up
and down, the housing may break.

iii. When unplugging male and female connectors, release

the lock and pull in parallel with both hands.
• Never try to pull apart with one hand.

iv. Action to take after removing connectors.

• After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil, or water from
getting in the connector portion.

40-22 ➁ WA500-6
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
B. Plugging connectors

i. 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, faulty contact,
corrosion, or damage to the connector pins.
• Check that there is no damage or breakage to the
outside of the connector.
★ If there is any oil, water, or dirt stuck to the
connector, wipe it off with a dry cloth.
★ If any water has gotten inside the connector, warm
the inside of the wiring with a dryer. Be careful not to
make it too hot as this will cause short circuits.
★ If there is any damage or breakage, replace the
connector.

ii. Assemble the connector securely.

• Align the position of the connector correctly then
insert it securely.
• For connectors with a lock stopper, push in the
connector until the stopper clicks into position.

iii. Correct any protrusion of the boot and any misalignment

of the wiring harness.
• For connectors fitted with boots, correct any
protrusion of the boot.
• If the wiring harness is misaligned or the clamp is out
of position, adjust it to its correct position.
★ When blowing with dry air, there is danger that the
oil in the air may cause improper contact; clean with
properly filtered air.

iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.

C. Connecting DT-type connectors

★ Since the 8-pole DT and 12-pole DT-type connectors
have two latches respectively, push them in until they
click twice.
• Male connector (1), female connector (2).
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c

WA500-6 40-23 ➁
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
D. Drying wiring harness
★ If there is any oil or dirt on the wiring harness, wipe it off
with a dry cloth. Avoid washing it in water or using
steam.
• If the connector must be washed in water, do not use
high-pressure water or steam directly on the wiring
harness.
• If water gets directly on the connector, unplug the
connector and wipe off the water with a dry cloth.
★ If the connector is blown dry with air, there is the risk that
oil in the air may cause a faulty contact; avoid blowing
with air.

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

• If water gets inside the connector, use a dryer to dry
the connector.
★ Hot air from the dryer can be used but be careful not
to make the connector or related parts too hot, as this
will deform or damage the connector.

ii. Carry out a continuity test on the connector.

• After drying, leave the wiring harness disconnected
and carry out a continuity test to check the pins for
any short circuits caused by water.
• After completely drying the connector, spray it with
contact restorer and reassemble.

40-24 ➁ WA500-6
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

Handling Electronic Control Unit

1. The electronic control unit contains a microcomputer and
electronic circuits. This control unit controls all of the electronic
circuits on the machine.
★ Be extremely careful when handling the control unit.

2. Do not open the cover of the control box unless necessary.

3. Do not place objects on top of the control unit.

4. Cover the control connectors with tape or a vinyl bag.

5. Do not leave the control unit in a place where it is exposed to rain.

6. Do not place the control unit on surfaces containing oil, water, or

soil, or place it in any hot place, even for a short time. Do not
immerse the control unit in oil, water, or soil.
★ Place it on a suitable dry stand.

7. Precautions when carrying out arc welding.

★ When carrying out arc welding on the machine body,
disconnect all wiring harness connectors connected to the
control unit. Attach the arc welding ground as close to the
welding point as possible.

WA500-6 40-25 ➁
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

Points to Remember when Troubleshooting Electrical Circuits

1. Always turn the power OFF before plugging or unplugging connectors.

2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Plug and unplug the related connectors several times to check.
• Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.

3. Always plug any unplugged connectors before going on to the next step.
★ If power is turned ON with the connectors still unplugged, unnecessary abnormal displays will be generated.

4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related
wiring and connectors several times and check that there is no change in the reading of the tester.
★ If there is any change, there is probably a defective contact in that circuit.

5. When checking a single diode circuit:

• Isolate the diode from the circuit.
• Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing
the meter leads, you should have a reading in one direction
only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.

6. When checking a dual diode circuit:

• Isolate the diode from the circuit.
• Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing
the meter leads, you should have a reading in one direction
only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.

7. Always be aware of what you are measuring: Voltage, Ohms, or

Amps. Always use caution when measuring a circuit.
• When measuring voltage, be sure the meter is set in the
voltage range, AC or DC, and above the voltage value you are
measuring.
• When measuring ohms, be sure the circuit is dead (has no
voltage in it) before you take any readings. Be sure the meter
is set in the proper ohms range.
• When measuring amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage your equipment or possibly cause
injury. Always study the operator’s manual for the meter you
are using.

40-26 ➁ WA500-6
TROUBLESHOOTING ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.

This wire code table will help you understand WIRING DIAGRAMS.

Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

Classification by Thickness
Table 3

Copper Wire
Nominal Cable O.D. Current
Number of Diameter of Cross- Applicable Circuit
Number (mm) Rating (A)
Strands Strand (mm) section (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal, etc.
2 26 0.32 2.09 3.1 20 Lighting, signal, etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting

Classification by Color and Code

Table 1

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Primary

Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 Black & Yellow & Green &
Color White & Red — Red & White Blue & White
White Red White
Code WB — BY RB YB GR LR
3 White & Black & Yellow &
Color — Red & Black Green & Red Blue & Red
Black Yellow Black
Code WL — BR RY YG GY LY
Auxiliary

4 Red & Yellow & Green & Blue &

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

WA500-6 40-27 ➁
TROUBLESHOOTING ELECTRIC WIRE CODE

How to Read Electric Wire Code

★ The information about the wires unique to each machine model is described in the Troubleshooting section.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.

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 nominal No. of 0.85

Indicates color of wire by color code.

Color codes are shown in Table 1.

Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 3.

Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 2.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)

Type, Symbol, and Material

Table 2

★ 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.

Using
Temperature
Type Symbol Material Example of Use
Range
°C (°F)
Annealed copper for electric
Low-voltage wire Conductor General wiring
AV appliance
for automobile (Nominal No. 5 and above)
Insulator Soft polyvinyl chloride -30 to +60°C
Annealed copper for electric (-22 to 140 °F)
Thin-cover, low- Conductor
appliance General wiring
voltage wire for AVS
(Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Annealed copper for electric
Heat-resistant, Conductor General wiring in extremely
appliance -50 to +110°C
low-voltage wire AEX cold district, wiring at high-
Heat-resistant crosslinked (-58 to 230°F)
for automobile Insulator temperature place
polyethylene

40-28 ➁ WA500-6
TROUBLESHOOTING ELECTRIC WIRE CODE

Dimensions
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
Strands/
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
Diameter 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 –
Cover D

AV Standard – – – – – – – 4.6
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/
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
Diameter 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 – – – – – – – – –
Cover D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

★ A nominal No. with an “f” designation (for example, 1.25f) means flexible.

WA500-6 40-29 ➁
TROUBLESHOOTING HANDLING HYDRAULIC EQUIPMENT

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 in locations where
there is a lot of dust.

2. Disassembly and maintenance work in the field.

If disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the
equipment. It is also difficult to confirm the performance after
repairs. It is desirable to use a unit exchange.
★ Disassembly and maintenance of hydraulic equipment should
be carried out in a specially prepared dustproof workshop and
the performance should be confirmed with special test
equipment.

3. Seal or cover all openings of disconnected piping.

★ After any piping or equipment is removed, the openings
should be sealed with caps, tape, or vinyl bags to prevent any
dirt or dust from entering.
★ Never leave any openings opened or blocked with a rag; this
could cause particles or dirt to get into the system.
★ Drain all oil into a container and not unto the ground. Be sure
to follow the proper environmental regulation for disposal of
oil.

4. Do not let any dirt or dust get in during refilling operations.

★ Be careful not to let any dirt or dust get in when refilling with
hydraulic oil.
★ Always keep the oil filler and the area around it clean.
★ Use clean pumps and oil containers.
★ If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage; this is a more effective
method.

40-30 ➁ WA500-6
TROUBLESHOOTING HANDLING HYDRAULIC EQUIPMENT
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; it is best to change the oil when it is still warm.
★ When changing the oil, as much as possible of the old hydraulic oil must be drained out.
★ Do not drain the oil from the hydraulic tank; 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 equipment, 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.
• 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 circuit.
★ The oil cleaning equipment is used to remove the ultra fine
(about 3µ) particles that the filter, built into the hydraulic
equipment, cannot remove. The filter is an extremely effective
device.

WA500-6 40-31 ➁
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Item Criteria Remedy
1. Check level and type of fuel — Add fuel
2. Check for foreign matter in fuel — Clean or drain
3. Check level and type of oil in engine oil pan Between H and L Add oil
4. Check coolant level Between FULL and LOW Add coolant

Lubricating 5. Check air cleaner for clogging No red Clean or replace

oil and 6. Check level and type of hydraulic oil Between H and L Add oil
coolant
In upper range of site
7. Check level and type of transmission oil Add oil
gauge
8. Check engine oil filter for clogging — Replace
9. Check hydraulic oil filter for clogging — Replace
10. Check transmission oil filter for clogging — Replace
11. Check battery terminal cables for looseness and
— Retighten or replace
corrosion
12. Check alternator terminal cables for looseness and
Electrical — Retighten or replace
corrosion
parts
13. Check starting motor terminal cables for looseness
— Retighten or replace
and corrosion
14. Check operation of instruments — Repair or replace
15. Check for abnormal noise and smell — Repair
Hydraulic
and 16. Check for oil leakage — Repair
mechanical 17. Bleeding air — Bleed air
equipment
18. Check effect of brake — Repair or adjust
19. Check battery voltage (with engine stopped) 20 – 30 V Charge or replace
20. Check battery electrolyte level Between U.L and L.L Add or replace
21. Check wires for discoloration, burn, and removal of
— Replace
cover
22. Check for removed wire clamp and drooping wire — Repair

Electrical 23. Check wiring for wetness (check connectors and Disconnect and dry
—
equipment terminals for wetness, in particular) connectors
24. Check slow-blow fuses and fuses for disconnection
— Replace
and corrosion
25. Check alternator voltage (with engine at medium After several-minute
Repair or replace
speed or higher) operation: 27.5 – 29.5 V
26. Check operating sound of battery relay (Starting
— Replace
switch OFF ⇔ ON)

40-32 ➁ WA500-6
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

Categories and Method of Using Troubleshooting Charts

Categories of Troubleshooting Codes

★ If the machine monitor displays a failure code, the name of the controller is also displayed at the same time.
★ The troubleshooting codes are categorized according to the name of each controller.
(This may also include some failure codes for the electrical system that are not displayed.)
★ Failures of the hydraulic and mechanical systems that the machine monitor cannot display are categorized as H mode.

Troubleshooting Code Troubleshooting System

FAILURE CODES Troubleshooting of electrical system using failure codes shown on monitor
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine system (see Engine Shop Manual)

Procedure for Troubleshooting

If a problem occurs on the machine, or if any problem is felt, carry out troubleshooting as follows.

1. Failure code is displayed on machine monitor.

★ A failure code is displayed on the machine monitor at the same time as the problem occurs.
★ Check the content of the display, then go to the applicable troubleshooting for the failure code.

2. No failure code is displayed on the machine monitor but the failure is recorded in memory.
★ It is impossible to check the failure code display on the machine monitor when a problem occurs.
★ Use the Troubleshooting History display function in the Service mode of the machine monitor to check if there is
a failure code.
★ If a failure code is recorded, it is probable that it is the cause; go to the applicable troubleshooting for the failure
code.

3. If no failure code is displayed and no failure history is recorded.

★ It is impossible to check the failure display on the machine monitor when a problem occurs, and there is also no
failure code recorded in the Troubleshooting History display function in the Service mode of the machine monitor.
★ It is probable that a problem has occurred in the hydraulic, mechanical, or electrical system that the controller
cannot detect.
★ In such a case, check the condition of the failure carefully, then go to the applicable troubleshooting for the
failure.

WA500-6 40-33 ➁
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

Troubleshooting Individual Electrical Circuits

★ This method is also displayed at the beginning of each electrical system troubleshooting mode. It is important to follow
each step in the troubleshooting chart. Do not skip steps, jump ahead, or stop when a problem is found. It is important to
complete all steps due to the fact that there may be several other problems causing the failure code. The chart is set up to
start with the most likely problem first and progress down to the least likely.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not write on original page of service manual. Remove this page from the service manual and make a copy for recording
information while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of
the procedure.
• Follow each step throughout this procedure; do not skip steps, jump ahead, or stop when a fault is found. It is important to
complete all steps and record information for final analysis.

Action code Failure code

Trouble Problem that appears on machine
Monitor display Monitor display

Contents of Trouble State where the monitor panel or controller detects the trouble.

Action taken by machine monitor or controller to protect the system or devices when engine
Action of Controller
controller detects trouble.

Problem That Problem that appears on machine as result of action taken by machine monitor or controller
Appears On Machine (shown above).

Related information Information related to detected trouble or troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective wiring harness>
• Disconnection in wiring
Possible causes Possible causes of trouble is
The connector connection is defective or the wiring harness
and standard value assumed to be detected.
is disconnected.
in normal state (The order number indicates a
serial number, not a priority • Grounding fault
sequence.) A harness not connected to ground (earth) circuit comes in
contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes in
contact with the power (24 V) circuit.
• Short circuit
A harness of an independent circuit abnormally comes in
contact with one of another circuit.

40-34 ➁ WA500-6
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

<Notes on troubleshooting>

(1) Method of indicating connector number and handling T-branch

For troubleshooting, insert or connect T-branch adapter as shown
3 below unless specifically specified.
• When male or female is not indicated for a connector
number, disconnect the connector and insert the T-branch
Possible causes of trouble is adapter in both the male and female.
Possible causes assumed to be detected.
• When male and female is indicated for a connector number,
and standard value (The order number indicates a
disconnect the connector, and insert the T-branch adapter in
in normal state serial number, not a priority
only either the male or female.
sequence.)
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
4 shown below unless specifically specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (–) lead to a pin or harness indicated in
the rear.

Circuit Diagram

This is part of the circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color).
• Arrow: Roughly indicates the location in the machine where it is installed.

WA500-6 40-35 ➁
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

Chart Use
★ Repair Shop Use
• When using this chart in a repair shop environment where you have access to a copier, it is advisable to remove the
pages of the fault codes displayed on the machine monitor and copy these pages.
• After copying the needed pages, return the original pages to the Shop Manual for future use.
• You can record your findings on the copied pages in the right-hand column of the chart for final analysis.
• Do not write on the original chart in the Shop Manual. Complete all test procedures.
★ Road Service Use
• When using this chart while on a road service call where a copier is not available, it is advisable to use a blank piece
of paper and number it from #1 through the last number listed in conjunction with the Shop Manual.
• Record your readings by each number on the paper for final analysis.
• Do not write on the original chart in the Shop Manual.
• Complete all test procedures.

Chart Tips
• Check all fuses and fuse links first.
• If the system has a relay, replace the relay with a known good relay. Do not test the relay itself.
• For diode checking procedures, see Points to Remember when Troubleshooting Electrical Circuits.
• When checking Ohms in a system or component, always isolate the component you are checking; this will ensure that
there are no additional circuits adding continuity to the component you are testing.
• Never measure Amps unless instructed in the testing procedure. Damage to the meter or injury may result.
• Never use a welder or a battery system of a higher voltage than the machine you are troubleshooting. The voltage of the
welder or battery system must NOT EXCEED that of the machine to which you are trying to supply electricity. Damage
to the machine’s electrical system may result.

40-36 ➁ WA500-6
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

Troubleshooting Individual Hydraulic Circuits

Like the electrical diagnostic procedures, it is important to complete all steps required in the testing procedures. This method is
broken down into three steps:

• Question the operator

• Checks before troubleshooting
• Using the cross-reference tables.

1. Question the operator

The questions to ask the operator are given below the failure
symptom.
★ If the answers to the questions match the information given,
follow the arrow to reach the probable cause of the failure.
Consider the contents of the question and consult the table
while proceeding to Steps 2 and 3 to find the true cause.

2. Checks before troubleshooting

Before starting the troubleshooting procedures or measuring any
pressures, first check the listed basic items in the Checks Before
Troubleshooting section.
★ These checks may avoid time wasted on unnecessary
troubleshooting.
★ The items given in this procedure are the items which must be
considered unique for that symptom before starting
troubleshooting.

3. Using the cross-reference table

A. Operate the machine to check the symptom.

★ If it is not necessary to follow the troubleshooting checks
in order, follow an order which is easiest to carry out
troubleshooting.

B. Find the appropriate cause from the cause column.

★ If the symptom appears, the ❍ marks on that line indicate
the possible causes. (For item No. 2 in the table on the
right, the possible causes are c or e.)
★ If there is only one ❍: Carry out the troubleshooting
items (where the same cause is marked with ❍). Check if
the symptom appears, then repair.
★ If there are two ❍: Go to Step C to narrow down the
possible causes.

WA500-6 40-37 ➁
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
C. Operate the machine and check the troubleshooting items
other than those in Step 1.
★ If the symptom appears, record that item for further
reference. (In the chart on the right, the symptom appears
again for item 5.)

D. Find the appropriate chart for the cause from the cause
column.
★ In the same way as in Step 2, if the symptom appears, the
❍ marks on that line indicate the possible causes. (For
items No. 5 in the table on the right, the possible causes
are b or e.)

E. Narrow down the possible causes.

★ There are common causes among the causes located in
Steps B and D. (One cause marked ❍ appears on the line
for both items.) This cause is common to both the
symptoms in troubleshooting Steps 1 and 3.
★ The causes which are not common to both
troubleshooting items (items which are not marked ❍ for
both symptoms) are unlikely causes; it is advisable to
ignore them. (In the example given on the right, the
causes for troubleshooting Item 2 are c or e, and the cause
for troubleshooting Item 5 are b or e, so cause e is
common to both.)

F. Repeat the operations in Steps C, D, and E until one cause

(one common cause) remains. If the cause cannot be narrowed
down to one cause, narrow the causes down to a possible
cause.

G. Remedy: If the causes are narrowed down to one common

cause, take the action given in the remedy column. The
symbols given in the remedy column indicate the following:

X: Replace Δ : Repair A: Adjust C: Clean

40-38 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins.
★ The terms male housing and female housing refer to the mating portion of the housing.
★ Deutsch connectors have marks of pin numbers on the wiring harness side.

X-Type Connectors
X-Type Connectors

Number T-adapter Part

Male (Female housing) Female (Male housing)
of Pins Number

1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010

2 799-601-7020

Part number: 08055-00282 Part number: 08055-00292

3 799-601-7030

Part number: 08055-00381 Part number: 08055-00391

4 799-601-7040

Part number: 08055-00481 Part number: 08055-00491

WA500-6 40-39 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

X-Type Connectors

Number T-adapter Part

Male (Female housing) Female (Male housing)
of Pins Number

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390

• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black

Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410

• Wire size: 2.0 • Wire size: 2.0
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: red • Grommet: red

40-40 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP-Type Connectors
SWP-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

6 799-601-7050

Part number: 08055-10681 Part number: 08055-10691

8 799-601-7060

Part number: 08055-10881 Part number: 08055-10891

12 799-601-7310

Part number: 08055-11281 Part number: 08055-11291

WA500-6 40-41 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

14 799-601-7070

Part number: 08055-11481 Part number: 08055-11491

16 799-601-7320

Part number: 08055-11681 Part number: 08055-11691

Terminal part number: Terminal part number:

• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black

Terminal part number: Terminal part number:

• Wire size: 1.25 • Wire size: 1.25
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: red • Grommet: red

40-42 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M-Type Connectors
M-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080

2 799-601-7090

Part number: 08056-00271 Part number: 08056-00281

3 799-601-7110

Part number: 08056-00371 Part number: 08056-00381

4 799-601-7120

Part number: 08056-00471 Part number: 08056-00481

WA500-6 40-43 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

6 799-601-7130

Part number: 08056-00671 Part number: 08056-00681

8 799-601-7340

Part number: 08056-00871 Part number: 08056-00881

40-44 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S-Type Connectors
S-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

8 799-601-7140

Part number: 08056-10871 Part number: 08056-10881

10
799-601-7150
(white)

Part number: 08056-11071 Part number: 08056-11081

12
799-601-7350
(white)

Part number: 08056-11271 Part number: 08056-11281

WA500-6 40-45 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

16
799-601-7330
(white)

Part number: 08056-11671 Part number: 08056-11681

10
—
(blue)

— —

12
799-601-7160
(blue)

Part number: 08056-11272 Part number: 08056-11282

16
799-601-7170
(blue)

Part number: 08056-11672 Part number: 08056-11682

40-46 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC-Type Connectors
MIC-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

Body part number: 79A-222-2640 Body part number: 79A-222-2630

7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)

Body part number: 79A-222-2680 Body part number: 79A-222-2670

11 —
(Quantity: 5 pieces) (Quantity: 5 pieces)

5 799-601-2710

Body part number: 79A-222-2620 Body part number: 79A-222-2610

(Quantity: 5 pieces) (Quantity: 5 pieces)

9 799-601-2950

Body part number: 79A-222-2660 Body part number: 79A-222-2650

(Quantity: 5 pieces) (Quantity: 5 pieces)

13 799-601-2720

Body part number: 79A-222-2710 Body part number: 79A-222-2690

(Quantity: 2 pieces) (Quantity: 2 pieces)

WA500-6 40-47 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

17 799-601-2730

Body part number: 79A-222-2730 Body part number: 79A-222-2720

(Quantity: 2 pieces) (Quantity: 2 pieces)

21 799-601-2740

Body part number: 79A-222-2750 Body part number: 79A-222-2740

(Quantity: 2 pieces) (Quantity: 2 pieces)

Terminal part number: 79A-222-2770 Terminal part number: 79A-222-2760

(Quantity: 50 pieces) (Quantity: 50 pieces)

40-48 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040-Type Connectors
AMP040-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

8 799-601-7180

Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)

12 799-601-7190

Housing part number: 79A-222-3440

—
(Quantity: 5 pieces)

16 799-601-7210

Housing part number: 79A-222-3450

—
(Quantity: 5 pieces)

WA500-6 40-49 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

20 799-601-7220

Housing part number: 79A-222-3460

—
(Quantity: 5 pieces)

★ Terminal part number: 79A-222-3470 (no relation to number of pins)

40-50 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070-Type Connectors
AMP070-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

10 799-601-7510

— Part number: 7821-92-7330

12 799-601-7520

— Part number: 7821-92-7340

14 799-601-7530

— Part number: 7821-92-7350

WA500-6 40-51 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070-Type Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

18 799-601-7540

— Part number: 7821-92-7360

20 799-601-7550

Part number: 7821-92-7370

40-52 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L-Type Connector
L-Type Connector

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

2 —

— —

PA-Type Connector
PA-Type Connector

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

9 —

— —

WA500-6 40-53 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Bendix (MS) Connector

BENDIX (MS) Connector

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

10 799-601-3460

— —

F-Type Connector
F-Type Connector

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

4 —

— —

40-54 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES1 (Automobile) Connectors

KES1 (Automobile) Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

2 —

Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)

3 —

Part number: 08027-10310 Part number: 08027-10360

4 —

Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)

WA500-6 40-55 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES1 (Automobile) Connectors

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

6 —

Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)

8 —

Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)

40-56 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Connectors for Relay (Socket-Type)

Connectors for Relay (Socket-Type)

Number T-adapter
Male (Female housing) Female (Male housing)
of Pins Part Number

5 799-601-7360

— —

6 799-601-7370

— —

WA500-6 40-57 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

HD30 Series Connectors

★ The pin No. is also marked on the connector (electric wire insertion end).

HD30 Series Connectors

Type (shell T-adapter
Body (Plug) Body (Receptacle)
size code) Part Number
Pin (Male terminal) Socket (Female terminal)

799-601-9210

Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Socket (Female terminal) Pin (Male terminal)

799-601-9210

Part number: 08191-11201, 08191-12202 Part number: 08191-13101, 08191-13102

08191-11205, 08191-12206 08191-13105, 08191-13106

40-58 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

HD30 Series Connectors

Type (shell T-adapter
Body (Plug) Body (Receptacle)
size code) Part Number
Pin (Male terminal) Socket (Female terminal)

799-601-9220

Part number: 08191-21201, 08191-12202 Part number: 08191-24101, 08191-24102

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Socket (Female terminal) Pin (Male terminal)

799-601-9220

Part number: 08191-22201, 08191-22202 Part number: 08191-23101, 08191-23102

08191-22205, 08191-22206 08191-23105, 08191-23106
Pin (Male terminal) Socket (Female terminal)

799-601-9230

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

(3) Socket (Female terminal) Pin (Male terminal)

799-601-9230

Part number: 08191-32201, 08191-32202 Part number: 08191-33101, 08191-33102

WA500-6 40-59 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

HD30 Series Connectors

Type (shell T-adapter
Body (Plug) Body (Receptacle)
size code) Part Number
Pin (Male terminal) Socket (Female terminal)

799-601-9240

18-21 Part number: 08191-41201, 08191-42202 Part number: 08191-44101, 08191-44102

(4) Socket (Female terminal) Pin (Male terminal)

799-601-9240

Part number: 08191-42201, 08191-42202 Part number: 08191-43101, 08191-43102

Pin (Male terminal) Socket (Female terminal)

799-601-9250

24-9 Part number: 08191-51201, 08191-51202 Part number: 08191-54101, 08191-54102

(5) Socket (Female terminal) Pin (Male terminal)

799-601-9250

Part number: 08191-52201, 08191-52202 Part number: 08191-53101, 08191-53102

40-60 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

HD30 Series Connectors

Type (shell T-adapter
Body (Plug) Body (Receptacle)
size code) Part Number
Pin (Male terminal) Socket (Female terminal)

799-601-9260

Part number: 08191-61201, 08191-62202 Part number: 08191-64101, 08191-64102

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
(6) Socket (Female terminal) Pin (Male terminal)

799-601-9260

Part number: 08191-62201, 08191-62202 Part number: 08191-63101, 08191-63102

08191-62205, 08191-62206 08191-63105, 08191-63106
Pin (Male terminal) Socket (Female terminal)

799-601-9270

Part number: 08191-71201, 08191-71202 Part number: 08191-74101, 08191-74102

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
(7) Socket (Female terminal) Pin (Male terminal)

799-601-9270

Part number: 08191-72201, 08191-72202 Part number: 08191-73101, 08191-73102

08191-72205, 08191-72206 08191-73105, 08191-73106

WA500-6 40-61 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

HD30 Series Connectors

Type (shell T-adapter
Body (Plug) Body (Receptacle)
size code) Part Number
Pin (Male terminal) Socket (Female terminal)

799-601-9280

Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
(8) Socket (Female terminal) Pin (Male terminal)

799-601-9280

Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106

40-62 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

HD30 Series Connectors

Type (shell T-adapter
Body (Plug) Body (Receptacle)
size code) Part Number
Pin (Male terminal) Socket (Female terminal)

799-601-9290

Part number: 08191-91203, 08191-91204 Part number: 08191-94103, 08191-94104

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
(9) Socket (Female terminal) Pin (Male terminal)

799-601-9290

Part number: 08191-92203, 08191-92204 Part number: 08191-93103, 08191-93104

08191-92205, 08191-92206 08191-93105, 08191-93106

WA500-6 40-63 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

DT Series Connectors
★ The pin No. is also marked on the connector (electric wire insertion end).

DT Series Connectors

Number T-adapter
Body (plug) Body (receptacle)
of Pins Part Number

2 799-601-9020

Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)

3 799-601-9030

Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)

4 799-601-9040

Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)

40-64 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

DT Series Connectors

Number T-adapter
Body (plug) Body (receptacle)
of Pins Part Number

6 799-601-9050

Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)

8GR:
799-601-9060
8B:
799-601-9070
8
8G:
799-601-9080
8BR:
799-601-9090
Part number: 08192-1820 ❏ (normal type) Part number: 08192-1810 ❏ (normal type)
08192-2820 ❏ (fine wire type) 08192-2810 ❏ (fine wire type)

12GR:
799-601-9110
12B:
799-601-9120
12
12G:
799-601-9130
12BR:
799-601-9140
Part number: 08192-1920 ❏ (normal type) Part number: 08192-1910 ❏ (normal type)
08192-2920 ❏ (fine wire type) 08192-2910 ❏ (fine wire type)

WA500-6 40-65 ➁
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

DTM Series Connectors

★ The pin No. is also marked on the connector (electric wire insertion end).

DTM Series Connector

Number T-adapter
Body (plug) Body (receptacle)
of Pins Part Number

2 799-601-9010

Part number: 08192-02200 Part number: 08192-02100

DTHD Series Connectors

★ The pin No. is also marked on the connector (electric wire insertion end).

DTHD Series Connector

T-adapter
Number
Body (plug) Body (receptacle) Part
of Pins
Number

2 —

Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)

40-66 ➁ WA500-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

DRC26 Series Connectors

★ The pin No. is also marked on the connector (electric wire insertion end).

DRC26 Series Connectors

Number T-adapter
Male pin (Female housing) Female pin (Male housing)
of Pins Part Number

24 799-601-9360

– Part No.: 7821-93-3110

40
799-601-9350
(A)

– Part No.: 7821-93-3120

40
799-601-9350
(B)

– Part No.: 7821-93-3130

50 799-601-4210

– –

WA500-6 40-67 ➁
TROUBLESHOOTING T-BRANCH BOX and T-BRANCH ADAPTER TABLE

T-BRANCH BOX and T-BRANCH ADAPTER TABLE

★ The part numbers of the T-branch boxes or T-branch adapters are shown in the columns.
★ The part numbers of the wiring harness checker assemblies are shown in the lines.

T-branch Adapter Kit

No. of Pins

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Others
Connector Type
Part No. ID Symbol
or Part Name

799-601-2600 T-branch box (For ECONO) 21 ● ● ● ● ● ●

799-601-3100 T-branch box (For MS) 37 ●
799-601-3200 T-branch box (For MS) 37 ●
799-601-3300 T-branch box (For ECONO) 24 ●
799-601-3360 • Plate for MS (24 pins) ●
799-601-3370 • Plate for MS (17 pins) ●
799-601-3380 • Plate for MS (14 pins) ●
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P ● ●
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P ● ●
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P ● ●
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P ● ●
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P ● ●
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P ● ●
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S ● ●
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P ● ●
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P ● ●
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P ● ●
799-601-3470 Case ●
799-601-2710 Adapter for MIC 5 MIC-5P ● ● ● ●
799-601-2720 Adapter for MIC 13 MIC-13P ● ● ● ●
799-601-2730 Adapter for MIC 17 MIC-17P ● ● ● ● ● ● ●
799-601-2740 Adapter for MIC 21 MIC-21P ● ● ● ● ● ● ●
799-601-2950 Adapter for MIC 9 MIC-9P ● ● ● ●
799-601-2750 Adapter for ECONO 2 ECONO 2P ● ●
799-601-2760 Adapter for ECONO 3 ECONO 3P ● ●
799-601-2770 Adapter for ECONO 4 ECONO 4P ● ●
799-601-2780 Adapter for ECONO 8 ECONO 8P ● ●
799-601-2790 Adapter for ECONO 12 ECONO 12P ● ●
799-601-2810 Adapter for DLI 8 DLI-8P ● ●
799-601-2820 Adapter for DLI 12 DLI-12P ● ●
799-601-2830 Adapter for DLI 16 DLI-16P ● ●
Additional cable
799-601-2840 12 ECONO 12P ● ● ●
(ECONO type)
799-601-2850 Case ●
799-601-4210 Adapter for DRC 50 DRC50 ●
799-601-7010 Adapter for X (T-branch) 1 ● ●

40-68 ➁ WA500-6
TROUBLESHOOTING T-BRANCH BOX and T-BRANCH ADAPTER TABLE

T-branch Adapter Kit

No. of Pins

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Others
Connector Type
Part No. ID Symbol
or Part Name

799-601-7020 Adapter for X 2 X2P ● ● ● ●

799-601-7030 Adapter for X 3 X3P ● ● ● ●
799-601-7040 Adapter for X 4 X4P ● ● ● ●
799-601-7050 Adapter for SWP 6 SW6P ● ● ●
799-601-7060 Adapter for SWP 8 SW8P ● ● ●
799-601-7310 Adapter for SWP 12 SW12P ●
799-601-7070 Adapter for SWP 14 SW14P ● ●
799-601-7320 Adapter for SWP 16 SW16P ●
799-601-7080 Adapter for M (T-branch) 1 ● ●
799-601-7090 Adapter for M 2 M2P ● ● ● ●
799-601-7110 Adapter for M 3 M3P ● ● ● ●
799-601-7120 Adapter for M 4 M4P ● ● ● ●
799-601-7130 Adapter for M 6 M6P ● ● ● ●
799-601-7340 Adapter for M 8 M8P ●
799-601-7140 Adapter for S 8 S8P ● ● ● ●
799-601-7150 Adapter for S (white) 10 S10P ● ● ● ●
799-601-7160 Adapter for S (blue) 12 S12P ● ● ●
799-601-7170 Adapter for S (blue) 16 S16P ● ● ● ●
799-601-7330 Adapter for S (white) 16 S16PW ●
799-601-7350 Adapter for S (white) 12 S12PW ●
799-601-7180 Adapter for AMP040 8 A8P ●
799-601-7190 Adapter for AMP040 12 A12P ● ●
799-601-7210 Adapter for AMP040 16 A16P ● ● ● ●
799-601-7220 Adapter for AMP040 20 A20P ● ● ● ●
799-601-7230 Short connector for X 2 ● ● ● ●
799-601-7240 Case ● ●
799-601-7270 Case ●
799-601-7510 Adapter for 070 10 07-10 ●
799-601-7520 Adapter for 070 12 07-12 ●
799-601-7530 Adapter for 070 14 07-14 ●
799-601-7540 Adapter for 070 18 07-18 ●
799-601-7550 Adapter for 070 20 07-20 ●
799-601-7360 Adapter for relay 5 REL-5P ●
799-601-7370 Adapter for relay 6 REL-6P ●
799-601-7380 Adapter for JFC 2 ●
799-601-9010 Adapter for DTM 2 DTM2 ● ●
799-601-9020 Adapter for DT 2 DT2 ● ●
799-601-9030 Adapter for DT 3 DT3 ● ●
799-601-9040 Adapter for DT 4 DT4 ● ●
799-601-9050 Adapter for DT 6 DT6 ● ●
799-601-9060 Adapter for DT (gray) 8 DT8GR ● ●

WA500-6 40-69 ➁
TROUBLESHOOTING T-BRANCH BOX and T-BRANCH ADAPTER TABLE

T-branch Adapter Kit

No. of Pins

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Others
Connector Type
Part No. ID Symbol
or Part Name

799-601-9070 Adapter for DT (black) 8 DT8B ● ●

799-601-9080 Adapter for DT (green) 8 DT8G ● ●
799-601-9090 Adapter for DT (brown) 8 DT8BR ● ●
799-601-9110 Adapter for DT (gray) 12 DT12GR ● ●
799-601-9120 Adapter for DT (black) 12 DT12B ● ●
799-601-9130 Adapter for DT (green) 12 DT12G ● ●
799-601-9140 Adapter for DT 12 DT12BR ● ●
799-601-9210 Adapter for HD30-18 8 D18-8 ● ●
799-601-9220 Adapter for HD30-18 14 D18-14 ● ●
799-601-9230 Adapter for HD30-18 20 D18-20 ● ●
799-601-9240 Adapter for HD30-18 21 D18-21 ● ●
799-601-9250 Adapter for HD30-24 9 D24-9 ● ●
799-601-9260 Adapter for HD30-24 16 D24-16 ● ●
799-601-9270 Adapter for HD30-24 21 D24-21 ● ●
799-601-9280 Adapter for HD30-24 23 D24-23 ● ●
799-601-9290 Adapter for HD30-24 31 D24-31 ● ●
799-601-9310 Plate for HD30 (24 pins) ● ● ●
799-601-9320 T-branch box (For DT HD) 12 ● ● ●
799-601-9330 Case ●
799-601-9340 Case ●
799-601-9350 Adapter for DRC 40 DRC-40 ●
799-601-9360 Adapter for DRC 24 DRC-24 ●
799-601-9410 Adapter for engine (CRI-T2) 2 G ●
Adapter for engine (CRI-T2)
799-601-9420 3 A3 ●
Adapter for engine (CRI-T3)
Adapter for engine (CRI-T2)
799-601-9430 2 P ●
Adapter for engine (CRI-T3)
799-601-9440 Adapter for engine (CRI-T2) 3 1, 2, 3 ●
795-799-5520 Adapter for engine (HPI-T2) 2 S ●
Adapter for engine (HPI-T2)
795-799-5530 2 C ●
Adapter for engine (CRI-T3)
Adapter for engine (HPI-T2)
795-799-5540 2 A ●
Adapter for engine (CRI-T3)
795-799-5460 Cable for engine (HPI-T2) 3 ●
795-799-5470 Cable for engine (HPI-T2) 3 ●
795-799-5480 Cable for engine (HPI-T2) 3 ●
799-601-4160 Adapter for engine (CRI-T3) 2 OIL ●
799-601-4340 Adapter for engine (CRI-T3) 2 1, 2, 3 ●
799-601-4130 Adapter for engine (CRI-T3) 3 FCIN ●
799-601-4140 Adapter for engine (CRI-T3) 3 FCIG ●
799-601-4150 Adapter for engine (CRI-T3) 3 FCIB ●
799-601-4180 Adapter for engine (CRI-T3) 3 FCIP3 ●

40-70 ➁ WA500-6
TROUBLESHOOTING T-BRANCH BOX and T-BRANCH ADAPTER TABLE

T-branch Adapter Kit

No. of Pins

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Others
Connector Type
Part No. ID Symbol
or Part Name

799-601-4190 Adapter for engine (CRI-T3) 3 1, 2, 3 ●

799-601-4240 Adapter for engine (CRI-T3) 3 1, 2, 3 ●
799-601-4250 Adapter for engine (CRI-T3) 3 1, 2, 3 ●
799-601-4330 Adapter for engine (CRI-T3) 3 1, 2, 3 ●
799-601-4230 Adapter for engine (CRI-T3) 4 1, 2, 3, 4 ●
799-601-4260 Adapter for controller (ENG) 4 DTP4 ●
799-601-4210 Adapter for controller (ENG) 50 DRC50 ●
799-601-4220 Adapter for controller (ENG) 60 DRC60 ●
799-601-4280 Box for controller (PUMP) 121 ●
799-601-9720 Adapter for controller (HST) 16 HST16A ●
799-601-9710 Adapter for controller (HST) 16 HST16B ●
799-601-9370 Adapter for controller (HST) 26 HST26A ●

WA500-6 40-71 ➁
TROUBLESHOOTING MODE CHART

MODE CHART

Troubleshooting Mode
No. Failure or Possible Phenomena Code
E-mode H-mode S-mode
Display
Problems 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. ●
Engine-related Problems (S-mode, see Engine Shop Manual, also)
3 Engine does not start easily. E-1 S-1
4 Engine does not crank. E-1 S-2 a)
5 Engine does Engine cranks but exhaust smoke does not come out. S-2 b)
not start.
Exhaust smoke comes out but engine does not start.
6 S-2 c)
(Fuel is injected.)
7 Engine does not pick up smoothly. S-3
8 Engine stops during operation. H-2 S-4
9 Engine does not run smoothly (engine hunts). S-5
10 Engine output is insufficient (lacks power). S-6
11 Exhaust gas color is black (incomplete combustion). S-7
12 Oil consumption is excessive (exhaust smoke is blue). S-8
13 Engine oil becomes contaminated quickly. S-9
14 Fuel consumption is excessive. S-10
15 Coolant contains oil (blows back or reduces). S-11
16 Engine oil pressure drops. S-12
17 Engine oil level rises (water or fuel is mixed in oil). S-13
18 Coolant temperature is too high (overheating). S-14
19 Abnormal sound is heard. S-15
20 Vibration is excessive. S-16
Power Train-related Problems
21 Machine does not start. H-1
Torque converter lockup is not switched (engine stalls).
22 H-2
[machine with lockup clutch (if equipped)]
Torque converter lockup is not switched.
23 H-3
[machine with lockup clutch (if equipped)]
Travel speed is slow; the thrusting force is weak; the uphill traveling
24 H-4
power is weak; and the gear is not shifted.
25 Shocks are large at the time of starting and shifting gear. H-5
26 Time lag is large at the time of starting and shifting gear. H-6
27 Torque converter oil temperature is high. H-7
Steering-related Problems
28 Machine cannot be steered. H-8

40-72 ➁ WA500-6
TROUBLESHOOTING MODE CHART

Troubleshooting Mode
No. Failure or Possible Phenomena Code
E-mode H-mode S-mode
Display
Machine cannot be steered.
29 H-9
[machine with joystick steering (if equipped)]
30 Steering response is low. H-10
Turning, response of steering is poor.
31 H-11
[machine with joystick steering (if equipped)]
32 Steering is heavy. H-12
33 When machine turns, it shakes or makes large shocks. H-13
When machine turns, it shakes or makes large shocks.
34 H-14
[machine with joystick steering (if equipped)]
Brake-related Problems
35 The wheel brake does not work or does not work well. H-15
36 The wheel brake is not released or it drags. H-16
37 The parking brake does not work or does not work well. H-17
Parking brake cannot be reset or it drags (including emergency release
38 H-18
system).
Work Equipment-related Problems
39 Lift arm does not rise. H-19
40 Lift arm speed is low or rising force of lift arm is insufficient. H-20
41 When rising, the lift arm starts to move slowly at a specific height. H-21
42 Bucket cannot be held with lift arm cylinder (bucket floats). H-22
43 Hydraulic drifts of the lift arm occur often. H-23
44 The lift arm wobbles during operation. H-24
45 Bucket does not tilt back. H-25
46 Bucket speed is low or tilting back force is insufficient. H-26
47 The bucket starts to operate slowly in the midst of tilting back. H-27
48 The bucket cylinder cannot hold down the bucket. H-28
49 Hydraulic drifts of the bucket occur often. H-29
The bucket wobbles during travel with cargo (work equipment valve is set
50 H-30
to HOLD).
Engine speed lowers remarkably or engine stalls during work equipment
51 H-31
control.
52 Large shocks are made when work equipment starts and stops. H-32
When work equipment circuit is relieved singly, other work equipment
53 H-33
moves.
54 ECSS does not operate; pitching or bouncing occurs. H-34
Additional Problems
55 Wiper does not operate. E-2
56 Windshield washer does not operate. E-3
Headlamp, clearance lamp, tail lamp, and license plate lamp do not light
57 E-4
up or go off.

WA500-6 40-73 ➁
TROUBLESHOOTING MODE CHART

Troubleshooting Mode
No. Failure or Possible Phenomena Code
E-mode H-mode S-mode
Display
58 Working lamp does not light up or go off. E-5
59 Turn signal lamp and hazard lamp do not light up or go off. E-6
60 Brake lamp does not light or it keeps lighting up. E-7
61 Backup lamp does not light or it keeps lighting up. E-8
62 Backup buzzer does not sound or it keeps sounding. E-9
63 Horn does not sound or it keeps sounding. E-10
64 Alarm buzzer does not sound or it keeps sounding. E-11
65 Air conditioner does not operate or stop. E-12
66 KOMTRAX system does not work properly. E-13

40-74 ➁ WA500-6
TROUBLESHOOTING MODE CHART

MEMORANDUM

WA500-6 40-75 ➁
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES

INFORMATION CONTAINED IN TESTING PROCEDURES

★ The testing table and the related circuit diagrams contain the following information. Read all information and each step
carefully; if necessary, redo each step in a test procedure to confirm the fault.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not write on original page of service manual. Remove this page from the service manual and make a copy for recording
information while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of
the procedure.
• Follow each step throughout this procedure; do not skip steps, jump ahead, or stop when a fault is found. It is important to
complete all steps and record information for final analysis.

Action code Failure code

Trouble Problem that appears on machine
Monitor display Monitor display

Contents of Trouble State where the monitor panel or controller detects the trouble.

Action taken by machine monitor or controller to protect the system or devices when engine
Action of Controller
controller detects trouble.

Problem That Problem that appears on machine as result of action taken by machine monitor or controller
Appears On Machine (shown above).

Related information Information related to detected trouble or troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective wiring harness>
• Disconnection in wiring
Possible causes Possible causes of trouble is
The connector connection is defective or the wiring harness
and standard value assumed to be detected.
is disconnected.
in normal state (The order number indicates a
serial number, not a priority • Grounding fault
sequence.) A harness not connected to ground (earth) circuit comes in
contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes in
contact with the power (24 V) circuit.
• Short circuit
A harness of an independent circuit abnormally comes in
contact with one of another circuit.

40-76 ➁ WA500-6
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES

<Notes on troubleshooting>

(1) Method of indicating connector number and handling T-branch

For troubleshooting, insert or connect T-branch adapter as shown
3 below unless specifically specified.
• When male or female is not indicated for a connector
number, disconnect the connector and insert the T-branch
Possible causes of trouble is adapter in both the male and female.
Possible causes assumed to be detected.
• When male and female is indicated for a connector number,
and standard value (The order number indicates a
disconnect the connector, and insert the T-branch adapter in
in normal state serial number, not a priority
only either the male or female.
sequence.)
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
4 shown below unless specifically specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (–) lead to a pin or harness indicated in
the rear.

Circuit Diagram

This is part of the circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color).
• Arrow: Roughly indicates the location in the machine where it is installed.

WA500-6 40-77 ➁
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

TROUBLESHOOTING BY FAILURE CODE

Failure Code Table
Failure Action Category of
Problem Part Trouble Controller
Code Code Record
Electrical
1500L0 TORQFLOW transmission Double meshing TM E03
system
Mechanical
15B0NX Transmission filter Clogging MON E01
system
When command current is OFF, fill Electrical
15SAL1 ECMV F clutch TM E03
signal is ON system
When command current is ON, fill Electrical
15SALH ECMV F clutch TM E01
signal is OFF system
When command current is OFF, fill Electrical
15SBL1 ECMV R clutch TM E03
signal is ON system
When command current is ON, fill Electrical
15SBLH ECMV R clutch TM E01
signal is OFF system
When command current is OFF, fill Electrical
15SEL1 ECMV 1st clutch TM E03
signal is ON system
When command current is ON, fill Electrical
15SELH ECMV 1st clutch TM E01
signal is OFF system
When command current is OFF, fill Electrical
15SFL1 ECMV 2nd clutch TM E03
signal is ON system
When command current is ON, fill Electrical
15SFLH ECMV 2nd clutch TM E01
signal is OFF system
When command current is OFF, fill Electrical
15SGL1 ECMV 3rd clutch TM E03
signal is ON system
When command current is ON, fill Electrical
15SGLH ECMV 3rd clutch TM E01
signal is OFF system
When command current is OFF, fill Electrical
15SHL1 ECMV 4th clutch TM E03
signal is ON system
When command current is ON, fill Electrical
15SHLH ECMV 4th clutch TM E01
signal is OFF system
Electrical
2F00MA Parking brake Malfunction MON E03
system
Mechanical
2G42ZG Front accumulator Low oil pressure MON E03
system
Mechanical
2G43ZG Rear accumulator Low oil pressure MON E03
system
Electrical
44K0L4 Bucket positioner ON/OFF signals disagree WRK E01
system
Mechanical
AA1ANX Air cleaner Clogging MON E01
system
Signal does not match engine running Electrical
AB00L6 Alternator MON E03
or stopped state system
Mechanical
AB00MA Alternator Malfunction MON E03
system

40-78 ➁ WA500-6
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Mechanical
B@BAZG Engine oil Low oil pressure ENG E03
system
Mechanical
B@BAZK Engine oil Low level MON E01
system
Mechanical
B@BCNS Coolant Overheating ENG E02
system
Mechanical
B@BCZK Coolant Low level MON E01
system
Mechanical
B@C7NS Brake oil Overheating MON E02
system
Mechanical
b@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@GAZK Battery electrolyte Low level MON E01
system
Mechanical
B@HANS Hydraulic oil Overheating MON E02
system
Electrical
CA111 Abnormality in engine controller — ENG E03
system
Engine Ne or Bkup speed sensor Electrical
CA115 — ENG E03
error system
Charge pressure sensor high Electrical
CA122 — ENG E03
error system
Electrical
CA123 Charge pressure sensor low error — ENG E03
system
Electrical
CA131 Throttle sensor high error — ENG E03
system
Electrical
CA132 Throttle sensor low error — ENG E03
system
Engine oil pressure sensor high Electrical
CA135 — ENG E01
error system
Engine oil pressure sensor low Electrical
CA141 — ENG E01
error system
Coolant temperature sensor high Electrical
CA144 — ENG E01
error system
Coolant temperature sensor low Electrical
CA145 — ENG E01
error system
Charge temperature sensor high Electrical
CA153 — ENG E01
error system
Charge temperature sensor low Electrical
CA154 — ENG E01
error system
Sensor power supply 2 voltage Electrical
CA187 — ENG E03
low error system
Atmospheric pressure sensor Electrical
CA221 — ENG E01
high error system

WA500-6 40-79 ➁
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Atmospheric pressure sensor low Electrical
CA222 — ENG E01
error system
Electrical
CA227 Sensor power supply 2 high error — ENG E03
system
Mechanical
CA234 Engine overspeed — ENG E02
system
Ne speed sensor power supply Electrical
CA238 — ENG E03
error system
Fuel temperature sensor high Electrical
CA263 — ENG E01
error system
Electrical
CA265 Fuel temperature sensor low error — ENG E01
system
Electrical
CA271 PCV1 short circuit — ENG E03
system
Electrical
CA272 PCV1 disconnection — ENG E03
system
Electrical
CA273 PCV2 short circuit — ENG E03
system
Electrical
CA274 PCV2 disconnection — ENG E03
system
Injector #1 (L/B #1) open/short Electrical
CA322 — ENG E03
error system
Injector #5 (L/B #5) open/short Electrical
CA323 — ENG E03
error system
Injector #3 (L/B #3) open/short Electrical
CA324 — ENG E03
error system
Injector #6 (L/B #6) open/short Electrical
CA325 — ENG E03
error system
Injector #2 (L/B #2) open/short Electrical
CA331 — ENG E03
error system
Injector #4 (L/B #4) open/short Electrical
CA332 — ENG E03
error system
Engine controller data Electrical
CA342 — ENG E03
inconsistency system
Electrical
CA351 Injector drive circuit error — ENG E03
system
Sensor power supply 1 voltage Electrical
CA352 — ENG E03
low error system
Electrical
CA386 Sensor power supply 1 high error — ENG E03
system
Electrical
CA431 Idle validation switch error — ENG E01
system
Electrical
CA432 Idle validation action error — ENG E03
system
Electrical
CA441 Battery voltage low error — ENG E03
system

40-80 ➁ WA500-6
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Electrical
CA442 Battery voltage high error — ENG E03
system
Common rail pressure high error Electrical
CA449 — ENG E03
2 system
Common rail pressure sensor Electrical
CA451 — ENG E03
high error system
Common rail pressure sensor low Electrical
CA452 — ENG E03
error system
Common rail pressure high error Electrical
CA553 — ENG E03
1 system
Common rail pressure sensor in- Electrical
CA554 — ENG E03
range error system
Supply pump pressure very low Electrical
CA559 — ENG E03
error 1 system
Electrical
CA689 Engine Ne speed sensor error — ENG E03
system
Engine Bkup speed sensor phase Electrical
CA731 — ENG E03
error system
Electrical
CA757 All continuous data lost error — ENG E03
system
Electrical
CA778 Engine Bkup speed sensor error — ENG E03
system
Electrical
CA1228 EGR valve servo error 1 — ENG E03
system
Electrical
CA1625 EGR valve servo error 2 — ENG E03
system
Bypass valve solenoid current Electrical
CA1626 — ENG E03
high error system
Bypass valve solenoid drive Electrical
CA1627 — ENG E03
circuit disconnection error system
Electrical
CA1628 Bypass valve servo error 1 — ENG E03
system
Electrical
CA1629 Bypass valve servo error 2 — ENG E03
system
Electrical
CA1631 Bypass valve lift sensor high error — ENG E03
system
Electrical
CA1632 Bypass valve lift sensor low error — ENG E03
system
Electrical
CA1633 KOMNET datalink timeout error — ENG E03
system
EGR inlet pressure sensor low Electrical
CA1642 — ENG E03
error system
EGR inlet pressure sensor high Electrical
CA1653 — ENG E03
error system
Throttle sensor supply voltage Electrical
CA2185 — ENG E03
high error system

WA500-6 40-81 ➁
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Throttle sensor power supply low Electrical
CA2186 — ENG E03
error system
Supply pump pressure very low Electrical
CA2249 — ENG E03
error 2 system
Electrical
CA2271 EGR valve lift sensor high error — ENG E03
system
Electrical
CA2272 EGR valve lift sensor low error — ENG E03
system
EGR valve solenoid operation Electrical
CA2351 — ENG E03
short circuit error system
EGR valve solenoid operation Electrical
CA2352 — ENG E03
disconnection error system
Intake heater relay voltage low Electrical
CA2555 — ENG E01
error system
Intake heater relay voltage high Electrical
CA2556 — ENG E01
error system
Electrical
D160KZ Backup lamp relay Disconnection or short circuit TM E01
system
Joystick steering neutral safety Electrical
D191KA Disconnection WRK E01
relay system
Joystick steering neutral safety Electrical
D191KB Short circuit WRK E01
relay system
Electrical
D192KA ECSS (travel damper) solenoid Disconnection TM E01
system
Electrical
D192KB ECSS (travel damper) solenoid Short circuit TM E01
system
Electrical
D192KY ECSS (travel damper) solenoid Short circuit with power supply line TM E01
system
Joystick steering solenoid cut Electrical
D193KA Disconnection WRK E03
relay system
Joystick steering solenoid cut Electrical
D193KB Short circuit WRK E03
relay system
Joystick steering solenoid cut Electrical
D193KY Short circuit with power supply line WRK E03
relay system
Electrical
D5ZHKA Terminal C signal Disconnection TM E01
system
Electrical
D5ZHKB Terminal C signal Short circuit TM E01
system
Electrical
D5ZHKZ Terminal C signal Disconnection or short circuit WRK E01
system
Signal does not match engine running Electrical
D5ZHL6 Terminal C signal MON E01
or stopped state system
Electrical
DA80L4 Auto grease controller ON/OFF signals disagree MON —
system
Electrical
DAF3KK Machine monitor Low source voltage (input) MON E03
system

40-82 ➁ WA500-6
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Electrical
DAF5KP Machine monitor Low output voltage MON E01
system
CAN communication with Defective communication (Abnormality Electrical
DAFRKR TM E03
machine monitor in target component system) system
Electrical
DAQ0KK Transmission controller Low source voltage TM E03
system
Electrical
DAQ0KT Transmission controller Abnormality in controller TM E01
system
Transmission controller load Electrical
DAQ2KK Low source voltage (input) TM E03
power supply line system
Transmission controller model Disagreement of model selection
DAQ9KQ MON E03 —
selection wiring harness signals
CAN communication with Defective communication (Abnormality Electrical
DAQRKR MON E03
transmission controller in target component system) system
CAN communication with
DAQRMA Malfunction MON E03 —
transmission controller
CAN communication with engine Defective communication (Abnormality Electrical
DB2RKR TM E03
controller in target component system) system
Electrical
DB90KK Work equipment controller Low source voltage (input) WRK E03
system
Electrical
DB90KT Work equipment controller Abnormality in controller WRK E01
system
Work equipment controller load Electrical
DB92KK Low source voltage (input) WRK E03
power supply line system
Work equipment controller power Electrical
DB95KX Out-of-input signal range WRK E03
supply output system
Work equipment controller model Disagreement of model selection
DB99KQ MON E03 —
selection wiring harness signals
CAN communication with work Defective communication (Abnormality Electrical
DB9RKR TM E03
equipment controller in target component system) system
CAN communication with work
DB9RMA Malfunction MON E03 —
equipment controller
CAN communication with work Electrical
DB9RMC Defective operation WRK E03
equipment controller system
Electrical
DD15LD ■ switch (Panel switch 1) Switch is kept pressed for long time MON E01
system
Electrical
DD16LD ◊ switch (Panel switch 2) Switch is kept pressed for long time MON E01
system
Electrical
DD17LD < switch (Panel switch 3) Switch is kept pressed for long time MON E01
system
Electrical
DD18LD > switch (Panel switch 4) Switch is kept pressed for long time MON E01
system
Remote positioner raise/lower set Electrical
DD1ALD Switch is kept pressed for long time WRK E01
switch (RAISE) system
Remote positioner raise/lower set Electrical
DD1BLD Switch is kept pressed for long time WRK E01
switch (LOWER) system

WA500-6 40-83 ➁
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Electrical
DD1CLD Load meter subtotal switch Switch is kept pressed for long time MON E01
system
Load meter mode selector switch Electrical
DD1FLD Switch is kept pressed for long time MON E01
(A/B) system
Load meter mode selector switch Electrical
DD1GLD Switch is kept pressed for long time MON E01
(+/–) system
Load meter display selector Electrical
DD1HLD Switch is kept pressed for long time MON E01
switch system
Electrical
DDA7L4 RPM set ON/OFF switch ON/OFF signals disagree TM E01
system
RPM set idle-up/down switch Electrical
DDA8KB Short circuit TM E01
(idle-up) system
RPM set idle-up/down switch Electrical
DDA9KB Short circuit TM E01
(idle-down) system
Turn parking brake switch Electrical
DDB6L4 ON/OFF signals disagree TM E03
(Neutralizer) system
Remote positioner bucket angle Electrical
DDD1LD Switch is kept pressed for long time WRK E01
set switch system
Electrical
DDE5MA Emergency steering drive switch Malfunction MON E01
system
Electrical
DDK3KA Right FNR switch Disconnection TM E03
system
Electrical
DDK3KB Right FNR switch Short circuit TM E03
system
Electrical
DDK4KA Joystick steering FNR switch Disconnection TM E03
system
Electrical
DDK4KB Joystick steering FNR switch Short circuit TM E03
system
Joystick steering shift-up/down Electrical
DDK5L4 ON/OFF signals disagree TM E01
selector switch system
Electrical
DDK6KA FNR lever switch Disconnection TM E03
system
Electrical
DDK6KB FNR lever switch Short circuit TM E03
system
Electrical
DDT0L4 Shift mode selector switch ON/OFF signals disagree TM E01
system
Electrical
DDT4LD Transmission cut-off set switch Switch is kept pressed for long time TM E01
system
Electrical
DDW9LD Kick-down switch Switch is kept pressed for long time TM E01
system
Electrical
DDWLLD Hold switch Switch is kept pressed for long time TM E01
system
Electrical
DDY0LD Load meter cancel switch Switch is kept pressed for long time MON E01
system
Electrical
DF10KA Transmission shift lever switch Disconnection TM E01
system

40-84 ➁ WA500-6
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Electrical
DF10KB Transmission shift lever switch Short circuit TM E01
system
Transmission oil temperature Electrical
DGF1KA Disconnection TM E01
sensor system
Transmission oil temperature Electrical
DGF1KB Short circuit TM E01
sensor system
Electrical
DGH2KX Hydraulic oil temperature sensor Out-of-input signal range MON E01
system
Rear brake oil temperature Electrical
DGR2KA Disconnection MON E01
sensor system
Rear brake oil temperature Electrical
DGR2KX Out-of-input signal range MON E01
sensor system
Torque converter oil temperature Electrical
DGT1KX Out-of-input signal range MON E01
sensor system
Oil pressure sensor of work Electrical
DH21KA Disconnection WRK E01
equipment pump system
Oil pressure sensor of work Electrical
DH21KB Short circuit WRK E01
equipment pump system
Lift arm cylinder bottom pressure Electrical
DHPCKX Out-of-input signal range MON E01
sensor system
Lift arm cylinder head pressure Electrical
DHPDKX Out-of-inputsignal range MON E01
sensor system
Electrical
DHT1KX Left brake pressure sensor Out-of-input signal range TM E01
system
Transmission filter clogging Signal does not match engine running Electrical
DHT2L6 MON E01
sensor or stopped state system
Lift arm EPC lever potentiometer Electrical
DK59KA Disconnection WRK E03
(Main) system
Lift arm EPC lever potentiometer Electrical
DK59KY Short circuit with power supply line WRK E03
(Main) system
Lift arm EPC lever potentiometer Electrical
DK59L8 Analog signals disagree WRK E03
(Main) system
Lift arm EPC lever potentiometer Electrical
DK5AKA Disconnection WRK E03
(Sub) system
Lift arm EPC lever potentiometer Electrical
DK5AKY Short circuit with power supply line WRK E03
(Sub) system
Bucket EPC lever potentiometer Electrical
DK5BKA Disconnection WRK E03
(Main) system
Bucket EPC lever potentiometer Electrical
DK5BKY Short circuit with power supply line WRK E03
(Main) system
Bucket EPC lever potentiometer Electrical
DK5BL8 Analog signals disagree WRK E03
(Main) system
Bucket EPC lever potentiometer Electrical
DK5CKA Disconnection WRK E03
(Sub) system
Bucket EPC lever potentiometer Electrical
DK5CKY Short circuit with power supply line WRK E03
(Sub) system

WA500-6 40-85 ➁
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
3rd valve (attachment) EPC lever Electrical
DK5DKA Disconnection WRK E03
potentiometer (Main) system
3rd valve (attachment) EPC lever Electrical
DK5DKY Short circuit with power supply line WRK E03
potentiometer (Main) system
3rd valve (attachment) EPC lever Electrical
DK5DL8 Analog signals disagree WRK E03
potentiometer (Main) system
3rd valve (attachment) EPC lever Electrical
DK5EKA Disconnection WRK E03
potentiometer (Sub) system
3rd valve (attachment) EPC lever Electrical
DK5EKY Short circuit with power supply line WRK E03
potentiometer (Sub) system
Joystick steering EPC lever Electrical
DK5FKA Disconnection WRK E03
potentiometer (Main) system
Joystick steering EPC lever Electrical
DK5FKY Short circuit with power supply line WRK E03
potentiometer (Main) system
Joystick steering EPC lever Electrical
DK5GKA Disconnection WRK E03
potentiometer (Sub) system
Joystick steering EPC lever Electrical
DK5GKY Short circuit with power supply line WRK E03
potentiometer (Sub) system
Joystick steering EPC lever Electrical
DK5FL8 Analog signals disagree WRK E03
potentiometer (Main) system
Electrical
DKA0KA Lift arm angle sensor Disconnection WRK E01
system
Electrical
DKA0KX Lift arm angle sensor Out-of-input signal range MON E01
system
Electrical
DKA0KY Lift arm angle sensor Short circuit with power supply line WRK E01
system
Electrical
DKA0L0 Lift arm angle sensor Double meshing WRK E01
system
Transmission input shaft speed Electrical
DLF1KA Disconnection TM E01
sensor system
Transmission input shaft speed Electrical
DLF1LC Speed signals disagree TM E01
sensor system
Transmission output shaft speed Electrical
DLT4KB Short circuit TM E03
sensor system
Transmission output shaft speed Electrical
DLT4KX Out-of-input signal range TM E03
sensor system
Transmission cut-off indicator Electrical
DT20KB Short circuit TM E01
lamp system
Remote positioner raise set
DUM1KB Short circuit WRK — —
indicator lamp
Remote positioner lower set
DUM2KB Short circuit WRK — —
indicator lamp
Electrical
DV00KB Alarm buzzer Short circuit MON E01
system
Electrical
DW4PKA Lift arm raise EPC solenoid Disconnection WRK E03
system

40-86 ➁ WA500-6
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Electrical
DW4PKB Lift arm raise EPC solenoid Short circuit WRK E03
system
Electrical
DW4PKY Lift arm raise EPC solenoid Short circuit with power supply line WRK E03
system
Electrical
DW4QKA Lift arm lower EPC solenoid Disconnection WRK E03
system
Electrical
DW4QKB Lift arm lower EPC solenoid Short circuit WRK E03
system
Electrical
DW4QKY Lift arm lower EPC solenoid Short circuit with power supply line WRK E03
system
Electrical
DW4RKA Bucket tilt EPC solenoid Disconnection WRK E03
system
Electrical
DW4RKB Bucket tilt EPC solenoid Short circuit WRK E03
system
Electrical
DW4RKY Bucket tilt EPC solenoid Short circuit with power supply line WRK E03
system
Electrical
DW4SKA Bucket dump EPC solenoid Disconnection WRK E03
system
Electrical
DW4SKB Bucket dump EPC solenoid Short circuit WRK E03
system
Electrical
DW4SKY Bucket dump EPC solenoid Short circuit with power supply line WRK E03
system
Electrical
DW7BKA Fan reverse solenoid Disconnection TM E01
system
Electrical
DW7BKB Fan reverse solenoid Short circuit TM E01
system
Electrical
DW7BKY Fan reverse solenoid Short circuit with power supply line TM E01
system
Hydraulic drive fan neutral Electrical
DW7DKA Disconnection TM E01
solenoid system
Hydraulic drive fan neutral Electrical
DW7DKB Short circuit TM E01
solenoid system
Hydraulic drive fan neutral Electrical
DW7DKY Short circuit with power supply line TM E01
solenoid system
Work equipment neutral lock EPC Electrical
DWM1KA Disconnection WRK E01
solenoid system
Work equipment neutral lock EPC Electrical
DWM1KB Short circuit WRK E01
solenoid system
Work equipment neutral lock EPC Electrical
DWM1KY Short circuit with power supply line WRK E01
solenoid system
Lift arm raise magnet detent Electrical
DWN6KA Disconnection WRK E01
solenoid system
Lift arm raise magnet detent Electrical
DWN6KB Short circuit WRK E01
solenoid system
Lift arm raise magnet detent Electrical
DWN6KY Short circuit with power supply line WRK E01
solenoid system

WA500-6 40-87 ➁
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Lift arm float magnet detent Electrical
DWN7KA Disconnection WRK E01
solenoid system
Lift arm float magnet detent Electrical
DWN7KB Short circuit WRK E01
solenoid system
Lift arm float magnet detent Electrical
DWN7KY Short circuit with power supply line WRK E01
solenoid system
Electrical
DWN8KA Bucket tilt magnet detent solenoid Disconnection WRK E01
system
Electrical
DWN8KB Bucket tilt magnet detent solenoid Short circuit WRK E01
system
Electrical
DWN8KY Bucket tilt magnet detent solenoid Short circuit with power supply line WRK E01
system
Electrical
DX16KA Fan pump EPC solenoid Disconnection TM E01
system
Electrical
DX16KB Fan pump EPC solenoid Short circuit TM E01
system
Electrical
DX16KY Fan pump EPC solenoid Short circuit with power supply line TM E01
system
Electrical
DXA1KA Pump PC-EPC solenoid Disconnection WRK E01
system
Electrical
DXA1KB Pump PC-EPC solenoid Short circuit WRK E01
system
Electrical
DXH1KA Lockup ECMV solenoid Disconnection TM E01
system
Electrical
DXH1KB Lockup ECMV solenoid Short circuit TM E01
system
Electrical
DXH1KY Lockup ECMV solenoid Short circuit with power supply line TM E03
system
Electrical
DXH4KA 1st clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH4KB 1st clutch ECMV solenoid Short circuit TM E03
system
Electrical
DXH4KY 1st clutch ECMV solenoid Short circuit with power supply line TM E03
system
Electrical
DXH5KA 2nd clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH5KB 2nd clutch ECMV solenoid Short circuit TM E03
system
Electrical
DXH5KY 2nd clutch ECMV solenoid Short circuit with power supply line TM E03
system
Electrical
DXH6KA 3rd clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH6KB 3rd clutch ECMV solenoid Short circuit TM E03
system
Electrical
DXH6KY 3rd clutch ECMV solenoid Short circuit with power supply line TM E03
system

40-88 ➁ WA500-6
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE

Failure Action Category of

Problem Part Trouble Controller
Code Code Record
Electrical
DXH7KA R clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH7KB R clutch ECMV solenoid Short circuit TM E03
system
Electrical
DXH7KY R clutch ECMV solenoid Short circuit with power supply line TM E03
system
Electrical
DXH8KA F clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH8KB F clutch ECMV solenoid Short circuit TM E03
system
Electrical
DXH8KY F clutch ECMV solenoid Short circuit with power supply line TM E03
system
Electrical
DXHHKA 4th clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXHHKB 4th clutch ECMV solenoid Short circuit TM E03
system
Electrical
DXHHKY 4th clutch ECMV solenoid Short circuit with power supply line TM E03
system
Electrical
DXHJKA 3rd valve extract EPC solenoid Disconnection WRK E03
system
Electrical
DXHJKB 3rd valve extract EPC solenoid Short circuit WRK E03
system
Electrical
DXHJKY 3rd valve extract EPC solenoid Short circuit with power supply line WRK E03
system
Electrical
DXHKKA 3rd valve retract EPC solenoid Disconnection WRK E03
system
Electrical
DXHKKB 3rd valve retract EPC solenoid Short circuit WRK E03
system
Electrical
DXHKKY 3rd valve retract EPC solenoid Short circuit with power supply line WRK E03
system
Joystick steering right EPC Electrical
DXHLKA Disconnection WRK E03
solenoid system
Joystick steering right EPC Electrical
DXHLKB Short circuit WRK E03
solenoid system
Joystick steering right EPC Electrical
DXHLKY Short circuit with power supply line WRK E03
solenoid system
Joystick steering left EPC Electrical
DXHMKA Disconnection WRK E03
solenoid system
Joystick steering left EPC Electrical
DXHMKB Short circuit WRK E03
solenoid system
Joystick steering left EPC Electrical
DXHMKY Short circuit with power supply line WRK E03
solenoid system

WA500-6 40-89 ➁
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE
★ Failure codes:
• Failure codes are listed in alphabetical order and start from the smallest number.
• A failure code in parentheses is not recorded in the failure history for either the electrical system or mechanical
system.

★ Applicable controller:
Applicable controller indicates in which controller system the failure has occurred.
MON: Machine monitor system
ENG: Engine controller system
TM : Transmission controller system
★ Action codes:
Action codes indicate what is displayed in the Operator mode when a failure is detected.

★ History classification:
History classification indicates in which system a failure has been recorded (either electrical or mechanical in the failure
history display function).

Remark
Optional equipment is also included in the table.

40-90 ➁ WA500-6
TROUBLESHOOTING FUSE BOX AND SLOW-BLOW FUSES

FUSE BOX AND SLOW-BLOW FUSES

Connection Table
★ This connection table indicates the devices to which the power of the fuse box and slow blow fuse is supplied.
• A switch power supply device supplies power while the starting switch is in the ON position.
• A constant power supply device supplies power while the starting switch is in the OFF and ON positions.
★ 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 A
Power Supply (Power Source) Fuse No. Fuse Capacity Description
Switch power supply
1 5A Engine controller circuit
Starting switch ACC
2 10 A Starting switch terminal B circuit
3 30 A Engine controller cut circuit

Constant power supply 4 10 A Hazard lamp circuit

slow-blow fuse 5 10 A Radio, auto-grease circuit
SBF1 (50 A) 6 10 A Transmission controller (B) circuit
7 10 A Work equipment controller (B) circuit
8 10 A Machine monitor (B) circuit
9 10 A Horn circuit
10 20 A Air conditioner circuit

Switch power supply 11 5A Air conditioner compressor circuit

slow-blow fuse 12 20 A Rear glass heater circuit
CBF2 (80 A) 13 10 A Radio, auto-grease circuit
14 20 A Air suspension seat, 12 V converter circuit
15 10 A KOMTRAX circuit

Fuse Box B
Power Supply (Power Source) Fuse No. Fuse Capacity Description
1 10 A Turn signal lamp circuit
2 10 A Back-up lamp and brake lamp circuit
3 20 A Front working lamp circuit
4 20 A Rear working lamp circuit

Switch power supply 5 10 A Transmission controller (A) circuit

slow-blow fuse 6 10 A Parking brake circuit
SBF2 (120 A) 7 10 A Work equipment controller (A) circuit
8 10 A Machine monitor (A) circuit
9 20 A Wiper and washer circuit
10 10 A Spare
11 20 A Main lamp circuit
Switch power supply 12 10 A Clearance lamp (right) circuit
lamp switch 13 10 A Clearance lamp (left) circuit
Switch power supply 14 10 A Headlamp (right) circuit
head lamp relay 15 10 A Headlamp (left) circuit

WA500-6 40-91 ➁
TROUBLESHOOTING FUSE BOX AND SLOW-BLOW FUSES

Slow-Blow Fuses
Power Supply Slow-blow Fuse
Fuse Capacity Description
(Power Source) No.
Starting switch B terminal circuit, engine controller cut circuit,
hazard lamp circuit, radio, auto-grease circuit, transmission
Constant power supply SBF1 50 A
controller (B) circuit, work equipment controller (B) circuit,
machine monitor (B) circuit
Horn circuit, air conditioner circuit, air conditioner compressor
80 A circuit, rear glass heater circuit, radio, auto-grease circuit, air
suspension seat, 12 V converter circuit, KOMTRAX circuit

SBF2 Turn signal lamp circuit, backup lamp, brake lamp circuit, front
Switch power supply working lamp circuit, rear working lamp circuit, transmission
120 A controller (A) circuit, parking brake circuit, work equipment
controller (A) circuit, machine monitor (A) circuit, wiper, washer
circuit, spare, main lamp circuit
SBF3 250 A Heater relay circuit

40-92 ➁ WA500-6
TROUBLESHOOTING FAILURE CODES

FAILURE CODES
Remark
Where applicable, the Failure Code table is on the left-hand page and the related diagram
is on the right-hand page.

WA500-6 40-93 ➁
TROUBLESHOOTING 1500LO

1500LO
TORQFLOW Transmission: Double Meshing
Action Code Failure Code TORQFLOW transmission: Double meshing
Trouble
E03 1500LOG (Transmission controller system)
Contents of
• A combination for double meshing is input as a fill signal.
trouble
Action of • Turns the centralized warning lamp and warning buzzer ON.
machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The transmission may be broken.
appears on
• The machine cannot travel.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Causes Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
1 See failure codes [15SAL1], [15SBL1], [15SEL1], [15SFL1], [15SGL1], and [15SHL1].
value in normal
state

40-94 ➁ WA500-6
TROUBLESHOOTING 1500LO

MEMORANDUM

WA500-6 40-95 ➁
TROUBLESHOOTING 15BONX

15BONX
Transmission Filter: Clogging
Action Code Failure Code Transmission filter: Clogging
Trouble
E01 15B0NX (Machine monitor system)

• Transmission filter clogging sensor circuit is OPEN. (When torque converter oil temperature is above
Contents of
50°C (122°F), engine is running and option is set)
trouble
• Trouble detected while engine is stopped is maintained even after engine is started.
Action of • Turns the transmission filter clogging caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The transmission filter clogging caution lamp illuminates.
appears on
machine • The transmission may be broken.

• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the
Related
monitoring function (Code: 40903, D-IN-24).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Transmission filter clogging
Defective transmission
clogging sensor (Internal
2
disconnection or short
circuit)
Disconnection in wiring
Possible causes harness (Disconnection or
3 Resistance Max. 1 Ω
and standard defective contact of
value in normal connector)
state
Hot short in wiring harness
4
(Contact with 24 V circuit)
5 Defective machine monitor
The transmission filter may be clogged. Check it directly.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
• Disconnect connector R12
R12 (male) Transmission oil filter Resistance
Normal Max. 1 Ω
Between (1) and (2)
Clogging Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L53 (female) (5) –
R12 (female) (1)
Wiring harness between R12 (male) (2) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L53 (female) (5) –
Voltage Max. 1 V
R12 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
L53 (female) Transmission oil filter Resistance
Between (5) – Normal Max. 1 Ω
chassis ground Clogging Min. 1 MΩ

40-96 ➁ WA500-6
TROUBLESHOOTING 15BONX
Related Circuit Diagram

WA500-6 40-97 ➁
TROUBLESHOOTING 15SAL1

15SAL1
ECMV F Clutch: When Command Current is OFF, Fill Signal is ON
Action Code Failure Code ECMV F clutch: When command current is OFF, fill signal is ON.
Trouble
E03 15SAL1 (Transmission controller system)
Contents of • When F ECMV solenoid output is turned OFF, F ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the F ECMV fill switch signal is turned ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • F travel is enabled, but R travel is disabled.
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
(Code: 31608, ECMV F DIR).
Related
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function
information
(Code: 40908, D-IN-25).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal F (forward)
1 clutch oil pressure (There is There is no pressure in position other than F.
residual pressure)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
Defective F ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
2 switch FNR (directional) lever,
(Internal short circuit) joystick steering FNR
F.SW (male) Resistance
(directional) switch, or right
FNR (directional) switch
Between (1) – F (Forward) Max. 1 Ω
Possible causes chassis ground Other than above Min. 1 MΩ
and standard
Grounding fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting without
value in normal
harness turning starting switch ON.
state 3
(Contact with ground Wiring harness between L03 (female) (27) – F.SW
circuit) Resistance Min. 1 MΩ
(female) (1) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission
4 FNR (directional) lever,
controller
joystick steering FNR
L03 Voltage
(directional) switch, or right
FNR (directional) switch
Between (27) – F (Forward) Max. 1 V
chassis ground Other than above 8 – 10 V

40-98 ➁ WA500-6
TROUBLESHOOTING 15SAL1
Related Circuit Diagram

WA500-6 40-99 ➁
TROUBLESHOOTING 15SALH

15SALH
ECMV F Clutch: When Command Current is ON, Fill Signal is OFF
Action Code Failure Code ECMV F clutch: When command current is ON, fill signal is OFF.
Trouble
E01 15SALH (Transmission controller system)
Contents of
• When F ECMV solenoid output is turned ON, F ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the F ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
(Code: 31608, ECMV F DIR).
Related
information • The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
40908, D-IN-25).
• Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch F (forward)

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal F (forward) clutch
oil pressure
1 Oil pressure is normal in F.
(There is no pressure while
command is ON.)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Possible causes
and standard Defective F ECMV fill switch FNR (directional) lever,
2
value in normal (Internal disconnection) joystick steering FNR
state F.SW (male) (directional) switch, or Resistance
right FNR (directional)
switch
Between (1) – F (Forward) Max. 1 Ω
chassis ground Other than above Min. 1 MΩ
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between L03 (female) (27) –
contact of connector) Resistance Max. 1 Ω
F.SW (female) (1)

40-100 ➁ WA500-6
TROUBLESHOOTING 15SALH

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
Possible causes • Keep pressing brake pedal to prevent machine from traveling.
and standard Defective transmission FNR (directional) lever,
4
value in normal controller joystick steering FNR
state L03 (directional) switch, or Voltage
right FNR (directional)
switch
Between (27) – F (Forward) Max. 1 V
chassis ground Other than above 8 – 10 V

Related Circuit Diagram

WA500-6 40-101 ➁
TROUBLESHOOTING 15SBL1

15SBL1
ECMV R Clutch: When Command Current is OFF, Fill Signal is ON
Action Code Failure Code ECMV R clutch: When command current is OFF, fill signal is ON.
Trouble
E03 15SBL1 (Transmission controller system)
Contents of • When R ECMV solenoid output is turned OFF, R ECMV fill switch signal ON is input and clutch is not
trouble released.
• Judges that the R ECMV fill switch signal is turned ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine can travel in the R position, but cannot travel in the F position.
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring
function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function
information
(Code: 40908, D-IN-26).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal R (reverse)
clutch oil pressure
1 There is no pressure in position other than R.
(There is residual
pressure.)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
Defective R ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
2 switch FNR (directional) lever,
(Internal short circuit) joystick steering FNR
R.SW (male) Resistance
(directional) switch, or right
FNR (directional) switch
Between (1) – R (Reverse) Max. 1 Ω
Possible causes
chassis ground Other than above Min. 1 MΩ
and standard
value in normal Grounding fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Contact with ground Wiring harness between L03 (female) (17) –
circuit) Resistance Min. 1 MΩ
R.SW (female) (1) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission
4 FNR (directional) lever,
controller
joystick steering FNR
L03 Voltage
(directional) switch, or right
FNR (directional) switch
Between (17) – R (Reverse) Max. 1 V
chassis ground Other than above 8 – 10 V

40-102 ➁ WA500-6
TROUBLESHOOTING 15SBL1
Related Circuit Diagram

WA500-6 40-103 ➁
TROUBLESHOOTING 15SBLH

15SBLH
ECMV R Clutch: When Command Current is ON, Fill Signal is OFF
Action code Failure code ECMV R clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SBLH (Transmission controller system)

Contents of • When R ECMV solenoid output is turned ON, R ECMV fill switch signal ON is not input.
trouble • Engine speed is below 500 rpm and clutch does not mesh.
Action of • Judges that the R ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may occur.
machine
• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring
function (Code: 31606, ECMV R DIR).
Related
information • The input state (ON/OFF) from the R fill switch can be checked with the monitoring function
(Code: 40908, D-IN-26).
• Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch R (reverse)

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal R (reverse) clutch
oil pressure
1 Oil pressure is normal in R.
(There is no pressure while
command is ON.)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Possible causes
and standard Defective R ECMV fill switch FNR (directional) lever,
2
value in normal (Internal short circuit) joystick steering FNR
state R.SW (male) (directional) switch, or Resistance
right FNR (directional)
switch
Between (1) – R (Reverse) Max. 1 Ω
chassis ground Other than above Min. 1 MΩ
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between L03 (female) (17) –
contact of connector) Resistance Max. 1 Ω
R.SW (female) (1)

40-104 ➁ WA500-6
TROUBLESHOOTING 15SBLH

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
Possible causes • Keep pressing brake pedal to prevent machine from traveling.
and standard Defective transmission FNR (directional) lever,
4
value in normal controller joystick steering FNR
state L03 (directional) switch, or Voltage
right FNR (directional)
switch
Between (17) – R (Reverse) Max. 1 V
chassis ground Other than above 8 – 10 V

Related Circuit Diagram

WA500-6 40-105 ➁
TROUBLESHOOTING 15SEL1

15SEL1
ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON
Action Code Failure Code ECMV 1st clutch: When command current is OFF, fill signal is ON.
Trouble
E03 15SEL1 (Transmission controller system)
Contents of • When 1st ECMV solenoid output is turned OFF, 1st ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the 1st ECMV fill switch signal is turned ON.
• Holds 2nd, 3rd, and 4th proportional solenoid outputs OFF.
Action of
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine can travel at 1st, but not at 2nd, 3rd, and 4th.
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
(Code: 31602, ECMV 1 DIR).
Related
• The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-27).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal 1st clutch oil
1 pressure
(There is residual pressure.)
Defective 1st ECMV fill
2 switch
(Internal short circuit)
Possible causes
Grounding fault in wiring
and standard
3 harness
value in normal
(Contact with ground circuit)
state
Defective transmission
4 position.
controller
There is no pressure in position other than 1st.
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
1.SW (male) Shift lever Resistance
Between (1) – chassis 1st (1st speed) Max. 1 Ω
ground Other than above Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (7) –
Resistance Min. 1 MΩ
1.SW (female) (1) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto-shift and manual shift selector switch in the MANUAL
• Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R (reverse).
L03 Shift lever Voltage
Between (7) – chassis 1st (1st speed) Max. 1 V
ground Other than above 8 – 10 V

40-106 ➁ WA500-6
TROUBLESHOOTING 15SEL1
Related Circuit Diagram

WA500-6 40-107 ➁
TROUBLESHOOTING 15SELH

15SELH
ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF
Action Code Failure Code ECMV 1st clutch: When command current is ON, fill signal is OFF.
Trouble
E01 15SELH (Transmission controller system)
Contents of
• When 1st ECMV solenoid output is turned ON, 1st ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 1st ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine may not travel at 1st.
appears on
machine • When the 1st gear speed is changed, a shock or a time lag may occur.

• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
(Code: 31602, ECMV 1 DIR).
Related • The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function
information (Code: 40908, D-IN-27).
• Method of reproducing failure code: Engine started + Manual/auto-shift selector switch to MANUAL +
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F
(forward) or R (reverse) + Shift lever 1st

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal 1st clutch oil
pressure
1 Oil pressure is normal in 1st.
(There is no pressure while
command is ON.)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
Defective 1st ECMV fill • Turn parking brake switch OFF.
2 switch • Keep pressing brake pedal to prevent machine from traveling.
(Internal disconnection)
1.SW (male) Shift lever Resistance
Between (1) – 1st (1st speed) Max. 1 Ω
chassis ground Other than above Min. 1 MΩ
Possible causes Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard harness without turning starting switch ON.
3
value in normal (Disconnection or defective Wiring harness between L03 (female) (7) –
state contact of connector) Resistance Max. 1 Ω
1.SW (female) (1)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission • Set the auto-shift and manual shift selector switch in the MANUAL
4 position.
controller
• Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R (reverse).
L03 Shift lever Voltage
Between (7) – 1st (1st speed) Max. 1 V
chassis ground Other than above 8 – 10 V

40-108 ➁ WA500-6
TROUBLESHOOTING 15SELH
Related Circuit Diagram

WA500-6 40-109 ➁
TROUBLESHOOTING 15SFL1

15SFL1
ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON
Action Code Failure Code ECMV 2nd clutch: When command current is OFF, fill signal is ON.
Trouble
E03 15SFL1 (Transmission controller system)
Contents of • When 2nd ECMV solenoid output is turned OFF, 2nd ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Turns the centralized warning lamp and alarm buzzer ON.
• Judges that the 2nd ECMV fill switch signal is turned ON.
Action of
controller • Holds 1st, 3rd, and 4th proportional solenoid outputs OFF.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine can travel at 2nd, but not at 1st, 3rd, and 4th.
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31603, ECMV 2 DIR).
Related
• The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function
information
(Code: 40908, D-IN-28).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal 2nd clutch oil
1 pressure
(There is residual pressure.)
Defective 2nd ECMV fill
2 switch
(Internal short circuit)
Possible causes Grounding fault in wiring
and standard 3 harness
value in normal (Contact with ground circuit)
state
Defective transmission
4 position.
controller
There is no pressure in position other than 2nd.
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
2.SW (male) Shift lever Resistance
Between (1) – 2nd (2nd speed) Max. 1 Ω
chassis ground Other than above Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (13) –
Resistance Min. 1 MΩ
2.SW (female) (1) and chassis ground
• Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto-shift and manual shift selector switch in the MANUAL
• Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R (reverse).
L03 Shift lever Voltage
Between (13) – 2nd (2nd speed) Max. 1 V
chassis ground Other than above 8 – 10 V

40-110 ➁ WA500-6
TROUBLESHOOTING 15SFL1
Related Circuit Diagram

WA500-6 40-111 ➁
TROUBLESHOOTING 15SFLH

15SFLH
ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF
Action Code Failure Code ECMV 2nd clutch: When command current is ON, fill signal is OFF.
Trouble
E01 15SFLH (Transmission controller system)
Contents of
• When 2nd ECMV solenoid output is turned ON, 2nd ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 2nd ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine may not travel at 2nd.
appears on
machine • When the 2nd gear speed is changed, a shock or a time lag may occur.

• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31603, ECMV 2 DIR).
Related • The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function
information (Code: 40908, D-IN-28).
• Method of reproducing failure code: Engine started + Manual/auto-shift selector switch to MANUAL +
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to
F (forward) or R (reverse) + Shift lever 2nd

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal 2nd clutch oil
pressure
1 Oil pressure is normal in 2nd.
(There is no pressure while
command is ON.)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
Defective 2nd ECMV fill • Turn parking brake switch OFF.
2 switch • Keep pressing brake pedal to prevent machine from traveling.
(Internal disconnection)
2.SW (male) Shift lever Resistance
Between (1) – 2nd (2nd speed) Max. 1 Ω
chassis ground Other than above Min. 1 MΩ
Possible causes Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard harness without turning starting switch ON.
3
value in normal (Disconnection or defective Wiring harness between L03 (female) (13) –
state contact of connector) Resistance Max. 1 Ω
2.SW (female) (1)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission • Set the auto-shift and manual shift selector switch in the MANUAL
4 position.
controller
• Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R (reverse).
L03 Shift lever Voltage
Between (13) – 2nd (2nd speed) Max. 1 V
chassis ground Other than above 8 – 10 V

40-112 ➁ WA500-6
TROUBLESHOOTING 15SFLH
Related Circuit Diagram

WA500-6 40-113 ➁
TROUBLESHOOTING 15SGL1

15SGL1
ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON
Action Code Failure Code ECMV 3rd: When command current is OFF, fill signal is ON.
Trouble
E03 15SGL1 (Transmission controller system)
Contents of • When 3rd ECMV solenoid output is turned OFF, 3rd ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the 3rd ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 4th proportional solenoid outputs OFF.
Action of
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine can travel at 3rd, but not at 1st, 2nd, and 4th.
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31604, ECMV 3 DIR).
Related
• The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function
information
(Code: 40908, D-IN-29).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal 3rd clutch oil
1 pressure
(There is residual pressure.)
Defective 3rd ECMV fill
2 switch
(Internal short circuit)
Possible causes Grounding fault in wiring
and standard 3 harness
value in normal (Contact with ground circuit)
state
Defective transmission
4 position.
controller
There is no pressure in position other than 3rd.
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
3.SW (male) Shift lever Resistance
Between (1) – 3rd (3rd speed) Max. 1 Ω
chassis ground Other than above Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (3) –
Resistance Min. 1 MΩ
3.SW (female) (1) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto-shift and manual shift selector switch in the MANUAL
• Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R (reverse).
L03 Shift lever Voltage
Between (3) – 3rd (3rd speed) Max. 1 V
chassis ground Other than above 8 – 10 V

40-114 ➁ WA500-6
TROUBLESHOOTING 15SGL1
Related Circuit Diagram

WA500-6 40-115 ➁
TROUBLESHOOTING 15GLH

15GLH
ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF
Action Code Failure Code ECMV 3rd clutch: When command current is ON, fill signal is OFF.
Trouble
E01 15SGLH (Transmission controller system)

Contents of • When 3rd ECMV solenoid output is turned ON, 3rd ECMV fill switch signal ON is not input.
trouble • Engine speed is below 500 rpm and clutch does not mesh.
Action of • Judges that the 3rd ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine may not travel at 3rd.
appears on
machine • When the 3rd gear speed is changed, a shock or a time lag may occur.

• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31604, ECMV 3 DIR).
Related • The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function
information (Code: 40908, D-IN-29).
• Method of reproducing failure code: Engine started + Manual/auto-shift selector switch to MANUAL +
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to
F (forward) or R (reverse) + Shift lever 3rd

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal 3rd clutch oil
pressure
1 Oil pressure is normal in 3rd.
(There is no pressure while
command is ON)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
Defective 3rd ECMV fill • Turn parking brake switch OFF.
2 switch • Keep pressing brake pedal to prevent machine from traveling.
(Internal disconnection)
3.SW (male) Shift lever Resistance
Between (1) – 3rd (3rd speed) Max. 1 Ω
chassis ground Other than above Min. 1 MΩ
Possible causes Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard harness without turning starting switch ON.
value in normal 3
(Disconnection or defective Wiring harness between L03 (female) (3) –
state contact of connector) Resistance Max. 1 Ω
3.SW (female) (1)
• Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission • Set the auto-shift and manual shift selector switch in the MANUAL
4 position.
controller
• Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R (reverse).
L03 Shift lever Voltage
Between (3) – 3rd (3rd speed) Max. 1 V
chassis ground Other than above 8 – 10 V

40-116 ➁ WA500-6
TROUBLESHOOTING 15GLH
Related Circuit Diagram

WA500-6 40-117 ➁
TROUBLESHOOTING 15SHL1

15SHL1
ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON
Action Code Failure Code ECMV 4th: When command current is OFF, fill signal is ON.
Trouble
E03 15SHL1 (Transmission controller system)
Contents of • When 4th ECMV solenoid output is turned OFF, 4th ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the 4th ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 3rd proportional solenoid outputs OFF.
Action of
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine can travel at 4th, but not at 1st, 2nd, and 3rd.
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
(Code: 31605, ECMV 4 DIR).
Related
• The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function
information
(Code: 40908, D-IN-30).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal 4th clutch oil
1 pressure There is no pressure in position other than 4th.
(There is residual pressure)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
Defective 4th ECMV fill • Turn parking brake switch OFF.
2 switch • Keep pressing brake pedal to prevent machine from traveling.
(Internal short circuit)
4.SW (male) Shift lever Resistance
Between (1) – 4th (4th speed) Max. 1 Ω
chassis ground Other than above Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Grounding fault in wiring without turning starting switch ON.
and standard 3 harness
value in normal (Contact with ground circuit) Wiring harness between L03 (female) (2) –
Resistance Min. 1 MΩ
state 4.SW (female) (1) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission • Set the auto-shift and manual shift selector switch in the MANUAL
4 position.
controller
• Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R (reverse).
L03 Shift lever Voltage
Between (2) – 4th (4th speed) Max. 1 V
chassis ground Other than above 8 – 10 V

40-118 ➁ WA500-6
TROUBLESHOOTING 15SHL1
Related Circuit Diagram

WA500-6 40-119 ➁
TROUBLESHOOTING 15SHLH

15SHLH
ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF
Action Code Failure Code ECMV 4th: When command current is ON, fill signal is OFF.
Trouble
E01 15SHLH (Transmission controller system)
Contents of
• When 4th ECMV solenoid output is turned ON, 4th ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 4th ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine may not travel at 4th.
appears on
machine • When the 4th gear speed is changed, a shock or a time lag may occur.

• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
(Code: 31605, ECMV 4).
Related • The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function
information (Code: 40908, D-IN-30).
• Method of reproducing failure code: Engine started + Manual/auto-shift selector switch to MANUAL +
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to
F (forward) or R (reverse) + Shift lever 4th

Cause Standard value in normal state/Remarks on troubleshooting

Abnormal 4th clutch oil
pressure
1 Oil pressure is normal in 4th.
(There is no pressure while
command is ON)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
Defective 4th ECMV fill • Turn parking brake switch OFF.
2 switch • Keep pressing brake pedal to prevent machine from traveling.
(Internal disconnection)
4.SW (male) Shift lever Resistance
Between (1) – 4th (4th speed) Max. 1 Ω
chassis ground Other than above Min. 1 MΩ
Possible causes Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard harness without turning starting switch ON.
3
value in normal (Disconnection or defective Wiring harness between L03 (female) (2) –
state contact of connector) Resistance Max. 1 Ω
4.SW (female) (1)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cutoff switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission • Set the auto shift and manual shift selector switch in the MANUAL
4 position.
controller
• Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R (reverse).
L03 Shift lever Voltage
Between (2) – 4th (4th speed) Max. 1 V
chassis ground Other than above 8 – 10 V

40-120 ➁ WA500-6
TROUBLESHOOTING 15SHLH
Related Circuit Diagram

WA500-6 40-121 ➁
TROUBLESHOOTING 2F00MA

2F00MA
Parking Brake: Malfunction
Action Code Failure Code Parking brake: Malfunction
Trouble
E03 2F00MA (Machine monitor system)
Contents of
• While the F or R clutch is operated, the parking brake operation sensor circuit is OPEN.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • While parking brake lamp is lighting up, actual gear speed is not neutral.
machine
• The input state (ON/OFF) from the parking indicator switch can be checked with the monitoring function
Related (Code: 40903 D-IN-26).
information • Method of reproducing failure code: Turn starting switch ON; turn parking brake switch OFF; and
perform forward or reverse travel operation.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective parking brake • Disconnect connector PB.SW.
1 indicator switch
PB.SW (male) Parking brake Resistance
(Internal disconnection)
Released Max. 1 Ω
Between (1) and (2)
Operates Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L54 (female) (1) –
value in normal 2 Resistance Max. 1 Ω
(Disconnection or defective PB.SW (female) (1)
state contact) Wiring harness between PB.SW (female) (2) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Parking brake oil
3 Defective machine monitor L54 Voltage
pressure
Between (1) – Released Max. 1 V
chassis ground Operates 20 – 30 V

40-122 ➁ WA500-6
TROUBLESHOOTING 2F00MA
Related Circuit Diagram

WA500-6 40-123 ➁
TROUBLESHOOTING 2G42ZG

2G42ZG
Front Accumulator: Low Oil Pressure
Action Code Failure Code Front accumulator: Low oil pressure
Trouble
E03 2G42ZG (Machine monitor system)
Contents of • After engine is started, pressure increases to set pressure and then front brake accumulator pressure
trouble sensor circuit is OPEN.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The front brake accumulator oil pressure lowers.
appears on
machine • The brake may not work.

• The input state (ON/OFF) from the front brake oil pressure sensor can be checked with the monitoring
Related
function (Code: 40902, D-IN-16).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

The front brake accumulator Check the front brake accumulator oil pressure.
1
oil pressure lowers. (See Testing and adjusting.)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Front brake accumulator
B05 (male) Resistance
oil pressure
Defective front brake oil Normal brake
2 pressure sensor pressure
(Internal disconnection) Max. 1 Ω
Min. 5.88 MPa
Between (1) and (2) (Min. 852.82 psi)
Low brake pressure
Max. 3.92 MPa Min. 1 MΩ
(Max. 568.55 psi)
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Disconnection in wiring without turning starting switch ON.
state harness
3 Wiring harness between L53 (female) (1) – B05
(Disconnection or defective Resistance Max. 1 Ω
(female) (1)
contact)
Wiring harness between B05 (female) (2) – GND Resistance Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Front brake accumulator
L53 (female) Resistance
oil pressure

4 Defective machine monitor Normal brake pressure

Min. 5.88 MPa Max. 1 Ω
Wiring harness (Min. 852.82 psi)
between (1) –
chassis ground Low brake pressure
Max. 3.92 MPa Min. 1 MΩ
(Max. 568.55 psi)

40-124 ➁ WA500-6
TROUBLESHOOTING 2G42ZG
Related Circuit Diagram

WA500-6 40-125 ➁
TROUBLESHOOTING 2G43ZG

2G43ZG
Rear Accumulator: Low Oil Pressure
Action Code Failure Code Rear accumulator: Low oil pressure
Trouble
E03 2G43ZG (Machine monitor system)
Contents of • After engine is started, pressure increases to set pressure and then rear brake accumulator pressure
trouble sensor circuit is OPEN.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• Low rear brake accumulator oil pressure
appears on
machine • The brake may not work.

• The input state (ON/OFF) from the rear brake oil pressure sensor can be checked with the monitoring
Related
function (Code: 40902, D-IN-17).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Low rear brake accumulator Check the rear brake accumulator oil pressure.
1
oil pressure (See Testing and adjusting.)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Rear brake accumulator
B04 (male) Resistance
oil pressure
Defective rear brake oil Normal brake
2 pressure sensor pressure
(Internal disconnection) Max. 1 Ω
Min. 5.88 MPa
Between (1) and (2) (Min. 852.82 psi)
Low brake pressure
Max. 3.92 MPa Min. 1 MΩ
(Max. 568.55 psi)
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Disconnection in wiring without turning starting switch ON.
value in normal harness Wiring harness between L53 (female) (7) – B04
state 3 Resistance Max. 1 Ω
(Disconnection or defective (female) (1)
contact) Wiring harness between B04 (female) (2) and
Resistance Max. 1 Ω
GND
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Rear brake accumulator
L53 (female) Resistance
oil pressure
Normal brake
4 Defective machine monitor pressure
Max. 1 Ω
Wiring harness Min. 5.88 MPa
between (7) – (Min. 852.82 psi)
chassis ground Low brake pressure
Max. 3.92 MPa Min. 1 MΩ
(Max. 568.55 psi)

40-126 ➁ WA500-6
TROUBLESHOOTING 2G43ZG
Related Circuit Diagram

WA500-6 40-127 ➁
TROUBLESHOOTING 44K0L4

44K0L4
Bucket Positioner: ON/OFF Signals Disagree
Action Code Failure Code Bucket positioner: ON/OFF signals disagree
Trouble
E01 44K0L4 (Work equipment controller system)

• The signals input from the bucket proximity switch are combined impossibly.
• After bucket level-over signal ON and full stroke signal OFF were continued for three seconds, full stroke
Contents of signal ON was detected for one second.
trouble • After bucket level-over signal ON and full stroke signal OFF were continued for three seconds, bucket
level-over signal OFF was detected for one second.
• If cause of failure disappears, system resets itself.
Action of
• Judged to be below bucket level.
controller
Problem that
appears on • Bucket leveler does not function.
machine
• The input state (ON/OFF) from the bucket cylinder full stroke proximity switch can be checked with the
monitoring function (Code: 40911, D-IN-8).
Related
• The input state (ON/OFF) from the bucket cylinder level proximity switch can be checked with the
information
monitoring function (Code: 40911, D-IN-9).
• Method of reproducing failure code: Start engine + Slowly full-tilt bucket ↔ Full dump

Cause Standard value in normal state/Remarks on troubleshootin

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective bucket cylinder
level proximity switch F11 Position of bucket Voltage
1
(Internal disconnection or Between (A) and (C) Constant 20 – 30 V
short circuit)
Below horizontal Max. 1 V
Between (B) and (C)
Above horizontal 8 – 10 V
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective bucket cylinder full F12 Position of bucket Voltage
Possible causes stroke proximity switch
and standard 2 Between (A) and (C) Constant 20 – 30 V
(Internal disconnection or
value in normal short circuit) Tilt full stroke 8 – 10 V
state Between (B) and (C) Other than tilt full
Max. 1 V
stroke
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between F12 (female) (B) – L07
contact of connector) Resistance Max. 1 Ω
(female) (10)
★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
4 harness
(Contact with ground circuit) Wiring harness between F11 (female) (B) – L07 Resistance Min. 1 MΩ
(female) (20) and chassis ground

40-128 ➁ WA500-6
TROUBLESHOOTING 44K0L4

Cause Standard value in normal state/Remarks on troubleshootin

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L07 Position of bucket Voltage
Possible causes
and standard Defective work equipment Between (20) – Below horizontal Max. 1 V
5
value in normal controller chassis ground Above horizontal 8 – 10 V
state
Tilt full stroke 8 – 10 V
Between (10) –
chassis ground Other than tilt full
Max. 1 V
stroke

Related Circuit Diagram

WA500-6 40-129 ➁
TROUBLESHOOTING AA1ANX

AA1ANX
Air Cleaner: Clogging
Action Code Failure Code Air cleaner: Clogging
Trouble
E01 AA1ANX (Machine monitor system)
Contents of
• The air cleaner clogging sensor circuit is OPEN (at engine running).
trouble
Action of • Turns the air cleaner clogging caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The engine does not start or pick up easily; its output is insufficient; and its exhaust gas color is black.
machine
• The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring
Related
function (Code: 40902, D-IN-20).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Clogged air cleaner The air cleaner may be clogged. Check it directly.
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective dust indicator Failure code
2 E15 (female) Dust indicator
(Internal short circuit) AA1ANX
Replace If condition becomes normal, dust indicator is
dust indicator. defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L107 (male) Resistance
Defective dust indicator relay
Between (1) and (2) 200 – 400 Ω
(L107) (Internal
3
disconnection or short ★ Prepare with starting switch OFF, then start engine and carry out
circuit) troubleshooting.
If dust indicator relay (L107) is replaced with a relay of the same type (5-
pin type) and the condition becomes normal, the exchanged relay is
Possible causes defective.
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state Disconnection in wiring without turning starting switch ON.
harness (Disconnection or Wiring harness between L53 (female) (3) –
4 Resistance Max. 1 Ω
defective contact of L107 (female) (3)
connector) Wiring harness between L107 (female) (6) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
5 harness (Contact with
ground circuit) Wiring harness between L107 (female) (2) –
Resistance Min. 1 MΩ
E15 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
L53 Dust indicator Voltage
6 Defective machine monitor Normal
20 – 30 V
Between (3) – (Air cleaner is normal.)
chassis ground Defective
Max. 1 V
(Air cleaner is clogged.)

40-130 ➁ WA500-6
TROUBLESHOOTING AA1ANX
Related Circuit Diagram

WA500-6 40-131 ➁
TROUBLESHOOTING AB00L6

AB00L6
Alternator: Signal Disagrees with Operating State of Engine
Action code Failure code Alternator: Signal does not match engine running or stopped state
Trouble
E03 AB00L6 (Machine monitor system)
Contents of
• When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Turns charge circuit abnormality caution lamp ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on • After engine start operation, after the starting switch is turned ON, the service meter advances.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function
Related
(Code: 04302, ALTERNATOR R).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Alternator Engine Voltage
Defective alternator
1 Wiring harness Start
(Internal defect) 27.5 – 29.5 V
between terminal R (Throttle: Above 1/2)
(E03) – chassis
ground Holds in position Max. 1 V

Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
Hot short in wiring harness
value in normal 2 Wiring harness between alternator terminal
(Contact with 24 V circuit)
state R (E03) – L52 (female) (18), Voltage Max. 1 V
– D02 (female) (3), – circuit branch
★ Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
L52 Engine Voltage
3 Defective machine monitor
Start
Between (18) – 27.5 – 29.5 V
(Throttle: Above 1/2)
chassis ground
Holds in position Max. 1 V

40-132 ➁ WA500-6
TROUBLESHOOTING AB00L6
Related Circuit Diagram

WA500-6 40-133 ➁
TROUBLESHOOTING AB00MA

AB00MA
Alternator: Malfunction
Action Code Failure Code Alternator: Malfunction
Trouble
E03 AB00MA (Machine monitor system)
Contents of
• While the engine is running, the alternator terminal R input voltage is below 5 V.
trouble
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Turns charge circuit abnormality caution lamp ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on • Deteriorated battery, lack of charge.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code: 04302,
Related
ALTERNATOR R).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Deteriorated battery The battery may be deteriorated. Check it directly.
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective alternator Alternator Engine Voltage
2
(Internal defect) Wiring harness Start
27.5 – 29.5 V
between terminal R (Throttle: Above 1/2)
(E03) – chassis ground Holds in position Max. 1 V
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
Possible causes (Disconnection or defective Wiring harness between alternator terminal R
contact of connector) Resistance Max. 1 Ω
and standard (E03) – L52 (female) (18)
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting
state
Grounding fault in wiring without turning starting switch ON.
4 harness Wiring harness between alternator terminal R
(Contact with ground circuit) (E03) – L52 (female) (18), – D02 (female) (3), Resistance Min. 1 MΩ
– circuit branch and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
L52 Engine Voltage
5 Defective machine monitor
Start
Between (18) – 27.5 – 29.5 V
(Throttle: Above 1/2)
chassis ground
Holds in position Max. 1 V

40-134 ➁ WA500-6
TROUBLESHOOTING AB00MA
Related Circuit Diagram

WA500-6 40-135 ➁
TROUBLESHOOTING B@BAZG

B@BAZG
Engine: Low Engine Oil Pressure
Action Code Failure Code Low engine oil pressure
Trouble
E03 B@BAZG (Engine controller system)
Contents of • When engine speed was below 500 rpm for 15 seconds or more, engine oil pressure became lower than
trouble operating range.
Action of • Limit output for travel (limit injection rate and engine speed).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200 ENG OIL PRESS).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
function (Code: 37201 ENG OIL PRESS).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out troubleshooting
1
supply system for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
POIL Voltage
Defective oil pressure sensor
2 Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected. Accordingly,
if voltage is abnormal, check wiring harness and controller for another
cause of trouble before judgment
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between ENG (female) (37) –
harness Resistance Max. 1 Ω
POIL (female) (1)
3 (Disconnection in wiring or
Possible causes Wiring harness between ENG (female) (47) –
defective contact in Resistance Max. 1 Ω
and standard connector) POIL (female) (2)
value in normal Wiring harness between ENG (female) (13) –
state Resistance Max. 1 Ω
POIL (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring Wiring harness between ENG (female) (37) –
Resistance Min. 1 MΩ
harness POIL (female) (1) and chassis ground
4
(Short circuit with GND Wiring harness between ENG (female) (47) –
circuit) Resistance Min. 1 MΩ
POIL (female) (2) and chassis ground
Wiring harness between ENG (female) (13) –
Resistance Min. 1 MΩ
POIL (female) (3) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
5 Defective engine controller ENG Voltage
Between
Power supply 4.75 – 5.25 V
(37) and (47)

40-136 ➁ WA500-6
TROUBLESHOOTING B@BAZG
Related Circuit Diagram

WA500-6 40-137 ➁
TROUBLESHOOTING B@BAZK

B@BAZK
Engine Oil: Low Level
Action Code Failure Code Engine oil: Low level
Trouble
E01 B@BAZK (Machine monitor system)

• The engine oil level OPEN sensor circuit was detected for a minimum of two seconds (when engine
Contents of
stopped). (However, no error is detected for five minutes after the engine stopped.)
trouble
• Error detected while engine is stopped is maintained until it is reset even after engine is started.
Action of • Turns the engine oil level caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The engine oil level sensor is connected between the target pin and chassis ground of the machine
monitor.
Related
• The input state (ON/OFF) from target pin – ground circuit of the machine monitor can be checked with
information
the monitoring function (Code: 40903, D-IN-29).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
1
(Disconnection or defective Wiring harness between L54 (female) (11) –
contact) Resistance Max. 1 Ω
Possible causes chassis ground
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state
2 Defective machine monitor L54 (female) Resistance
Wiring harness between Normal Max. 1 Ω
(11) – chassis ground Disconnection Min. 1 MΩ

40-138 ➁ WA500-6
TROUBLESHOOTING B@BAZK
Related Circuit Diagram

WA500-6 40-139 ➁
TROUBLESHOOTING B@BCNS

B@BCNS
Engine: Coolant: Overheating
Action Code Failure Code Coolant: Overheating
Trouble
E02 B@BCNS (Engine controller system)
Contents of • When engine speed was below 500 rpm for three seconds or more, coolant temperature exceeded
trouble operating range.
Action of • Limits output and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the monitoring
function (Code: 04104 COOLANT TEMP).
Related
• The input state (voltage) from the coolant temperature sensor can be checked with the monitoring
information
function (Code: 04105 COOLANT TEMP).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective coolant without turning starting switch ON.
1 temperature sensor TWTR (male) Coolant temperature Resistance
(Internal defect) 10 – 100°C
Between (A) and (B) 0.6 – 20 kΩ
(50 – 212°F)
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes
harness
and standard Wiring harness between ENG (female) (15) –
2 (Disconnection in wiring or Resistance Max. 1 Ω
value in normal TWTR (female) (A)
defective contact in
state Wiring harness between ENG (female) (38) –
connector)
Resistance Max. 1 Ω
TWTR (female) (B)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective engine controller ENG (female) Coolant temperature Resistance
10 – 100°C
Between (15) and (38) 0.6 – 20 kΩ
(50 – 212°F

40-140 ➁ WA500-6
TROUBLESHOOTING B@BCNS
Related Circuit Diagram

WA500-6 40-141 ➁
TROUBLESHOOTING B@BCZK

B@BCZK
Engine: Coolant: Low Level
Action Code Failure Code Coolant: Low level
Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• The coolant level sensor circuit is OPEN (detected time 30 seconds).
trouble
Action of • Turns the coolant level caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The coolant level is low. The engine overheats (the engine may be broken).
machine
• The input state (ON/OFF) from the coolant level sensor can be checked with the monitoring function
Related
(Code: 40903, D-IN-27).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

1 Low coolant level The coolant level may be low. Check it directly.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective coolant level R13 (male) Sub-tank Resistance
2 sensor Below low level
(Internal ground fault) Max. 1 Ω
(Abnormal)
Between (1) and (2)
Above low level
Min. 1 MΩ
(Normal)
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between L54 (female) (10) –
Possible causes 3 Resistance Max. 1 Ω
(Disconnection or defective R13 (female) (1)
and standard contact) Wiring harness between L116 (female) (6) –
value in normal Resistance Max. 1 Ω
state GND
★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
4 harness
(Contact with ground circuit) Wiring harness between L116 (female) (2) –
Resistance Min. 1 MΩ
R13 (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L54 (female) Subtank Resistance
5 Defective machine monitor Below low level
Wiring harness Min. 1 MΩ
(Abnormal)
between (10) –
Above low level
chassis ground Max. 1 Ω
(Normal)

40-142 ➁ WA500-6
TROUBLESHOOTING B@BCZK
Related Circuit Diagram

WA500-6 40-143 ➁
TROUBLESHOOTING B@C7NS

B@C7NS
Brake: Brake Oil: Overheating
Action Code Failure Code Brake oil: Overheating
Trouble
E02 B@C7NS (Machine monitor system)

• Brake oil temperature was above 130°C (266°F) for five seconds.
Contents of
trouble • When travel speed was above 35 km/h (22 mph), brake oil temperature (125°C (257°F) and higher),
was detected continuously for five seconds.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• Brake oil temperature caution lamp lights up
appears on
machine • The brake may be damaged.

• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the monitoring
information
function (Code: 30205 R BRAKE OIL).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

• Brake may overheat because brake was operated improperly during
travel.
1 Defective brake operation
• Instruct the operator on how to operate the machine properly when
traveling.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective rear brake oil Rear brake oil
R17 (male) Resistance
2 temperature sensor temperature
Possible causes
(Internal defect) 25°C (77°F)
and standard 35 – 50 kΩ
value in normal Between (1) and (2) (Normal temperature)
state 100°C (212°F) 3.1 – 4.5 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Rear brake oil
L55 (female) Resistance
3 Defective machine monitor temperature
25°C (77°F)
Wiring harness between 35 – 50 kΩ
(Normal temperature)
(8) – chassis ground
100°C (212°F) 3.1 – 4.5 kΩ

40-144 ➁ WA500-6
TROUBLESHOOTING B@C7NS
Related Circuit Diagram

WA500-6 40-145 ➁
TROUBLESHOOTING b@CENS

b@CENS
Torque Converter Oil: Overheating
Action Code Failure Code Torque converter oil: Overheating
Trouble
E02 b@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 120°C (248°F).
trouble
Action of • If cause of failure disappears, system resets itself. (A temperature of 120°C (248°F) and lower was
controller detected continuously for one second.)
Problem that
• The torque converter oil temperature caution lamp is turned ON. If the machine is used in this state, the
appears on
torque converter may be damaged.
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked with
the monitoring function (Code: 40100 TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101 TC OIL TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Torque converter oil may overheat due to torque converter stall, etc. (See
Overheating of torque
1 Troubleshooting Hydraulic and Mechanical Systems (H-mode) in this
converter oil
section.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective torque converter Torque converter oil
T05 (male) Resistance
2 oil temperature sensor temperature
Possible causes (Internal defect) 25°C (77°F)
and standard 35 – 50 kΩ
Between (1) and (2) (Normal temperature)
value in normal
100°C (212°F) 3.1 – 4.5 kΩ
state
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Torque converter oil
L55 (female) Resistance
3 Defective machine monitor temperature
25°C (77°F)
Between (2) – 35 – 50 kΩ
(Normal temperature)
chassis ground
100°C (212°F) 3.1 – 4.5 kΩ

40-146 ➁ WA500-6
TROUBLESHOOTING b@CENS
Related Circuit Diagram

WA500-6 40-147 ➁
TROUBLESHOOTING B@CENS

B@CENS
Torque Converter Oil: Overheating
Action Code Failure Code Torque converter oil: Overheating
Trouble
E02 B@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 130°C (266°F).
trouble
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
controller • If cause of failure disappears, system resets itself. A temperature of 130°C (266°F) and lower was
detected continuously for one second.
Problem that
• The torque converter oil temperature caution lamp is turned ON. If the machine is used in this state, the
appears on
torque converter may be broken.
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked with
the monitoring function (Code: 40100 TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101 TC OIL TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Torque converter oil may overheat due to torque converter stall, etc. (See
Overheating of torque
1 Troubleshooting Hydraulic and Mechanical Systems (H-mode) in this
converter oil
section.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective torque converter Torque converter oil
T05 (male) Resistance
2 oil temperature sensor temperature
Possible causes (Internal defect) 25°C (77°F)
and standard 35 – 50 kΩ
Between (1) and (2) (Normal temperature)
value in normal
100°C (212°F) 3.1 – 4.5 kΩ
state
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Torque converter oil
L55 (female) Resistance
3 Defective machine monitor temperature
25°C (77°F)
Between (2) – 35 – 50 kΩ
(Normal temperature)
chassis ground
100°C (212°F) 3.1 – 4.5 kΩ

40-148 ➁ WA500-6
TROUBLESHOOTING B@CENS
Related Circuit Diagram

WA500-6 40-149 ➁
TROUBLESHOOTING B@GAZK

B@GAZK
Battery Electrolyte: Low Level
Action Code Failure Code Battery electrolyte: Low level
Trouble
E01 B@GAZK (Machine monitor system)
Contents of
• The electrolyte level sensor (if equipped) voltage is below 2 V (continuously for 10 seconds).
trouble
Action of • Turns the electrolyte level caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that • Turns the electrolyte level caution lamp ON.
appears on • The electrolyte level is low.
machine • Engine may not start easily.
• The input state (voltage) from the electrolyte level sensor can be checked with the monitoring function
Related
(Code: 40300, BATTERY A).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

1 The electrolyte level is low The electrolyte level may be low. Check it directly.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective electrolyte level Battery electrolyte
R18 (male) Voltage
2 sensor level
(Internal disconnection) Normal Min. 2 V
Between (1) –
chassis ground Insufficient level
Max. 2 V
(Low level)
Possible causes
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 3
state (Disconnection or defective Wiring harness between L55 (female) (5) – R18
contact) Resistance Max. 1 Ω
(female) (1)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Battery electrolyte
L55 (female) Voltage
4 Defective machine monitor level
Normal Min. 2 V
Wiring harness between
(5) – chassis ground Insufficient level
Max. 2 V
(low level)

40-150 ➁ WA500-6
TROUBLESHOOTING B@GAZK
Related Circuit Diagram

WA500-6 40-151 ➁
TROUBLESHOOTING B@HANS

B@HANS
Hydraulic Oil: Overheating
Action Code Failure Code Hydraulic oil: Overheating
Trouble
E02 B@HANS (Machine monitor system)
Contents of
• The hydraulic oil temperature is above 100°C (212°F). Detected time: 10 seconds
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The hydraulic oil overheat warning is turned ON. If the machine is used in this state, the pump and
appears on
cylinder seals may be broken.
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitoring
information
function (Code: 04404 HYD TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

1 Overheating of hydraulic oil The hydraulic oil may be overheating.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective hydraulic oil Hydraulic oil
T03 (male) Resistance
2 temperature sensor temperature
(Internal defect) 25°C (77°F)
Possible causes 35 – 50 kΩ
Between (1) and (2) (Normal temperature)
and standard
100°C (212°F) 3.1 – 4.5 kΩ
value in normal
state ★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hydraulic oil
L55 (female) Voltage
3 Defective machine monitor temperature
25°C (77°F)
Wiring harness between 4.4 – 4.6 V
(Normal temperature)
(7) – chassis ground
100°C (212°F) 2.1 – 2.3 V

40-152 ➁ WA500-6
TROUBLESHOOTING B@HANS
Related Circuit Diagram

WA500-6 40-153 ➁
TROUBLESHOOTING CA111

CA111
Abnormality in Engine Controller
Action Code Failure Code Abnormality in engine controller
Trouble
E03 CA111 (Engine controller system)
Contents of
• Internal defect occurred in controller.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 3 of fuse If the fuse is burnt, the circuit probably has a grounding fault.
1
box A (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L117 (male) Resistance
Defective engine control cut
Between (1) and (2) 200 – 400 Ω
relay 1 (L117)
2
(Internal disconnection or ★ Prepare with starting switch OFF, then turn starting switch ON
short circuit) and carry out troubleshooting.
If engine control cut relay 1 (L117) is replaced with a relay of the same
type and the condition becomes normal, engine control cut relay 1 is
defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard
L119 (male) Resistance
value in normal
Defective engine control cut
state Between (1) and (2) 200 – 400 Ω
relay 2 (L119)
3
(Internal disconnection or ★ Prepare with starting switch OFF, then turn starting switch ON
short circuit) and carry out troubleshooting.
If engine control cut relay 2 (L119) is replaced with a relay of the same
type and the condition becomes normal, engine control cut relay 2 is
defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
D01 (male) Diode range Continuity
Defective diode (D01)
4 Measure at (1) in
(Internal disconnection) Between (1) and (2)
diode range.
Continue
Measure at (3) in
Between (3) and (2)
diode range.

40-154 ➁ WA500-6
TROUBLESHOOTING CA111

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between LS4 (female) (2) –
Resistance Max. 1 Ω
D01 (female) (1)
Wiring harness between D01 (female) (2) –
Resistance Max. 1 Ω
L117 (female) (1), – L119 (female) (1)
Disconnection in wiring Wiring harness between L117 (female) (2), –
Resistance Max. 1 Ω
harness L119 (female) (2) – E18 (female) (33)
5 (Disconnection in wiring or Wiring harness between fuse No. 3 of fuse
defective contact in box A – L117 (female) (5), – L119 (female) Resistance Max. 1 Ω
connector) (5)
Wiring harness between L117 (female) (3) –
Resistance Max. 1 Ω
E19 (female) (3)
Wiring harness between L119 (female) (3) –
Resistance Max. 1 Ω
E19 (female) (4)
Wiring harness between E19 (female) (1),
Resistance Max. 1 Ω
(2) – chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between LS4 (female) (2) –
state Resistance Min. 1 MΩ
D01 (female) (1) and chassis ground
Wiring harness between D01 (female) (2) –
L117 (female) (1), – L119 (female) (1) and Resistance Min. 1 MΩ
chassis ground
Ground fault in wiring
Wiring harness between L117 (female) (2), –
harness
6 L119 (female) (2) – E18 (female) (33) and Resistance Min. 1 MΩ
(Short circuit with GND
chassis ground
circuit)
Wiring harness between fuse No. 3 of fuse
box A – L117 (female) (5), – L119 (female) Resistance Min. 1 MΩ
(5) and chassis ground
Wiring harness between L117 (female) (3) –
Resistance Min. 1 MΩ
E19 (female) (3) and chassis ground
Wiring harness between L119 (female) (3) –
Resistance Min. 1 MΩ
E19 (female) (4) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
7 Defective engine controller
E19 Voltage
Between (1), (2) – (3), (4) 20 – 30 V

WA500-6 40-155 ➁
TROUBLESHOOTING CA111
Related Circuit Diagram

40-156 ➁ WA500-6
TROUBLESHOOTING CA115

CA115
Engine Ne or Bkup Speed Sensor Error
Action Code Failure Code Engine Ne or Bkup speed sensor error
Trouble
E03 CA115 (Engine controller system)
Contents of
• Abnormality occurred in Ne and Bkup speed sensor circuits at the same time.
trouble
Action of • Stops the engine.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• The engine does not start (if engine has been stopped).
appears on
machine • Engine stops (if engine has been running).

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for failure code [CA778].
system
Defective installation of Ne Ne speed sensor may be installed incorrectly. Check it directly.
3
Possible causes speed sensor (Defective installation of sensor itself, internal defect of flywheel, etc.)
and standard Bkup speed sensor may be installed incorrectly. Check it directly.
value in normal Defective installation of Bkup
4 (Defective installation of sensor itself, internal defect of supply pump,
state speed sensor
etc.)
Defective sensor connection Ne and Bkup speed sensors may be connected incorrectly (improper
5
(Improper connection) connection). Check them directly.
If causes 1 – 5 are not the cause of the problem, the engine controller
6 Defective engine controller may be defective. (Since problem is in system, troubleshooting cannot
be carried out.)

WA500-6 40-157 ➁
TROUBLESHOOTING CA122

CA122
Charge Pressure Sensor High Error
Action Code Failure Code Charge pressure sensor high error
Trouble
E03 CA122 (Engine controller system)
Contents of
• Charge pressure sensor (boost pressure sensor) circuit is abnormally high.
trouble
Action of • Sets charge pressure (boost pressure) to fixed value (400 kPa [58 psi]), and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine does not accelerate smoothly.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: 36500 CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
information
the monitoring function (Code: 36502 CHG PRESS-A).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective power supply
system of charge pressure
1
sensor (boost pressure
sensor)
Defective charge pressure
sensor (boost pressure
2 Between (1) and (3)
sensor)
(Internal defect)
Possible causes
and standard Disconnection in wiring
value in normal harness
state 3 (Disconnection in wiring or
defective contact in
connector)
Ground fault in wiring
harness
4
(Short circuit with GND
circuit)
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting
for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
PIM Voltage
Power supply 4.75 – 5.25 V
Charge pressure sensor voltage is measured with wiring harness
connected. If voltage is abnormal, check wiring harness and controller for
another cause of the problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) –
Resistance Max. 1 Ω
PIM (female) (1)
Wiring harness between ENG (female) (47) –
Resistance Max. 1 Ω
PIM (female) (2)
Wiring harness between ENG (female) (44) –
Resistance Max. 1 Ω
PIM (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) –
Resistance Min. 1 MΩ
PIM (female) (1) and chassis ground
Wiring harness between ENG (female) (47) –
Resistance Min. 1 MΩ
PIM (female) (2) and chassis ground
Wiring harness between ENG (female) (44) –
Resistance Min. 1 MΩ
PIM (female) (3) and chassis ground

40-158 ➁ WA500-6
TROUBLESHOOTING CA122

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) –
PIM (female) (1) and between ENG Resistance Min. 1 MΩ
Short circuit in wiring (female) (47) – PIM (female) (2)
5 harness (with another wiring Wiring harness between ENG (female) (37) –
harness) PIM (female) (1) and between ENG Resistance Min. 1 MΩ
Possible causes
and standard (female) (44) – PIM (female) (3)
value in normal Wiring harness between ENG (female) (47) –
state PIM (female) (2) and between ENG Resistance Min. 1 MΩ
(female) (44) – PIM (female) (3)
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
6 Defective engine controller ENG Voltage
Between
Power supply 4.75 – 5.25 V
(37) and (47)

Related Circuit Diagram

WA500-6 40-159 ➁
TROUBLESHOOTING CA123

CA123
Charge Pressure Sensor Low Error
Action Code Failure Code Charge pressure sensor low error
Trouble
E03 CA123 (Engine controller system)
Contents of
• Charge pressure sensor (boost pressure sensor) circuit is abnormally low.
trouble
Action of • Sets charge pressure (boost pressure) to fixed value (400 kPa [58 psi]) and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine does not accelerate smoothly.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: 36500 CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
information
the monitoring function (Code: 36502 CHG PRESS-A).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA122].
value in normal
state

40-160 ➁ WA500-6
TROUBLESHOOTING CA123

MEMORANDUM

WA500-6 40-161 ➁
TROUBLESHOOTING CA131

CA131
Throttle Sensor High Error
Action Code Failure Code Throttle sensor high error
Trouble
E03 CA131 (Engine controller system)
Contents of
• Throttle sensor circuit is abnormally high.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • The engine does not reach full throttle.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the
monitoring function (Code: 31701 THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function
information
(Code: 31707 THROTTLE POS).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective throttle sensor If failure code [CA2185] or [CA2186] is also indicated, carry out
1
power supply system troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L15 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 – 5.25 V
Defective accelerator pedal (Power supply)
2
(Internal defect) When released (13 ±2% of power supply)
Between (2) and (3)
When pressed (77 ±2% of power supply)
Sensor voltage is measured with wiring harness connected. If voltage is
abnormal, check wiring harness and controller for another cause of the
problem before making a decision.
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Disconnection in wiring Wiring harness between E18 (female) (22) –
state harness Resistance Max. 1 Ω
L15 (female) (1)
3 (Disconnection in wiring or
Wiring harness between E18 (female) (9) –
defective contact in Resistance Max. 1 Ω
connector) L15 (female) (2)
Wiring harness between E18 (female) (23) –
Resistance Max. 1 Ω
L15 (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between E18 (female) (22) –
Grounding fault in wiring Resistance Min. 1 MΩ
L15 (female) (1) and chassis ground
4 harness
(Contact with ground circuit) Wiring harness between E18 (female) (9) –
Resistance Min. 1 MΩ
L15 (female) (2) and chassis ground
Wiring harness between E18 (female) (23) –
Resistance Min. 1 MΩ
L15 (female) (3) and chassis ground

40-162 ➁ WA500-6
TROUBLESHOOTING CA131

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
E18 Accelerator pedal Voltage
5 Defective engine controller Between All range
4.75 – 5.25 V
(22) and (23) (Power supply)
When released (13 ±2% of power supply)
Between (9) and (23)
When pressed (77 ±2% of power supply)

Related Circuit Diagram

WA500-6 40-163 ➁
TROUBLESHOOTING CA132

CA132
Throttle Sensor Low Error
Action Code Failure Code Throttle sensor low error
Trouble
E03 CA132 (Engine controller system)
Contents of
• Throttle sensor circuit is abnormally low.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • The engine does not reach full throttle.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the
monitoring function (Code: 31707 THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
31701 THROTTLE POS).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA131].
value in normal
state

40-164 ➁ WA500-6
TROUBLESHOOTING CA132
Related Circuit Diagram

WA500-6 40-165 ➁
TROUBLESHOOTING CA135

CA135
Engine Oil Pressure Sensor High Error
Action Code Failure Code Engine oil pressure sensor high error
Trouble
E01 CA135 (Engine controller system)
Contents of
• Engine oil pressure sensor circuit is abnormally high.
trouble
Action of
controller • Sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues operation.

Problem that
appears on —
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200 ENG OIL PRESS).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
function (Code: 37201 ENG OIL PRESS).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective power supply
If failure code [CA187] or [CA227] is also indicated, carry out
1 system of engine oil pressure
troubleshooting for it first.
sensor
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
Defective engine oil pressure POIL Voltage
2 sensor Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected. If voltage is
abnormal, check wiring harness and controller for another cause of the
problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring Wiring harness between ENG (female) (37)
harness Resistance Max. 1 Ω
value in normal – POIL (female) (1)
state 3 (Disconnection in wiring or
Wiring harness between ENG (female) (47)
defective contact in Resistance Max. 1 Ω
connector) – POIL (female) (2)
Wiring harness between ENG (female) (13)
Resistance Max. 1 Ω
– POIL (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring Wiring harness between ENG (female) (37)
Resistance Min. 1 MΩ
harness – POIL (female) (1) and chassis ground
4
(Short circuit with GND Wiring harness between ENG (female) (47)
circuit) Resistance Min. 1 MΩ
– POIL (female) (2) and chassis ground
Wiring harness between ENG (female) (13)
Resistance Min. 1 MΩ
– POIL (female) (3) and chassis ground

40-166 ➁ WA500-6
TROUBLESHOOTING CA135

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
– POIL (female) (1) and between ENG Resistance Min. 1 MΩ
Short circuit in wiring (female) (47) – POIL (female) (2)
5 harness (with another wiring Wiring harness between ENG (female) (37)
Possible causes harness) – POIL (female) (1) and between ENG Resistance Min. 1 MΩ
and standard (female) (13) – POIL (female) (3)
value in normal
Wiring harness between ENG (female) (47)
state
– POIL (female) (2) and between ENG Resistance Min. 1 MΩ
(female) (13) – POIL (female) (3)
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
6 Defective engine controller ENG Voltage
Between
Power supply 4.75 – 5.25 V
(37) and (47)

Related Circuit Diagram

WA500-6 40-167 ➁
TROUBLESHOOTING CA141

CA141
Engine Oil Pressure Sensor Low Error
Action Code Failure Code Engine oil pressure sensor low error
Trouble
E01 CA141 (Engine controller system)
Contents of
• Engine oil pressure sensor circuit is abnormally low.
trouble
Action of
• Sets engine oil pressure to default (250 kPa [36 psi]), and continues operation.
controller
Problem that
appears on —
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200 ENG OIL PRESS).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
function (Code: 37201 ENG OIL PRESS).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA135].
value in normal
state

40-168 ➁ WA500-6
TROUBLESHOOTING CA141

MEMORANDUM

WA500-6 40-169 ➁
TROUBLESHOOTING CA144

CA144
Coolant Temperature Sensor High Error
Action Code Failure Code Coolant temperature sensor high error
Trouble
E01 CA144 (Engine controller system)
Contents of
• Coolant temperature sensor circuit is abnormally high.
trouble
Action of
• Sets coolant temperature to fixed value (90°C [194°F]) and continues operation.
controller
Problem that
appears on —
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the monitoring
function (Code: 04104 COOLANT TEMP).
Related
• The input state (voltage) from the coolant temperature sensor can be checked with the monitoring
information
function (Code: 04105 COOLANT TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective coolant
1 temperature sensor
(Internal defect)
Disconnection in wiring
harness
Possible causes 2 (Disconnection in wiring or
and standard defective contact in
connector)
value in normal
state
Ground fault in wiring
harness
3
(Short circuit with GND
circuit)
Defective engine
4 ENG (female)
controller
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
TWTR (male) Coolant temperature Resistance
10 – 100°C
Between (A) and (B) 0.6 – 20 kΩ
(50 – 212°F)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between ENG (female) (15) –
Resistance Max. 1 Ω
TWTR (female) (A)
Wiring harness between ENG (female) (38) –
Resistance Max. 1 Ω
TWTR (female) (B)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between ENG (female) (15) –
Resistance Min. 1 MΩ
TWTR (female) (A) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Coolant temperature Resistance
Between 10 – 100°C
0.6 – 20 kΩ
(15) and (38) (50 – 212°F)

40-170 ➁ WA500-6
TROUBLESHOOTING CA144
Related Circuit Diagram

WA500-6 40-171 ➁
TROUBLESHOOTING CA145

CA145
Coolant Temperature Sensor Low Error
Action Code Failure Code Coolant temperature sensor low error
Trouble
E01 CA145 (Engine controller system)
Contents of
• Coolant temperature sensor circuit is abnormally low.
trouble
Action of
• Sets coolant temperature to fixed value (90°C [194°F]) and continues operation.
controller
Problem that
appears on —
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the monitoring
function (Code: 04104 COOLANT TEMP).
Related
• The input state (voltage) from the coolant temperature sensor can be checked with the monitoring
information
function (Code: 04105 COOLANT TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA144].
value in normal
state

40-172 ➁ WA500-6
TROUBLESHOOTING CA145

MEMORANDUM

WA500-6 40-173 ➁
TROUBLESHOOTING CA153

CA153
Charge Temperature Sensor High Error
Action Code Failure Code Charge temperature sensor high error
Trouble
E01 CA153 (Engine controller system)
Contents of
• Charge temperature sensor (boost temperature sensor) circuit is abnormally high.
trouble
Action of
• Sets charge temperature (boost temperature) to fixed value (70°C [158°F]) and continues operation.
controller
Problem that
appears on —
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can be
checked with the monitoring function (Code: 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: 18501 CHG TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective charge Charge temperature
TIM (male) Resistance
temperature sensor (boost (Boost temperature)
1
temperature sensor) 10 – 100°C
(Internal defect) Between (A) and (B) 0.5 – 20 kΩ
(50 – 212°F)
Between (A) and
In all range Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting without
Disconnection in wiring turning starting switch ON.
harness
Possible causes Wiring harness between ENG (female) (23) –
2 (Disconnection in wiring or Resistance Max. 1 Ω
and standard TIM (female) (A)
defective contact in
value in normal connector) Wiring harness between ENG (female) (47) –
state Resistance Max. 1 Ω
TIM (female) (B)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting without
harness turning starting switch ON.
3
(Short circuit with GND Wiring harness between ENG (female) (23) –
circuit) Resistance Min. 1 MΩ
TIM (female) (A) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Charge temperature
4 Defective engine controller ENG (female) Resistance
(Boost temperature)
Between 10 – 100°C
0.5 – 20 kΩ
(23) and (47) (50 – 212°F)

40-174 ➁ WA500-6
TROUBLESHOOTING CA153
Related Circuit Diagram

WA500-6 40-175 ➁
TROUBLESHOOTING CA154

CA154
Charge Temperature Sensor Low Error
Action Code Failure Code Charge temperature sensor low error
Trouble
E01 CA154 (Engine controller system)
Contents of
• Charge temperature sensor (boost temperature sensor) circuit is abnormally low.
trouble
Action of
• Sets charge temperature (boost temperature) to fixed value (70°C [158°F]) and continues operation.
controller
Problem that
appears on —
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can be
checked with the monitoring function (Code: 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: 18501 CHG TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA153].
value in normal
state

40-176 ➁ WA500-6
TROUBLESHOOTING CA187

CA187
Sensor Power Supply 2 Low Error

Action Code Failure Code Sensor power supply 2 voltage low error
Trouble
E03 CA187 (Engine controller system)
Contents of
• Sensor power supply 2 (5 V) circuit is abnormally low.
trouble
• Bkup speed sensor operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa [36.26 psi]) and continues
operation.
• Atmospheric pressure sensor sets atmospheric pressure to default (52.44 kPa [7.61 psi]) and continues
operation.
Action of • Charge pressure sensor sets charge pressure to fixed value (400 kPa [58.02 psi]) and continues
controller operation.
• EGR inlet pressure sensor sets EGR inlet pressure to default (102 kPa [14.79 psi]) and limits output to
continue operation.
• EGR valve lift sensor limits output and closes EGR and bypass valves.
• Bypass valve lift sensor limits output and closes EGR and bypass valves.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA227].
value in normal
state

WA500-6 40-177 ➁
TROUBLESHOOTING CA221

CA221
Atmospheric Pressure Sensor High Error
Action Code Failure Code Atmospheric pressure sensor high error
Trouble
E01 CA221 (Engine controller system)
Contents of
• Atmospheric pressure sensor circuit is abnormally high.
trouble
Action of
• Sets atmospheric pressure to default (52.44 kPa [7.61 psi]) and continues operation.
controller
Problem that
appears on • Engine output drops.
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with the
monitoring function (Code: 37400 AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: 37402 AMBIENT PRESS).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective power supply
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting
1 system of atmospheric
for it first.
pressure sensor
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
PAMB Voltage
Defective atmospheric
Between (1) and (3) Power supply 4.75 – 5.25 V
2 pressure sensor
(Internal defect) Between (2) and (3) Signal 0.3 – 4.7 V
Sensor voltage is measured with wiring harness connected. If voltage is
abnormal, check wiring harness and controller for another cause of the
problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring Wiring harness between ENG (female) (37) –
value in normal harness Resistance Max. 1 Ω
state PAMB (female) (1)
3 (Disconnection in wiring or
Wiring harness between ENG (female) (38) –
defective contact in Resistance Max. 1 Ω
connector) PAMB (female) (2)
Wiring harness between ENG (female) (3) –
Resistance Max. 1 Ω
PAMB (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring Wiring harness between ENG (female) (37) –
Resistance Min. 1 MΩ
harness PAMB (female) (1) and chassis ground
4
(Short circuit with GND Wiring harness between ENG (female) (38) –
circuit) Resistance Min. 1 MΩ
PAMB (female) (2) and chassis ground
Wiring harness between ENG (female) (3) –
Resistance Min. 1 MΩ
PAMB (female) (3) and chassis ground

40-178 ➁ WA500-6
TROUBLESHOOTING CA221

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) –
PAMB (female) (1) and between ENG Resistance Min. 1 MΩ
Short circuit in wiring (female) (38) – PAMB (female) (2)
5 harness (with another wiring Wiring harness between ENG (female) (37) –
harness) PAMB (female) (1) and between ENG Resistance Min. 1 MΩ
Possible causes
(female) (3) – PAMB (female) (3)
and standard
value in normal Wiring harness between ENG (female) (38) –
state PAMB (female) (2) and between ENG Resistance Min. 1 MΩ
(female) (3) – PAMB (female) (3)
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
6 Defective engine controller ENG Voltage
Between (37) and (38) 4.75 – 5.25 V
Between (3) and (38) 0.3 – 4.7 V

Related Circuit Diagram

WA500-6 40-179 ➁
TROUBLESHOOTING CA222

CA222
Atmospheric Pressure Sensor Low Error
Action Code Failure Code Atmospheric pressure sensor low error
Trouble
E01 CA222 (Engine controller system)
Contents of
• Atmospheric pressure sensor circuit is abnormally low.
trouble
Action of
• Sets atmospheric pressure to default (52.44 kPa [7.61 psi]), and continues operation.
controller
Problem that
appears on • Engine output drops.
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with the
monitoring function (Code: 37400 AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: 37402 AMBIENT PRESS).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA221].
value in normal
state

40-180 ➁ WA500-6
TROUBLESHOOTING CA222

MEMORANDUM

WA500-6 40-181 ➁
TROUBLESHOOTING CA227

CA227
Sensor Power Supply 2 High Error
Action Code Failure Code Sensor power supply 2 high error
Trouble
E03 CA227 (Engine controller system)
Contents of
• Sensor power supply 2 (5 V) circuit is abnormally high.
trouble
• Bkup speed sensor operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa [36.26 psi]) and continues
operation.
• Atmospheric pressure sensor sets atmospheric pressure to default (52.44 kPa [7.61 psi]) and
continues operation.
Action of
• Charge pressure sensor (boost pressure sensor) sets charge pressure to fixed value (400 kPa
controller
[58.02 psi]) and continues operation.
• EGR inlet pressure sensor sets EGR inlet pressure to default (102 kPa [14.79 psi]) and limits
output to continue operation.
• EGR and bypass valve lift sensors limit output and close EGR and bypass valves.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Bkup speed sensor
G connector
system
Oil pressure sensor POIL connector
Disconnect device Charge pressure sensor PIM connector
Defective sensor suggested on the
2 Atmospheric pressure
(Internal defect) right. At this time, if PAMB connector
sensor
failure code is not
indicated, the device EGR inlet pressure
PEVA connector
is defective. sensor
Possible causes EGR valve lift sensor SEGR connector
and standard Bypass valve position
value in normal SBP connector
sensor
state
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENG (female) (37) –
3 (Disconnection in wiring or Resistance Max. 1 Ω
each sensor (female)
defective contact in
connector) Wiring harness between ENG (female) (47) –
Resistance Max. 1 Ω
each sensor (female)
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
harness Wiring harness between ENG (female) (37) –
4 Resistance Min. 1 MΩ
(Short circuit with GND each sensor (female) and chassis ground
circuit)
Wiring harness between ENG (female) (47) –
Resistance Min. 1 MΩ
each sensor (female) and chassis ground

40-182 ➁ WA500-6
TROUBLESHOOTING CA227

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
5 harness (with another wiring Wiring harness between ENG (female) (37) –
Possible causes harness) each sensor (female) and between ENG Resistance Min. 1 MΩ
and standard (female) (47) – each sensor (female)
value in normal
state
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective engine controller
ENG Voltage
Between (37) and (47) 4.75 – 5.25 V

Related Circuit Diagram

WA500-6 40-183 ➁
TROUBLESHOOTING CA234

CA234
Engine Overspeed
Action Code Failure Code Engine overspeed
Trouble
E02 CA234 (Engine controller system)
Contents of
• Engine speed exceeded operating range.
trouble
Action of • Reduces fuel injection rate until engine speed lowers to operating range.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine speed changes.
machine
Related • Engine speed can be checked by monitoring function (Code: 01002 ENG SPEED).
information • Method of reproducing failure code: Start engine and keep running at high idle.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
Possible causes Improper use of the machine. Instruct the operator on how to use the
2 Usage is improper.
and standard machine properly.
value in normal If causes 1 and 2 are not the cause of the problem, the engine controller
state 3 Defective engine controller may be defective. (Since problem is in system, troubleshooting cannot be
carried out.)

40-184 ➁ WA500-6
TROUBLESHOOTING CA234

MEMORANDUM

WA500-6 40-185 ➁
TROUBLESHOOTING CA238

CA238
Ne Speed Sensor Power Supply Error
Action Code Failure Code Ne speed sensor power supply error
Trouble
E03 CA238 (Engine controller system)
Contents of
• Error occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of • Controls with signal from Bkup speed sensor.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine stops during operations (when engine Bkup speed sensor is also defective).
appears on
machine • Engine cannot be started during operations (when engine Bkup speed sensor is also defective).

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective Ne speed sensor Disconnect device

1 suggested on the right. At
(Internal defect)
this time, if failure code is Ne speed sensor NE connector
not indicated, the device
is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENGINE (female) (16)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– NE (female) (1)
defective contact in
connector) Wiring harness between ENGINE (female) (48)
Resistance Max. 1 Ω
– NE (female) (2)
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Ground fault in wiring without turning starting switch ON.
state harness Wiring harness between ENG (female) (16) –
3 Resistance Min. 1 MΩ
(Short circuit with GND NE (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (48) –
Resistance Min. 1 MΩ
NE (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness (with another wiring Wiring harness between ENG (female) (16) –
harness) NE (female) (1) and between ENG (female) (48) Resistance Min. 1 MΩ
– NE (female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective engine controller
ENG Voltage
Between (16) and (48) 4.75 – 5.25 V

40-186 ➁ WA500-6
TROUBLESHOOTING CA238
Related Circuit Diagram

WA500-6 40-187 ➁
TROUBLESHOOTING CA263

CA263
Fuel Temperature Sensor High Error
Action Code Failure Code Fuel temperature sensor high error
Trouble
E01 CA263 (Engine controller system)
Contents of
• Fuel temperature sensor circuit is abnormally high.
trouble
Action of
• Sets fuel temperature to fixed value (95°C [203°F]), and continues operation.
controller
Problem that
appears on —
machine
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204 FUEL TEMP).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring function
information
(Code: 14201 FUEL TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fuel temperature
1 TFUEL (male) Fuel temperature Resistance
sensor (Internal defect)
10 – 100°C
Between (A) and (B) 0.6 – 20 kΩ
(50 – 212°F)
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENG (female) (30) –
2 (Disconnection in wiring or Resistance Max. 1 Ω
Possible causes TFUEL (female) (A)
defective contact in
and standard connector) Wiring harness between ENG (female) (47) –
Resistance Max. 1 Ω
value in normal TFUEL (female) (B)
state
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
harness Wiring harness between ENG (female) (30) –
3 Resistance Min. 1 MΩ
(Short circuit with GND TFUEL (female) (A) and chassis ground
circuit)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Fuel temperature Resistance
4 Defective engine controller Between 10 – 100°C
0.6 – 20 kΩ
(30) and (47) (50 – 212°F)

40-188 ➁ WA500-6
TROUBLESHOOTING CA263
Related Circuit Diagram

WA500-6 40-189 ➁
TROUBLESHOOTING CA265

CA265
Fuel Temperature Sensor Low Error
Action Code Failure Code Fuel temperature sensor low error
Trouble
E01 CA265 (Engine controller system)
Contents of
• Fuel temperature sensor circuit is abnormally low.
trouble
Action of
• Sets fuel temperature to fixed value (95°C [203°F]) and continues operation.
controller
Problem that
appears on —
machine
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204 FUEL TEMP).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring function
information
(Code: 14201 FUEL TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA263].
value in normal
state

40-190 ➁ WA500-6
TROUBLESHOOTING CA265

MEMORANDUM

WA500-6 40-191 ➁
TROUBLESHOOTING CA271

CA271
PCV1 Short Circuit
Action Code Failure Code PCV1 short circuit
Trouble
E03 CA271 (Engine controller system)
Contents of
• Short circuit was detected in supply pump PCV1 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective supply pump
1 PCV1
(Internal short circuit)
Grounding fault in wiring
2 harness
(Contact with ground circuit)
Possible causes
and standard
value in normal
state
Hot short in wiring harness
3 Voltage
(Contact with 24 V circuit)
4 Defective engine controller
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
PCV1 (male) Resistance
Between (1) and (2) 2.3 – 5.3 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (4) –
Resistance Min. 1 MΩ
PCV1 (female) (1) and chassis ground
Wiring harness between ENG (female) (5) –
Resistance Min. 1 MΩ
PCV1 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting
Wiring harness between ENG (female) (4) –
Max. 1 V
PCV1 (female) (1) and chassis ground
Wiring harness between ENG (female) (5) –
Voltage Max. 1 V
PCV1 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
Between (4) and (5) 2.3 – 5.3 Ω
Between (4), (5) and
Min. 1 MΩ
chassis ground

40-192 ➁ WA500-6
TROUBLESHOOTING CA271
Related Circuit Diagram

WA500-6 40-193 ➁
TROUBLESHOOTING CA272

CA272
PCV1 Disconnection
Action Code Failure Code PCV1 disconnection
Trouble
E03 CA272 (Engine controller system)
Contents of
• Disconnection was detected in supply pump PCV1 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective supply pump
1 PCV1
(Internal disconnection)
Disconnection in wiring
harness
2 Resistance
(Disconnection or defective
contact of connector)
Possible causes
and standard
value in normal
state
Grounding fault in wiring
3 harness
(Contact with ground circuit)
4 Defective engine controller
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
PCV1 (male) Resistance
Between (1) and (2) 2.3 – 5.3 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (4) –
Max. 1 Ω
PCV1 (female) (1)
Wiring harness between ENG (female) (5) –
Resistance Max. 1 Ω
PCV1 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (4) –
Resistance Min. 1 MΩ
PCV1 (female) (1) and chassis ground
Wiring harness between ENG (female) (5) –
Resistance Min. 1 MΩ
PCV1 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
Between (4) and (5) 2.3 – 5.3 Ω
Between (4), (5) and
Min. 1 MΩ
chassis ground

40-194 ➁ WA500-6
TROUBLESHOOTING CA272
Related Circuit Diagram

WA500-6 40-195 ➁
TROUBLESHOOTING CA273

CA273
PCV2 Short Circuit
Action Code Failure Code PCV2 short circuit
Trouble
E03 CA273 (Engine controller system)
Contents of
• Short circuit was detected in supply pump PCV2 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective supply pump
1 PCV2
(Internal short circuit)
Grounding fault in wiring
2 harness
(Contact with ground circuit)
Possible causes
and standard
value in normal
state
Hot short in wiring harness
3 Voltage
(Contact with 24 V circuit)
4 Defective engine controller
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
PCV2 (male) Resistance
Between (1) and (2) 2.3 – 5.3 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (9) –
Resistance Min. 1 MΩ
PCV2 (female) (1) and chassis ground
Wiring harness between ENG (female) (10)
Resistance Min. 1 MΩ
– PCV2 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting
Wiring harness between ENG (female) (9) –
Max. 1 V
PCV2 (female) (1) and chassis ground
Wiring harness between ENG (female) (10)
Voltage Max. 1 V
– PCV2 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
Between (9) and (10) 2.3 – 5.3 Ω
Between (9), (10) and
Min. 1 MΩ
chassis ground

40-196 ➁ WA500-6
TROUBLESHOOTING CA273
Related Circuit Diagram

WA500-6 40-197 ➁
TROUBLESHOOTING CA274

CA274
PCV2 Disconnection
Action Code Failure Code PCV2 disconnection
Trouble
E03 CA274 (Engine controller system)
Contents of
• Disconnection was detected in supply pump PCV2 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective supply pump
1 PCV2
(Internal disconnection)
Disconnection in wiring
harness
2 Resistance
(Disconnection or defective
contact of connector)
Possible causes
and standard
value in normal
state Grounding fault in wiring
3 harness
(Contact with ground circuit)
4 Defective engine controller
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
PCV2 (male) Resistance
Between (1) and (2) 2.3 – 5.3 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (9) –
Max. 1 Ω
PCV2 (female) (1)
Wiring harness between ENG (female) (10)
Resistance Max. 1 Ω
– PCV2 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (9) –
Resistance Min. 1 MΩ
PCV2 (female) (1) and chassis ground
Wiring harness between ENG (female) (10)
Resistance Min. 1 MΩ
– PCV2 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
Between (9) and (10) 2.3 – 5.3 Ω
Between (9), (10) and
Min. 1 MΩ
chassis ground

40-198 ➁ WA500-6
TROUBLESHOOTING CA274
Related Circuit Diagram

WA500-6 40-199 ➁
TROUBLESHOOTING CA322

CA322
Injector #1 (L/B #1) Open/Short Error
Action Code Failure Code Injector #1 (L/B #1) open/short error
Trouble
E03 CA322 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #1 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
machine • Speed does not become stable.

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #1 CN1 (male) Resistance
1
(Internal defect) Between (1) and (2) 0.4 – 1.1 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENG (female) (45) –
2 (Disconnection in wiring or Resistance Max. 1 Ω
CN1 (female) (1)
defective contact in
Possible causes connector) Wiring harness between ENG (female) (53) –
Resistance Max. 1 Ω
and standard CN1 (female) (2)
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Ground fault in wiring
harness Wiring harness between ENG (female) (45) –
3 Resistance Min. 1 MΩ
(Short circuit with GND CN1 (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (53) –
Resistance Min. 1 MΩ
CN1 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (45) and (53) 0.4 – 1.1 Ω
Between (45), (53) and
Min. 1 MΩ
chassis ground

40-200 ➁ WA500-6
TROUBLESHOOTING CA322
Related Circuit Diagram

WA500-6 40-201 ➁
TROUBLESHOOTING CA323

CA323
Injector #5 (L/B #5) Open/Short Error
Action Code Failure Code Injector #5 (L/B #5) open/short error
Trouble
E03 CA323 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #5 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
machine • Speed does not become stable.

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #5 CN5 (male) Resistance
1
(Internal defect) Between (1) and (2) 0.4 – 1.1 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENG (female) (46)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– CN5 (female) (1)
defective contact in
Possible causes connector) Wiring harness between ENG (female) (60)
Resistance Max. 1 Ω
and standard – CN5 (female) (2)
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Ground fault in wiring
harness Wiring harness between ENG (female) (46)
3 Resistance Min. 1 MΩ
(Short circuit with GND – CN5 (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (60)
Resistance Min. 1 MΩ
– CN5 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (46) and (60) 0.4 – 1.1 Ω
Between (46), (60) and
Min. 1 MΩ
chassis ground

40-202 ➁ WA500-6
TROUBLESHOOTING CA323
Related Circuit Diagram

WA500-6 40-203 ➁
TROUBLESHOOTING CA324

CA324
Injector #3 (L/B #3) Open/Short Error
Action Code Failure Code Injector #3 (L/B #3) open/short error
Trouble
E03 CA324 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #3 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
machine • Speed does not become stable.

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #3 CN3 (male) Resistance
1
(Internal defect) Between (1) and (2) 0.4 – 1.1 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENG (female) (55)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– CN3 (female) (1)
defective contact in
Possible causes connector) Wiring harness between ENG (female) (52)
Resistance Max. 1 Ω
and standard – CN3 (female) (2)
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Ground fault in wiring
harness Wiring harness between ENG (female) (55)
3 Resistance Min. 1 MΩ
(Short circuit with GND – CN3 (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (52)
Resistance Min. 1 MΩ
– CN3 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (55) and (52) 0.4 – 1.1 Ω
Between (55), (52) and
Min. 1 MΩ
chassis ground

40-204 ➁ WA500-6
TROUBLESHOOTING CA324
Related Circuit Diagram

WA500-6 40-205 ➁
TROUBLESHOOTING CA325

CA325
Injector #6 (L/B #6) Open/Short Error
Action Code Failure Code Injector #6 (L/B #6) open/short error
Trouble
E03 CA325 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #6 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
machine • Speed does not become stable.

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #6 CN6 (male) Resistance
1
(Internal defect) Between (1) and (2) 0.4 – 1.1 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENG (female) (57)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– CN6 (female) (1)
defective contact in
Possible causes connector) Wiring harness between ENG (female) (59)
Resistance Max. 1 Ω
and standard – CN6 (female) (2)
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Ground fault in wiring
harness Wiring harness between ENG (female) (57)
3 Resistance Min. 1 MΩ
(Short circuit with GND – CN6 (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (59)
Resistance Min. 1 MΩ
– CN6 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (57) and (59) 0.4 – 1.1 Ω
Between (57), (59) and
Min. 1 MΩ
chassis ground

40-206 ➁ WA500-6
TROUBLESHOOTING CA325
Related Circuit Diagram

WA500-6 40-207 ➁
TROUBLESHOOTING CA331

CA331
Injector #2 (L/B #2) Open/Short Error
Action Code Failure Code Injector #2 (L/B #2) open/short error
Trouble
E03 CA331 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #2 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
machine • Speed does not become stable.

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #2 CN2 (male) Resistance
1
(Internal defect) Between (1) and (2) 0.4 – 1.1 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENG (female) (54)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– CN2 (female) (1)
defective contact in
Possible causes connector) Wiring harness between ENG (female) (51)
Resistance Max. 1 Ω
and standard – CN2 (female) (2)
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Ground fault in wiring
harness Wiring harness between ENG (female) (54)
3 Resistance Min. 1 MΩ
(Short circuit with GND – CN2 (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (51)
Resistance Min. 1 MΩ
– CN2 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (54) and (51) 0.4 – 1.1 Ω
Between (54), (51) and
Min. 1 MΩ
chassis ground

40-208 ➁ WA500-6
TROUBLESHOOTING CA331
Related Circuit Diagram

WA500-6 40-209 ➁
TROUBLESHOOTING CA332

CA332
Injector #4 (L/B #4) Open/Short Error
Action Code Failure Code Injector #4 (L/B #4) open/short error
Trouble
E03 CA332 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #4 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
machine • Speed does not become stable.

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #4 CN4 (male) Resistance
1
(Internal defect) Between (1) and (2) 0.4 – 1.1 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENG (female) (56)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– CN4 (female) (1)
defective contact in
Possible causes connector) Wiring harness between ENG (female) (58)
Resistance Max. 1 Ω
and standard – CN4 (female) (2)
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Ground fault in wiring
harness Wiring harness between ENG (female) (56)
3 Resistance Min. 1 MΩ
(Short circuit with GND – CN4 (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (58)
Resistance Min. 1 MΩ
– CN4 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (56) and (58) 0.4 – 1.1 Ω
Between (56), (58) and
Min. 1 MΩ
chassis ground

40-210 ➁ WA500-6
TROUBLESHOOTING CA332
Related Circuit Diagram

WA500-6 40-211 ➁
TROUBLESHOOTING CA342

CA342
Calibration Code Data Inconsistency
Action Code Failure Code Engine controller data inconsistency
Trouble
E03 CA342 (Engine controller system)
Contents of
• Data inconsistency occurred in engine controller.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in stopped
appears on
state.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA111].
value in normal
state

40-212 ➁ WA500-6
TROUBLESHOOTING CA351

CA351
Injectors Drive Circuit Error
Action Code Failure Code Injector drive circuit error
Trouble
E03 CA351 (Engine controller system)
Contents of
• Error was detected in injector drive circuit.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 3 of fuse If the fuse is burnt, the circuit probably has a grounding fault.
1
box A (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L117 (male) Resistance
Defective engine control cut
Between (1) and (2) 200 – 400 Ω
relay 1 (L117)
2
(Internal disconnection or ★ Prepare with starting switch OFF, then turn starting switch ON and
short circuit) carry out troubleshooting.
If engine control cut relay 1 (L117) is replaced with a relay of the same
type and the condition becomes normal, engine control cut relay 1 is
defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard
L119 (male) Resistance
value in normal Defective engine control cut
state Between (1) and (2) 200 – 400 Ω
relay 2 (L119)
3
(Internal disconnection or ★ Prepare with starting switch OFF, then turn starting switch ON and
short circuit) carry out troubleshooting.
If engine control cut relay 2 (L119) is replaced with a relay of the same
type and the condition becomes normal, engine control cut relay 2 is
defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
D01 (male) Diode range Continuity
Defective diode (D01)
4 Measure at (1) in
(Internal disconnection) Between (1) and (2)
diode range.
Continue
Measure at (3) in
Between (3) and (2)
diode range.

WA500-6 40-213 ➁
TROUBLESHOOTING CA351

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between LS4 (female) (2) –
Resistance Max. 1 Ω
D01 (female) (1)
Wiring harness between D01 (female) (2) –
Resistance Max. 1 Ω
L117 (female) (1), – L119 (female) (1)
Disconnection in wiring Wiring harness between L117 (female) (2), –
Resistance Max. 1 Ω
harness L119 (female) (2) – E18 (female) (33)
5 (Disconnection in wiring or Wiring harness between fuse No. 3 of
defective contact in fuse box A – L117 (female) (5), – L119 Resistance Max. 1 Ω
connector) (female) (5)
Wiring harness between L117 (female) (3) –
Resistance Max. 1 Ω
E19 (female) (3)
Wiring harness between L119 (female) (3) –
Resistance Max. 1 Ω
E19 (female) (4)
Wiring harness between E19 (female) (1),
Resistance Max. 1 Ω
(2) – chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between LS4 (female) (2) –
state Resistance Min. 1 MΩ
D01 (female) (1) and chassis ground
Wiring harness between D01 (female) (2) –
L117 (female) (1), – L119 (female) (1) and Resistance Min. 1 MΩ
chassis ground
Ground fault in wiring
Wiring harness between L117 (female) (2), –
harness
6 L119 (female) (2) – E18 (female) (33) and Resistance Min. 1 MΩ
(Short circuit with GND
chassis ground
circuit)
Wiring harness between fuse No. 3 of
fuse box A – L117 (female) (5), – L119 Resistance Min. 1 MΩ
(female) (5) and chassis ground
Wiring harness between L117 (female) (3) –
Resistance Min. 1 MΩ
E19 (female) (3) and chassis ground
Wiring harness between L119 (female) (3) –
Resistance Min. 1 MΩ
E19 (female) (4) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
7 Defective engine controller
E19 Voltage
Between (1), (2) – (3), (4) 20 – 30 V

40-214 ➁ WA500-6
TROUBLESHOOTING CA351
Related Circuit Diagram

WA500-6 40-215 ➁
TROUBLESHOOTING CA352

CA352
Sensor Power Supply 1 Low Error
Action Code Failure Code Sensor power supply 1 low error
Trouble
E03 CA352 (Engine controller system)
Contents of
• Sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of • Common rail pressure sensor: Limits output for travel (limits common rail pressure).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA386].
value in normal
state

40-216 ➁ WA500-6
TROUBLESHOOTING CA352

MEMORANDUM

WA500-6 40-217 ➁
TROUBLESHOOTING CA386

CA386
Sensor Power Supply 1 High Error
Action Code Failure Code Sensor power supply 1 high error
Trouble
E03 CA386 (Engine controller system)
Contents of
• Sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of • Common rail pressure sensor: Limits output for travel (limits common rail pressure).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.

Defective sensor Disconnect device

2 suggested on the right. At
(Internal defect) Common rail
this time, if failure code is PFUEL
pressure sensor
not indicated, the device
is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between ENG (female) (33) –
3 (Disconnection in wiring or Resistance Max. 1 Ω
PFUEL (female) (1)
defective contact in
connector) Wiring harness between ENG (female) (47) –
Resistance Max. 1 Ω
Possible causes PFUEL (female) (3)
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Ground fault in wiring
harness Wiring harness between ENG (female) (33) –
4 Resistance Min. 1 MΩ
(Short circuit with GND PFUEL (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (47) –
Resistance Min. 1 MΩ
PFUEL (female) (3) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
5 harness (with another wiring Wiring harness between ENG (female) (33) –
harness) PFUEL (female) (1) and between ENG (female) Resistance Min. 1 MΩ
(47) – PFUEL (female) (3)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective engine controller
ENG Voltage
Between (33) and (47) 4.75 – 5.25 V

40-218 ➁ WA500-6
TROUBLESHOOTING CA386
Related Circuit Diagram

WA500-6 40-219 ➁
TROUBLESHOOTING CA431

CA431
Idle Validation Switch Error
Action Code Failure Code Idle validation switch error
Trouble
E01 CA431 (Engine controller system)
Contents of
• Error was detected 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 function
(Code: 18300 IVS 1).
Related
• The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring function
information
(Code: 18301 IVS 2).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L15 Signal name Voltage
Defective accelerator pedal Between (5) and (4) Signal 1 See Figure 1 on next
1
(Internal defect) page.
Between (6) and (4) Signal 2
Sensor voltage is measured with wiring harness connected. If voltage is
abnormal, check wiring harness and controller for another cause of the
problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between E18 (female) (32) –
harness Resistance Max. 1 Ω
L15 (female) (4)
2 (Disconnection in wiring or
Wiring harness between E18 (female) (11) –
defective contact in Resistance Max. 1 Ω
connector) L15 (female) (5)
Possible causes Wiring harness between E18 (female) (1) –
Resistance Max. 1 Ω
and standard L15 (female) (6)
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting
state
without turning starting switch ON.
Ground fault in wiring Wiring harness between E18 (female) (32) –
Resistance Min. 1 MΩ
harness L15 (female) (4) and chassis ground
3
(Short circuit with GND Wiring harness between E18 (female) (11) –
circuit) Resistance Min. 1 MΩ
L15 (female) (5) and chassis ground
Wiring harness between E18 (female) (1) –
Resistance Min. 1 MΩ
L15 (female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between E18 (female) (32) –
Voltage Max. 1 V
Hot short in wiring harness L15 (female) (4) and chassis ground
4
(Contact with 24 V circuit) Wiring harness between E18 (female) (11) –
Voltage Max. 1 V
L15 (female) (5) and chassis ground
Wiring harness between E18 (female) (1) –
Voltage Max. 1 V
L15 (female) (6) and chassis ground

40-220 ➁ WA500-6
TROUBLESHOOTING CA431

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Possible causes
and standard E18 Signal name Voltage
5 Defective engine controller
value in normal Between
state Signal 1 See Figure 1 on this
(11) and (32)
page.
Between (1) and (32) Signal 2

Related Circuit Diagram

WA500-6 40-221 ➁
TROUBLESHOOTING CA432

CA432
Idle Validation Action Error
Action Code Failure Code Idle validation action error
Trouble
E03 CA432 (Engine controller system)
Contents of
• Signals disagree between idle validation switch and throttle sensor (inconsistent).
trouble
• 1) Idle validation switch with accelerator pedal OFF, throttle sensor with accelerator pedal ON: Control
the position of throttle to 0% when accelerator pedal is OFF and to 50% when it is ON.
Action of
• 2) Idle validation switch with accelerator pedal ON, throttle sensor with accelerator pedal OFF: Control
controller
the position of throttle to 0% (fix to low idle).
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring function
(Code: 18300 IVS 1).
Related
• The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring function
information
(Code: 18301 IVS 2).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA431].
value in normal
state

40-222 ➁ WA500-6
TROUBLESHOOTING CA441

CA441
Battery Voltage Low Error
Action Code Failure Code Battery voltage low error
Trouble
E03 CA441 (Engine controller system)
Contents of
• Low voltage was detected in battery voltage circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in stopped
appears on
state.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA111].
value in normal
state

WA500-6 40-223 ➁
TROUBLESHOOTING CA442

CA442
Battery Voltage High Error
Action Code Failure Code Battery voltage high error
Trouble
E03 CA442 (Engine controller system)
Contents of
• High voltage was detected in battery voltage circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in stopped
appears on
state.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA111].
value in normal
state

40-224 ➁ WA500-6
TROUBLESHOOTING CA449

CA449
Common Rail Pressure High Error 2
Action Code Failure Code Common rail pressure high error 2
Trouble
E03 CA449 (Engine controller system)
Contents of
• There is high pressure error (level 2) in common rail pressure sensor circuit.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the
monitoring function (Code: 36400 RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402 RAIL PRESS).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA553].
value in normal
state

WA500-6 40-225 ➁
TROUBLESHOOTING CA451

CA451
Common Rail Pressure Sensor High Error
Action Code Failure Code Common rail pressure sensor high error
Trouble
E03 CA451 (Engine controller system)
Contents of
• Common rail pressure sensor circuit is abnormally high.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the
monitoring function (Code: 36400 RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402 RAIL PRESS).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective common rail
If failure code [CA352] or [CA386] is also indicated, carry out
1 pressure sensor power
troubleshooting for it first.
system
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
PFUEL Voltage
Defective common rail
Between (1) and (3) Power supply 4.75 – 5.25 V
2 pressure sensor
(Internal defect) Between (2) and (3) Signal 0.25 – 4.6 V
Sensor voltage is measured with wiring harness connected. If voltage is
abnormal, check wiring harness and controller for another cause of the
problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring Wiring harness between ENG (female) (33) –
value in normal harness Resistance Max. 1 Ω
state PFUEL (female) (1)
3 (Disconnection in wiring or
Wiring harness between ENG (female) (25) –
defective contact in Resistance Max. 1 Ω
connector) PFUEL (female) (2)
Wiring harness between ENG (female) (47) –
Resistance Max. 1 Ω
PFUEL (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring Wiring harness between ENG (female) (33) –
Resistance Min. 1 MΩ
harness PFUEL (female) (1) and chassis ground
4
(Short circuit with GND Wiring harness between ENG (female) (25) –
circuit) Resistance Min. 1 MΩ
PFUEL (female) (2) and chassis ground
Wiring harness between ENG (female) (47) –
Resistance Min. 1 MΩ
PFUEL (female) (3) and chassis ground

40-226 ➁ WA500-6
TROUBLESHOOTING CA451

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (33) –
PFUEL (female) (1) and between ENG Resistance Min. 1 MΩ
Short circuit in wiring (female) (25) – PFUEL (female) (2)
5 harness (with another wiring Wiring harness between ENG (female) (33) –
harness) PFUEL (female) (1) and between ENG Resistance Min. 1 MΩ
Possible causes
(female) (47) – PFUEL (female) (3)
and standard
value in normal Wiring harness between ENG (female) (25) –
state PFUEL (female) (2) and between ENG Resistance Min. 1 MΩ
(female) (47) – PFUEL (female) (3)
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
6 Defective engine controller ENG Voltage
Between (33) and (47) 4.75 – 5.25 V
Between (25) and (47) 0.25 – 4.6 V

Related Circuit Diagram

WA500-6 40-227 ➁
TROUBLESHOOTING CA452

CA452
Common Rail Pressure Sensor Low Error
Action Code Failure Code Common rail pressure sensor low error
Trouble
E03 CA452 (Engine controller system)
Contents of
• Common rail pressure sensor circuit is abnormally low.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the
monitoring function (Code: 36400 RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402 RAIL PRESS).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA451].
value in normal
state

40-228 ➁ WA500-6
TROUBLESHOOTING CA553

CA553
Common Rail Pressure High Error 1
Action Code Failure Code Common rail pressure high error 1
Trouble
E03 CA553 (Engine controller system)
Contents of
• There is high pressure error (level 1) in common rail pressure sensor circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on —
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the
monitoring function (Code: 36400 RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402 RAIL PRESS).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
2 Use of improper fuel Fuel used may be improper. Check it directly. (Viscosity is high.)
Defective electrical system of Electrical system of common rail pressure sensor may be defective. Carry
3
common rail pressure sensor out troubleshooting for failure code [CA451].
Possible causes
Defective mechanical system
and standard Mechanical system of common rail pressure sensor may be defective.
4 of common rail pressure
value in normal Check it directly.
sensor
state
Spring damage, seat wear, or overflow valve ball is stuck is suspected.
5 Defective overflow valve
Check it directly.
6 Clogged overflow pipe Overflow pipe may be clogged. Check it directly.
7 Defective pressure limiter Pressure limiter may be damaged mechanically. Check it directly.

WA500-6 40-229 ➁
TROUBLESHOOTING CA554

CA554
Common Rail Pressure In-Range Error
Action Code Failure Code Common rail pressure sensor in-range error
Trouble
E03 CA554 (Engine controller system)
Contents of
• In-range error occurred in common rail pressure sensor circuit.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the
monitoring function (Code: 36400 RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402 RAIL PRESS).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA451].
value in normal
state

40-230 ➁ WA500-6
TROUBLESHOOTING CA554

MEMORANDUM

WA500-6 40-231 ➁
TROUBLESHOOTING CA559

CA559
Supply Pump Pressure Very Low Error 1
Action Code Failure Code Supply pump pressure very low error 1
Trouble
E03 CA559 (Engine controller system)
Contents of
• There is no-pressure feed error (level 1) in supply pump.
trouble
Action of • Limits common rail pressure.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the
Related
monitoring function (Code: 36400 RAIL PRESS).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Use of improper fuel Fuel used may be incorrect. Check it directly.
• For more information on troubleshooting, see Note 1.
• To check pressure in fuel low pressure circuit, see Fuel System:
Defect in low pressure
3 Testing Fuel Pressure in Testing and Adjusting section.
circuit parts
Pressure in fuel low-pressure circuit Min. 0.15 MPa
(high idle or rated load (stall load)) (21.76 psi)
4 Clogged fuel filter, strainer For more information on troubleshooting, see Note 2.
Defective electrical system of Electrical system of supply pump PCV may be defective. Carry out
5
supply pump PCV troubleshooting for failure code [CA271], [CA272], [CA273], or [CA274].
Defective common rail Mechanical system of common rail pressure sensor may be defective.
6
pressure sensor Check whether wiring harness is damaged.
Possible causes For check of leakage through pressure limiter, see FUEL SYSTEM:
and standard Testing Fuel Return Rate and Leakage in Testing and Adjusting section.
value in normal 7 Defective pressure limiter
state Max. 10 cc/min
Leakage through pressure limiter
Rated load (stall load)
For check of limited return rate (spill) from injector, see Fuel System:
Testing Fuel Return Rate and Leakage in Testing and Adjusting section.
Limited return (spill) rate from
Rated load (stall load)
injector

8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
If causes 1 – 8 are not the cause of the problem, supply pump may be
9 Defective supply pump
defective.

Using Checksheet

While carrying out troubleshooting, record troubleshooting results on the Checksheet for No-Pressure Feed.

40-232 ➁ WA500-6
TROUBLESHOOTING CA559
Note 1

When low-pressure circuit is defective, check the following:

• Fuel level
• Clogged fuel tank breather
• Stuck or worn feed pump, clogged filter
• Leaked or clogged low-pressure fuel pipe
• Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
• Clogged fuel filter
• Fuel in oil pan (fuel leakage in head cover)

Figure 1

Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through hole on nut side.
• Fuel inlet joint (3): Gauze filter is seen through both holes.

Note 2

Check, clean, and replace the filters and strainers according to the following procedure.

1. Gauze filter: Disassemble and check. If clogged, clean.

2. Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter also.

3. Fuel filter: If the trouble is not solved by performing Steps 1 and 2, replace the fuel filter.

WA500-6 40-233 ➁
TROUBLESHOOTING CA559

Checksheet for No-Pressure Feed

Machine model Working No.
Model serial No. # Checked on / /
Engine Service meter h
Engine serial No. # Worker name

A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather

B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle rpm 625 ± 5
01002 Engine speed High idle rpm 2,150 ±50
Full stall (P-mode) rpm 1,800 ±100
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
36200 Rating or equivalent MPa
command
4
Common rail fuel
36400 Rating or equivalent MPa
pressure
Low idle CA — — —
Injection timing
36300 High idle CA — — —
command
Rating or equivalent CA — — —
kPa Min. 147
36500 Boost pressure Rating or equivalent — —
(psi) (Min. 21.32)
Engine coolant
04104 Low idle °C — — —
temperature
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Standard value Measured
Function Cut-out cylinder Check conditions Unit Good Bad
(Reference value) value
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
Cylinder
Cylinder 3 Low idle rpm — — —
cut-out
function Cylinder 4 Low idle rpm — — —
Cylinder 5 Low idle rpm — — —
Cylinder 6 Low idle rpm — — —

Standard value Measured

C. Checking fuel circuit pressure Check conditions Unit Good Bad
(Reference value) value
Pressure in fuel low-pressure High idle or rated load (stall MPa Min. 0.15
6
circuit load) (psi) (Min. 21.76)

D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

40-234 ➁ WA500-6
TROUBLESHOOTING CA559

E. Checking leakage and fuel return rate

Standard value Measured
Check conditions Unit Good Bad
(Reference value) value
No load (stall load), full stall,
11 Leakage through pressure limiter cc/min Max. 10
or relief
Rating or equivalent Speed:
cc/min 960
<by model> 1,600 rpm
Rating or equivalent
cc/min 1,020
<by model> 1,700 rpm
Rating or equivalent
12 Return rate from injector cc/min 1,080 Return
<by model> 1,800 rpm
rate:
Rating or equivalent
cc/min 1,140
<by model> 1,900 rpm
Rating or equivalent
cc/min 1,200
<by model> 2,000 rpm

WA500-6 40-235 ➁
TROUBLESHOOTING CA689

CA689
Engine Ne Speed Sensor Error
Action Code Failure Code Engine Ne speed sensor error
Trouble
E03 CA689 (Engine controller system)
Contents of
• Error was detected in engine Ne speed sensor circuit.
trouble
Action of • Operates the engine with signal from engine Bkup speed sensor.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine stops during operations (when engine Bkup speed sensor is also defective).
appears on
machine • Engine cannot be started during stop (when engine Bkup speed sensor is also defective).

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooti

Defective sensor power
1 If failure code [CA238] is displayed, carry out troubleshooting for it first.
supply system
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between ENGINE
harness Resistance Max. 1 Ω
(female) (16) – NE (female) (1)
2 (Disconnection in wiring or
Wiring harness between ENGINE
defective contact in Resistance Max. 1 Ω
connector) (female) (48) – NE (female) (2)
Wiring harness between ENGINE
Resistance Max. 1 Ω
(female) (27) – NE (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring Wiring harness between ENG (female) (16) –
Resistance Min. 1 MΩ
harness NE (female) (1) and chassis ground
3
Possible causes (Short circuit with GND Wiring harness between ENG (female) (48) –
and standard circuit) Resistance Min. 1 MΩ
NE (female) (2) and chassis ground
value in normal
state Wiring harness between ENG (female) (27) –
Resistance Min. 1 MΩ
NE (female) (3) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (16) –
NE (female) (1) and between ENG Resistance Min. 1 MΩ
Short circuit in wiring (female) (48) – NE (female) (2)
4 harness (with another wiring Wiring harness between ENG (female) (16) –
harness) NE (female) (1) and between ENG Resistance Min. 1 MΩ
(female) (27) – NE (female) (3)
Wiring harness between ENG (female) (48) –
NE (female) (2) and between ENG Resistance Min. 1 MΩ
(female) (27) – NE (female) (3)
Defective installation of
Installation of Ne speed sensor (clearance error) may be incorrect or
5 sensor or defective speed
speed sensor parts (fly wheel) may be defective. Check it directly.
sensor parts

40-236 ➁ WA500-6
TROUBLESHOOTING CA689

Cause Standard value in normal state/Remarks on troubleshooti

If causes 1 – 4 are not the cause of the problem, engine Ne speed sensor
Defective engine Ne speed
Possible causes 6 may be defective. (Since problem is in system, troubleshooting cannot be
sensor
and standard carried out.)
value in normal If causes 1 – 4 are not the cause of the problem, engine controller may be
state 7 Defective engine controller defective. (Since problem is in system, troubleshooting cannot be carried
out.)

Related Circuit Diagram

WA500-6 40-237 ➁
TROUBLESHOOTING CA731

CA731
Engine Bkup Speed Sensor Phase Error
Action Code Failure Code Engine Bkup speed sensor phase error
Trouble
E03 CA731 (Engine controller system)
Contents of
• There is phase error in engine Bkup speed sensor circuit.
trouble
Action of • Controls the engine with signal from engine Ne speed sensor.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine stops during operations (when engine Ne speed sensor is also defective).
appears on
machine • Engine cannot be started during stop (when engine Ne speed sensor is also defective).

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troubleshooting
1
and standard sensor system for failure code [CA689].
value in normal Defective engine Bkup speed Engine Bkup speed sensor may be defective. Carry out troubleshooting
state 2
sensor system for failure code [CA778].

40-238 ➁ WA500-6
TROUBLESHOOTING CA757

CA757
All Continuous Data Lost Error
Action Code Failure Code All continuous data lost error
Trouble
E03 CA757 (Engine controller system)
Contents of
• All data in engine controller are lost.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on • Operations are continued but engine may stop during operations or may not start in stopped state.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA111].
value in normal
state

WA500-6 40-239 ➁
TROUBLESHOOTING CA778

CA778
Engine Bkup Speed Sensor Error
Action Code Failure Code Engine Bkup speed sensor error
Trouble
E03 CA778 (Engine controller system)
Contents of
• Error was detected in engine Bkup speed sensor circuit.
trouble
Action of • Operates the engine with signal from engine Ne speed sensor.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine stops during operations (when engine Ne speed sensor is also defective).
appears on
machine • Engine cannot be started during stop (when engine Ne speed sensor is also defective).

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out troubleshooting
1
supply system for it first.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between ENG (female) (37) –
harness Resistance Max. 1 Ω
G (female) (1)
2 (Disconnection in wiring or
defective contact in Wiring harness between ENG (female) (47) –
Resistance Max. 1Ω
connector) G (female) (2)
Wiring harness between ENG (female) (26) –
Resistance Max. 1 Ω
G (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring Wiring harness between ENG (female) (37) –
Resistance Min. 1 MΩ
harness G (female) (1) and chassis ground
3
(Short circuit with GND Wiring harness between ENG (female) (47) –
circuit) Resistance Min. 1 MΩ
G (female) (2) and chassis ground
Possible causes
and standard Wiring harness between ENG (female) (26) –
Resistance Min. 1 MΩ
value in normal G (female) (3) and chassis ground
state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) –
G (female) (1) and between ENG (female) (47) Resistance Min. 1 MΩ
Short circuit in wiring – G (female) (2)
4 harness (with another wiring Wiring harness between ENG (female) (37) –
harness) G (female) (1) and between ENG (female) (26) Resistance Min. 1 MΩ
– G (female) (3)
Wiring harness between ENG (female) (47) –
G (female) (2) and between ENG (female) (26) Resistance Min. 1 MΩ
– G (female) (3)
If causes 1 – 4 are not the cause of the problem, engine Bkup speed
Defective engine Bkup
5 sensor may be defective. (Since problem is in system, troubleshooting
speed sensor
cannot be carried out.)
If causes 1 – 4 are not the cause of the problem, engine controller may be
6 Defective engine controller defective. (Since problem is in system, troubleshooting cannot be carried
out.)

40-240 ➁ WA500-6
TROUBLESHOOTING CA778
Related Circuit Diagram

WA500-6 40-241 ➁
TROUBLESHOOTING CA1228

CA1228
EGR Valve Servo Error 1
Action Code Failure Code EGR valve servo error 1
Trouble
E03 CA1228 (Engine controller system)
Contents of
• There is servo error (level 1) of EGR valve.
trouble
Action of • Performs open control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system
Defective engine oil pressure
2
system (main circuit)
Possible causes
and standard
value in normal Defective EGR valve oil
3
state pump
Defective EGR valve oil
4
pressure supply piping
Defective EGR valve oil
5
pressure return piping
6 Defective EGR valve
7 Defective engine controller
If another failure code is displayed, carry out troubleshooting for it.
To check engine oil pressure, see Engine Components: Measuring
Engine Oil Pressure in the Testing and Adjusting section.
Engine Engine oil pressure
Low idle 0.08 MPa (11.60 psi)
High idle 0.21 MPa (30.46 psi)
If engine oil pressure is not normal, carry out troubleshooting (S-mode) for
the mechanical system. (See S-12: Oil Pressure Drops in the Engine
Shop Manual.)
Oil pump or relief valve for EGR valve circuit may be defective. Check it
directly.
Oil pressure supply piping for EGR valve circuit may be defective. Check
it directly.
Oil pressure return piping for EGR valve circuit may be defective. Check it
directly.
EGR valve may be damaged mechanically. Check it directly.
If causes 1 – 6 are not the cause of the problem, engine controller may be
defective. (Since problem is in system, troubleshooting cannot be carried
out.)

40-242 ➁ WA500-6
TROUBLESHOOTING CA1625

CA1625
EGR Valve Servo Error 2
Action Code Failure Code EGR valve servo error 2
Trouble
E03 CA1625 (Engine controller system)
Contents of
• There is servo error (level 2) of EGR valve.
trouble
• Limits output and continues operation.
Action of
• Closes EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA1228].
value in normal
state

WA500-6 40-243 ➁
TROUBLESHOOTING CA1626

CA1626
Bypass Valve Solenoid Current High Error
Action Code Failure Code Bypass valve solenoid current high error
Trouble
E03 CA1626 (Engine controller system)
Contents of
• High current was detected in drive circuit of bypass valve solenoid.
trouble
• Limits output and continues operation.
Action of
• Closes EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective bypass valve
1
solenoid (Internal defect)
Disconnection in wiring
harness
2 (Disconnection in wiring or
defective contact in
connector)
Possible causes Ground fault in wiring
and standard harness
3 Resistance
value in normal (Short circuit with GND
state circuit)
Hot short in wiring harness
4 Voltage
(Contact with 24 V circuit)
5 Defective engine controller
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
BP (male) Resistance
Between (1) and (2) 10 – 21 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (31)
Resistance Max. 1 Ω
– BP (female) (1)
Wiring harness between ENG (female) (11) –
Resistance Max. 1 Ω
BP (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (31)
Min. 1 MΩ
– BP (female) (1) and chassis ground
Wiring harness between ENG (female) (11) –
Resistance Min. 1 MΩ
BP (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between ENG (female) (31)
Max. 1 V
– BP (female) (1) and chassis ground
Wiring harness between ENG (female) (11) –
Voltage Max. 1 V
BP (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
Between (31) and (11) 10 – 21 Ω

40-244 ➁ WA500-6
TROUBLESHOOTING CA1626
Related Circuit Diagram

WA500-6 40-245 ➁
TROUBLESHOOTING CA1627

CA1627
Bypass Valve Solenoid Drive Circuit Disconnection Error
Action Code Failure Code Bypass valve solenoid drive circuit disconnection error
Trouble
E03 CA1627 (Engine controller system)
Contents of
• Disconnection error was detected in drive circuit of bypass valve solenoid.
trouble
• Limits output and continues operation.
Action of
• Closes EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA1626].
value in normal
state

40-246 ➁ WA500-6
TROUBLESHOOTING CA1628

CA1628
Bypass Valve Servo Error 1
Action Code Failure Code Bypass valve servo error 1
Trouble
E03 CA1628 (Engine controller system)
Contents of
• There is servo error (level 1) of bypass valve.
trouble
Action of • Performs open control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system
Defective engine oil pressure
2
system (main circuit)
Possible causes
and standard
value in normal Defective bypass valve oil
3
state pump
Defective bypass valve oil
4
pressure supply piping
Defective bypass valve oil
5
pressure return piping
6 Defective bypass valve
7 Defective engine controller
If another failure code is displayed, carry out troubleshooting for it.
For check of engine oil pressure, see Engine Components: Measuring
Engine Oil Pressure in the Testing and Adjusting section.
Engine Engine oil pressure
Low idle 0.08 MPa (11.60 psi)
High idle 0.21 MPa (30.46 psi)
If engine oil pressure is not normal, carry out troubleshooting (S-mode) for
the mechanical system. (See S-12: Oil Pressure Drops in the Engine
Shop Manual.)
Oil pump or relief valve for bypass valve circuit may be defective. Check it
directly.
Oil pressure supply piping for bypass valve circuit may be defective.
Check it directly.
Oil pressure return piping for bypass valve circuit may be defective.
Check it directly.
Bypass valve may be damaged mechanically. Check it directly.
If causes 1 – 6 are not the cause of the problem, engine controller may be
defective. (Since problem is in system, troubleshooting cannot be carried
out.)

WA500-6 40-247 ➁
TROUBLESHOOTING CA1629

CA1629
Bypass Valve Servo Error 2
Action Code Failure Code Bypass valve servo error 2
Trouble
E03 CA1629 (Engine controller system)
Contents of
• There is servo error (level 2) of bypass valve.
trouble
• Limits output and continues operation.
Action of
• Closes EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA1628].
value in normal
state

40-248 ➁ WA500-6
TROUBLESHOOTING CA1629

MEMORANDUM

WA500-6 40-249 ➁
TROUBLESHOOTING CA1631

CA1631
Bypass Valve Lift Sensor High Error
Action Code Failure Code Bypass valve lift sensor high error
Trouble
E03 CA1631 (Engine controller system)
Contents of
• Bypass valve lift sensor circuit is abnormally high.
trouble
• Limits output and continues operation.
Action of
• Closes EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
function (Code: 18200 BPS VALVE POS).
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring function
information
(Code: 18202 BPS VALVE POS).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out troubleshooting
1
supply system for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
Defective bypass valve lift SBP Voltage
2 sensor Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected. If voltage is
abnormal, check wiring harness and controller for another cause of the
problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes Disconnection in wiring Wiring harness between ENG (female) (37) –
and standard harness Resistance Max. 1 Ω
SBP (female) (1)
value in normal 3 (Disconnection in wiring or
state Wiring harness between ENG (female) (38) –
defective contact in Resistance Max. 1 Ω
connector) SBP (female) (2)
Wiring harness between ENG (female) (29) –
Resistance Max. 1 Ω
SBP (female) (3), (4)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) –
Ground fault in wiring Resistance Min. 1 MΩ
SBP (female) (1) and chassis ground
4 harness (Short circuit with
GND circuit) Wiring harness between ENG (female) (38) –
Resistance Min. 1 MΩ
SBP (female) (2) and chassis ground
Wiring harness between ENG (female) (29) –
Resistance Min. 1 MΩ
SBP (female) (3), (4) and chassis ground

40-250 ➁ WA500-6
TROUBLESHOOTING CA1631

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between wiring harness of ENG (female) (37) –
SBP (female) (1) and between Resistance Min. 1 MΩ
Short circuit in wiring ENG (female) (38) – SBP (female) (2)
5 harness (with another wiring Between wiring harness of ENG (female) (37) –
Possible causes harness) SBP (female) (1) and between Resistance Min. 1 MΩ
and standard ENG (female) (29) – SBP (female) (3), (4)
value in normal
Between wiring harness of ENG (female) (38) –
state
SBP (female) (2) and between Resistance Min. 1 MΩ
ENG (female) (29) – SBP (female) (3), (4)
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
6 Defective engine controller
ENG Voltage
Between (37) and (38) 4.75 – 5.25 V

Related Circuit Diagram

WA500-6 40-251 ➁
TROUBLESHOOTING CA1632

CA1632
Bypass Valve Lift Sensor Low Error
Action Code Failure Code Bypass valve lift sensor low error
Trouble
E03 CA1632 (Engine controller system)
Contents of
• Bypass valve lift sensor circuit is abnormally low.
trouble
• Limits output and continues operation.
Action of
• Closes EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
function (Code: 18200 BPS VALVE POS).
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring function
information
(Code: 18202 BPS VALVE POS).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA1631].
value in normal
state

40-252 ➁ WA500-6
TROUBLESHOOTING CA1633

CA1633
KOMNET Datalink Timeout Error
Action Code Failure Code KOMNET datalink timeout error
Trouble
E03 CA1633 (Engine controller system)
Contents of
• There is an error in KOMNET communication circuit with applicable machine.
trouble
Action of • Operates in default mode or holds the state set when error occurred.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
1 Carry out troubleshooting for failure code [DB2RKR].
value in normal
state

WA500-6 40-253 ➁
TROUBLESHOOTING CA1642

CA1642
EGR Inlet Pressure Sensor Low Error
Action Code Failure Code EGR inlet pressure sensor low error
Trouble
E03 CA1642 (Engine controller system)
Contents of
• EGR inlet pressure sensor circuit is abnormally low.
trouble
• Sets EGR inlet pressure to default (100 kPa [14.50 psi]) and continues operation.
Action of
• Limits output and continues operation.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (EGR inlet pressure) from the EGR inlet pressure sensor can be checked with the
monitoring function (Code: 18000 EGR IN PRESS-A).
Related
• The input state (voltage) from the EGR inlet pressure sensor can be checked with the monitoring
information
function (Code: 18002 EGR IN PRESS-A).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out troubleshooting for failure code [CA1653].
value in normal
state

40-254 ➁ WA500-6
TROUBLESHOOTING CA1642

MEMORANDUM

WA500-6 40-255 ➁
TROUBLESHOOTING CA1653

CA1653
EGR Inlet Pressure Sensor High Error
Action Code Failure Code EGR inlet pressure sensor high error
Trouble
E03 CA1653 (Engine controller system)
Contents of
• EGR inlet pressure sensor circuit is abnormally high.
trouble
• Sets EGR inlet pressure to default (100 kPa [14.50 psi]) and continues operation.
Action of
• Limits output and continues operation.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (EGR inlet pressure) from the EGR inlet pressure sensor can be checked with the
monitoring function (Code: 18000 EGR IN PRESS-A).
Related
• The input state (voltage) from the EGR inlet pressure sensor can be checked with the monitoring
information
function (Code: 18002 EGR IN PRESS-A).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out troubleshooting
1
supply system for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
Defective EGR inlet pressure PEVA Voltage
2 sensor Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
EGR inlet pressure sensor voltage is measured with wiring harness
connected. If voltage is abnormal, check wiring harness and controller for
another cause of the problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes
Disconnection in wiring Wiring harness between ENG (female) (37)
and standard Resistance Max. 1 Ω
harness – PEVA (female) (1)
value in normal 3
state (Disconnection or defective Wiring harness between ENG (female) (47)
contact in connector) Resistance Max. 1 Ω
– PEVA (female) (2)
Wiring harness between ENG (female) (20)
Resistance Max. 1 Ω
– PEVA (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
Resistance Min. 1 MΩ
Ground fault in wiring harness – PEVA (female) (1) and chassis ground
4
(Contact with ground circuit) Wiring harness between ENG (female) (47)
Resistance Min. 1 MΩ
– PEVA (female) (2) and chassis ground
Wiring harness between ENG (female) (20)
Resistance Min. 1 MΩ
– PEVA (female) (3) and chassis ground

40-256 ➁ WA500-6
TROUBLESHOOTING CA1653

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
– PEVA (female) (1) and between ENG Resistance Min. 1 MΩ
(female) (47) – PEVA (female) (2)
Short circuit in wiring harness
5
(with another wiring harness) Wiring harness between ENG (female) (37)
Possible causes – PEVA (female) (1) and between ENG Resistance Min. 1 MΩ
and standard (female) (20) – PEVA (female) (3)
value in normal
Wiring harness between ENG (female) (47)
state
– PEVA (female) (2) and between ENG Resistance Min. 1 MΩ
(female) (20) – PEVA (female) (3)
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
6 Defective engine controller
ENG Voltage
Between (37) and (47) 4.75 – 5.25 V

Related Circuit Diagram

WA500-6 40-257 ➁
TROUBLESHOOTING CA2185

CA2185
Throttle Sensor Supply Voltage High Error
Action Code Failure Code Throttle sensor supply voltage high error
Trouble
E03 CA2185 (Engine controller system)
Contents of
• Voltage of throttle sensor power supply (5V) circuit is high.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on • Engine continues normal operation but may not run at full throttle.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.

Defective accelerator pedal Disconnect device

1 suggested on the right.
(Internal defect)
At this time, if failure Accelerator pedal L15 connector
code is not indicated,
the device is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between E18 (female) (22) –
2 Resistance Max. 1 Ω
(Disconnection or defective L15 (female) (1)
contact in connector) Wiring harness between E18 (female) (23) –
Resistance Max. 1 Ω
L15 (female) (3)
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Ground fault in wiring harness Wiring harness between E18 (female) (22) –
3 Resistance Min. 1 MΩ
(Contact with ground circuit) L15 (female) (1) and chassis ground
Wiring harness between E18 (female) (23) –
Resistance Min. 1 MΩ
L15 (female) (3) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness
4 Wiring harness between E18 (female) (22) –
(with another wiring harness)
L15 (female) (1) and between E18 (female) Resistance Min. 1 MΩ
(23) – L15 (female) (3)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective engine controller
E18 Voltage
Between (22) and (23) 4.75 – 5.25 V

40-258 ➁ WA500-6
TROUBLESHOOTING CA2185
Related Circuit Diagram

WA500-6 40-259 ➁
TROUBLESHOOTING CA2186

CA2186
Throttle Sensor Power Supply Low Error
Action Code Failure Code Throttle sensor power supply low error
Trouble
E03 CA2186 (Engine controller system)
Contents of
• Voltage of throttle sensor power supply (5V) circuit is low.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on • Engine continues normal operation but may not run at full throttle.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA2185].
value in normal
state

40-260 ➁ WA500-6
TROUBLESHOOTING CA2249

CA2249
Supply Pump Pressure Very Low Error 2
Action Code Failure Code Supply pump pressure very low error 2
Trouble
E03 CA2249 (Engine controller system)
Contents of
• There is a no-pressure feed error (level 2) in supply pump.
trouble
Action of • Limits common rail pressure.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the
monitoring function (Code: 36400 RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402 RAIL PRESS).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA559].
value in normal
state

WA500-6 40-261 ➁
TROUBLESHOOTING CA2271

CA2271
EGR Valve Lift Sensor High Error
Action Code Failure Code EGR valve lift sensor high error
Trouble
E03 CA2271 (Engine controller system)
Contents of
• EGR valve lift sensor circuit is abnormally high.
trouble
• Limits output and continues operation.
Action of
• Closes EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
function (Code: 18100 BGR VALVE POS).
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101 BGR VALVE POS).
• Method of reproducing failure code: Start engine.

Causes Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out troubleshooting
1
supply system for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
Defective EGR valve lift SEGR Voltage
2 sensor Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected. If voltage is
abnormal, check wiring harness and controller for another cause of the
problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes
Disconnection in wiring Wiring harness between ENG (female) (37)
and standard Resistance Max. 1 Ω
harness – SEGR (female) (1)
value in normal 3
state (Disconnection or defective Wiring harness between ENG (female) (47)
contact in connector) Resistance Max. 1 Ω
– SEGR (female) (2)
Wiring harness between ENG (female) (19)
Resistance Max. 1 Ω
– SEGR (female) (3), (4)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
Resistance Min. 1 MΩ
Ground fault in wiring harness – SEGR (female) (1) and chassis ground
4
(Contact with ground circuit) Wiring harness between ENG (female) (47)
Resistance Min. 1 MΩ
– SEGR (female) (2) and chassis ground
Wiring harness between ENG (female) (19)
Resistance Min. 1 MΩ
– SEGR (female) (3), (4) and chassis ground

40-262 ➁ WA500-6
TROUBLESHOOTING CA2271

Causes Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning staring switch ON.
Wiring harness between ENG (female) (37)
– SEGR (female) (1) and ENG (female) (19) Resistance Min. 1 MΩ
– SEGR (female) (3), (4)
Short circuit in wiring harness
5
(with another wiring harness) Wiring harness between ENG (female) (37)
Possible causes – SEGR (female) (1) and ENG (female) (47) Resistance Min. 1 MΩ
and standard – SEGR (female) (2)
value in normal
Wiring harness between ENG (female) (47)
state
– SEGR (female) (2) and ENG (female) (19) Resistance Min. 1 MΩ
– SEGR (female) (3), (4)
★ Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
6 Defective engine controller
ENG Voltage
Between (37) and (47) 4.75 – 5.25 V

Related Circuit Diagram

WA500-6 40-263 ➁
TROUBLESHOOTING CA2272

CA2272
EGR Valve Lift Sensor Low Error
Action Code Failure Code EGR valve lift sensor low error
Trouble
E03 CA2272 (Engine controller system)
Contents of
• EGR valve lift sensor circuit is abnormally low.
trouble
• Limits output and continues operation.
Action of
• Closes EGR valve.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
function (Code: 18100 BGR VALVE POS).
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101 BGR VALVE POS).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA2271].
value in normal
state

40-264 ➁ WA500-6
TROUBLESHOOTING CA2272

MEMORANDUM

WA500-6 40-265 ➁
TROUBLESHOOTING CA2351

CA2351
EGR Valve Solenoid Operation Short Circuit
Action Code Failure Code EGR valve solenoid operation short circuit error
Trouble
E03 CA2351 (Engine controller system)
Contents of
• Short circuit was detected in drive circuit of EGR valve solenoid.
trouble
• Limits output and continues operation.
Action of
• Closes EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective EGR valve solenoid without turning starting switch ON.
1
(Internal defect) EGR (male) Resistance
Between (1) and (2) 10 – 21 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between ENG (female) (22)
2 Resistance Max. 1 Ω
(Disconnection or defective – EGR (female) (1)
contact in connector) Wiring harness between ENG (female) (11) –
Resistance Max. 1 Ω
EGR (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Ground fault in wiring harness Wiring harness between ENG (female) (22)
3 Resistance Min. 1 MΩ
value in normal (Contact with ground circuit) – EGR (female) (1) and chassis ground
state Wiring harness between ENG (female) (11) –
Resistance Min. 1 MΩ
EGR (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness Wiring harness between ENG (female) (22)
4 Voltage Max. 1 V
(Contact with 24 V circuit) – EGR (female) (1) and chassis ground
Wiring harness between ENG (female) (11) –
Voltage Max. 1 V
EGR (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
ENG (female) Resistance
Between (22) and (11) 10 – 21 Ω

40-266 ➁ WA500-6
TROUBLESHOOTING CA2351
Related Circuit Diagram

WA500-6 40-267 ➁
TROUBLESHOOTING CA2352

CA2352
EGR Valve Solenoid Operation Disconnection Error
Action Code Failure Code EGR valve solenoid operation disconnection error
Trouble
E03 CA2352 (Engine controller system)
Contents of
• Disconnection error was detected in drive circuit of EGR valve solenoid.
trouble
• Limits output and continues operation.
Action of
• Closes EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA2351].
value in normal
state

40-268 ➁ WA500-6
TROUBLESHOOTING CA2555

CA2555
Intake Heater Relay Disconnection Error
Action Code Failure Code Intake heater relay voltage low error
Trouble
E01 CA2555 (Engine controller system)
Contents of
• Disconnection error was detected in intake air heater relay circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
Carry out trouble shooting for failure code [CA2556].
value in normal
state

WA500-6 40-269 ➁
TROUBLESHOOTING CA2556

CA2556
Intake Heater Relay Short Circuit Error
Action Code Failure Code Intake heater relay short circuit error
Trouble
E01 CA2556 (Engine controller system)
Contents of
• Short circuit was detected in intake heater relay circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related • Method of reproducing failure code: Turn starting switch ON while engine coolant temperature below
information 5°C (41°F).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective intake heater relay without turning starting switch ON.
1
(Internal defect) L106 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between E18 (female) (40) –
2 Resistance Max. 1 Ω
(Disconnection or defective L106 (female) (1)
contact in connector) Wiring harness between E18 (female) (42) –
Possible causes Resistance Max. 1 Ω
L106 (female) (2)
and standard
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
state
Ground fault in wiring harness Wiring harness between E18 (female) (40) –
3 Resistance Min. 1 MΩ
(Contact with ground circuit) L106 (female) (1) and chassis ground
Wiring harness between E18 (female) (42) –
Resistance Min. 1 MΩ
L106 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
4 Defective engine controller E18 Heater relay Voltage
Between Operating condition 20 – 30 V
(40) and (42) Stop condition Max. 1 V

40-270 ➁ WA500-6
TROUBLESHOOTING CA2556
Related Circuit Diagram

WA500-6 40-271 ➁
TROUBLESHOOTING D160KZ

D160KZ
Backup Lamp Relay: Disconnection or Short Circuit
Action Code Failure Code Backup lamp relay: Disconnection or short circuit
Trouble
E01 D160KZ (Transmission controller system)
Contents of
• Since the backup lamp relay output system is shorted, signals are not output to the backup relay.
trouble
Action of • Turns the output to the backup lamp relay OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Backup lamp does not light up.
appears on
machine • Backup buzzer does not sound.

Related • Method of reproducing failure code: Turn starting switch ON and set FNR (directional) lever, joystick
information steering FNR (directional) switch, or right FNR (directional) switch to R (reverse).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L101 (male) Resistance
Defective backup lamp relay Between (1) and (2) 200 – 400 Ω
1
(L101) (Internal short circuit)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Replace backup lamp relay (L101) with another one of same type. If
condition becomes normal at this time, backup lamp relay is defective.

Possible causes Grounding fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
and standard 2
value in normal (Disconnection or defective Wiring harness between L04 (female) (18) –
contact of connector) Resistance Max. 1 Ω
state L101 (female) (1)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
FNR (directional) lever,
joystick steering FNR
Defective transmission L04 (directional) switch, or Voltage
3
controller right FNR
(directional) switch
Between (18) and R (Reverse) 20 – 30 V
chassis ground Other than above Max. 1 V

40-272 ➁ WA500-6
TROUBLESHOOTING D160KZ
Related Circuit Diagram

WA500-6 40-273 ➁
TROUBLESHOOTING D191KA

D191KA
Joystick Steering Neutral Safety Relay: Disconnection
Action Code Failure Code Joystick steering neutral safety relay: Disconnection
Trouble
E01 D191KA (Work equipment controller system)
Contents of • Signals are not output to neutral safety relay due to disconnection of joystick steering neutral safety relay
trouble output system.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that • While operating the joystick steering, engine can be started. Steering moves immediately after engine
appears on started.
machine • Engine can be started while joystick or right FNR switch is not in N (neutral).
• The neutral safety relay does not operate when the joystick steering neutral position is not adjusted
(initial setting).
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
Related
(Code: 40954, D-OUT-20).
information
• Machine with joystick steering only
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering (engine
stopped state).

Cause Standard value in normal state/Remarks on troubleshooting

Defective joystick steering
1 neutral safety relay (L104)
(Internal disconnection)
Disconnection in wiring
Possible causes harness
and standard 2 Resistance
(Disconnection or defective
value in normal contact of connector)
state
Defective work equipment
3
controller
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L104 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L07 (female) (4) –
Max. 1 Ω
L104 (female) (1)
Wiring harness between L104 (female) (2) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Operate the joystick steering lever.
L07 Voltage
Between (4) and chassis ground 20 – 30 V

40-274 ➁ WA500-6
TROUBLESHOOTING D191KA
Related Circuit Diagram

WA500-6 40-275 ➁
TROUBLESHOOTING D191KB

D191KB
Joystick Steering Neutral Safety Relay: Short Circuit
Action Code Failure Code Joystick steering neutral safety relay: Short circuit
Trouble
E01 D191KB (Work equipment controller system)
Contents of • Signals are not output to joystick steering neutral safety relay due to grounding fault in joystick steering
trouble neutral safety relay output system.
Action of • Turns the output to the joystick steering neutral safety relay OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • While operating the joystick steering, engine can be started. Steering moves immediately after engine
appears on started.
machine • Engine can be started while joystick or right FNR switch is not in N (neutral).
• The neutral safety relay does not operate when the joystick steering neutral position is not adjusted
(initial setting).
• Work equipment controller does not output signals to joystick steering neutral safety relay while
outputting a failure code.
Related
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
information
(Code: 40954, D-OUT-20).
• Machine with joystick steering only
• Method of reproducing failure code: Turn the starting switch ON and joystick steering operation (engine
stopped state).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective joystick steering
1 neutral safety relay (L104) L104 (male) Resistance
(Internal short circuit) Between (1) and (2) 200 – 400 Ω
Between (1) and chassis ground Min. 1 MΩ
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (4) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state L104 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment • Operate the joystick steering lever.
3
controller
L07 Voltage
Between (4) and chassis ground 20 – 30 V

40-276 ➁ WA500-6
TROUBLESHOOTING D191KB
Related Circuit Diagram

WA500-6 40-277 ➁
TROUBLESHOOTING D192KA

D192KA
ECSS Solenoid: Disconnection
Action Code Failure Code ECSS (travel damper) solenoid: Disconnection
Trouble
E01 D192KA (Transmission controller system)
Contents of • Since the ECSS solenoid system is disconnected, no current flows when ECSS solenoid output is turned
trouble ON.
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The ECSS does not operate.
machine
• The output state (current) to the ECSS solenoid can be checked with the monitoring function
(Code: 93300 ECSS V DIR).
Related
• Applicable only to ECSS specification machines (if equipped).
information
• Method of reproducing failure code: Turn the starting switch and travel damper switch ON, and travel at
a speed other than 1st.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective ECSS solenoid without turning starting switch ON.
1
(Internal disconnection) F24 (male) Resistance
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes
harness Wiring harness between L04 (female) (17) –
and standard 2 Resistance Max. 1 Ω
(Disconnection or defective F24 (female) (1)
value in normal
contact in connector) Wiring harness between F24 (female) (2) –
state Resistance Max. 1 Ω
L04 (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission
3 L04 (female) Resistance
controller
Wiring harness
5 – 15 Ω
between (17) and (3)

Related Circuit Diagram

40-278 ➁ WA500-6
TROUBLESHOOTING D192KB

D192KB
ECSS Solenoid: Short Circuit
Action Code Failure Code ECSS (travel damper) solenoid: Short circuit
Trouble
E01 D192KB (Transmission controller system)
Contents of • Since the ECSS solenoid system is shorted with the chassis ground, abnormal current flows when
trouble ECCS solenoid output is ON.
Action of • Turns the output to the ECSS solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The ECSS does not operate.
appears on
machine • The wiring harness or controller may be burnt out.

• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code:
93300 ECSS V DIR).
Related
• Applicable only to ECSS specification machines (if equipped).
information
• Method of reproducing failure code: Turn starting switch ON + Travel dumper switch ON + non-1st
speed

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective ECSS solenoid F24 (male) Resistance
1
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Wiring harness between L04 (female) (17) –
Resistance Min. 1 MΩ
F24 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (17) and (3) 5 – 15 Ω
Between (17), (3) and
Min. 1 MΩ
chassis ground

Related Circuit Diagram

WA500-6 40-279 ➁
TROUBLESHOOTING D192KY

D192KY
ECSS Solenoid Relay: Short Circuit with Power Supply Line
Action Code Failure Code ECSS (travel damper) solenoid: Short circuit with power supply line
Trouble
E01 D192KY (Transmission controller system)
Contents of • Since the ECSS solenoid system is shorted with the power source, abnormal voltage was applied when
trouble ECSS solenoid output was turned OFF.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • ECCS keeps operating.
machine
• The output state (current) to the ECSS solenoid can be checked with the monitoring function
Related (Code: 93300 ECSS V DIR).
information • Applicable only to ECSS specification machines (if equipped).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective ECSS solenoid F24 (male) Resistance
1
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (17) – F24
state Voltage Max. 1 V
(female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (17) and (3) 5 – 15 Ω
Between (17), (3) and
Min. 1 MΩ
chassis ground

40-280 ➁ WA500-6
TROUBLESHOOTING D192KY
Related Circuit Diagram

WA500-6 40-281 ➁
TROUBLESHOOTING D193KA

D193KA
Joystick Steering Solenoid Cut Relay: Disconnection
Action Code Failure Code Joystick steering solenoid cut relay: Disconnection
Trouble
E03 D193KA (Work equipment controller system)
Contents of • Signals are not output to joystick steering solenoid cut relay due to disconnection of joystick steering
trouble solenoid cut relay output system.
• Stops outputting the signal to the joystick steering left-right EPC solenoid.
Action of • Turns the output to the joystick steering cut relay OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the monitoring
function (Code: 40953, D-OUT-8).
Related
• Machine with joystick steering only
information
• Method of reproducing failure code: Turn the starting switch ON and joystick steering operation (engine
stopped state).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective joystick steering without turning starting switch ON.
1 neutral cut relay (L118)
L118 (male) Resistance
(Internal disconnection)
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes harness Wiring harness between L07 (female) (26) –
2 Resistance Max. 1 Ω
and standard (Disconnection or defective L118 (female) (1)
value in normal contact in connector) Wiring harness between L118 (female) (2) –
state Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment • Operate the joystick steering lever.
3
controller L07 Voltage
Between (26) and
20 – 30 V
chassis ground

40-282 ➁ WA500-6
TROUBLESHOOTING D193KA
Related Circuit Diagram

WA500-6 40-283 ➁
TROUBLESHOOTING D193KB

D193KB
Joystick Steering Solenoid Cut Relay: Short Circuit
Action Code Failure Code Joystick steering solenoid cut relay: Short circuit
Trouble
E03 D193KB (Work equipment controller system)
Contents of • Signals are not output to joystick steering solenoid cut relay due to grounding fault in joystick steering
trouble solenoid cut relay output system.
• Stops the output to the joystick steering left-right EPC solenoid.
Action of • Turns the output to the joystick steering cut relay OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the monitoring
function (Code: 40953, D-OUT-8).
Related
• Machine with joystick steering only
information
• Method of reproducing failure code: Turn the starting switch ON and joystick steering operation (engine
stopped state).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective joystick steering
1 cut relay (L118) (Internal L118 (male) Resistance
short circuit) Between (1) and (2) 200 – 400 Ω
Between (1) and chassis ground Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes
Ground fault in wiring harness without turning starting switch ON.
and standard 2
(Contact with ground circuit) Wiring harness between L07 (female) (26) –
value in normal Resistance Min. 1 MΩ
state L118 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment • Operate the joystick steering lever.
3
controller L07 Voltage
Between (26) and
20 – 30 V
chassis ground

40-284 ➁ WA500-6
TROUBLESHOOTING D193KB
Related Circuit Diagram

WA500-6 40-285 ➁
TROUBLESHOOTING D193KY

D193KY
Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line
Action Code Failure Code Joystick steering solenoid cut relay: Short circuit with power supply line
Trouble
E03 D193KY (Work equipment controller system)
Contents of • Signals are not output to joystick steering solenoid cut relay due to hot short circuit in joystick steering
trouble solenoid cut relay output system.
• Stops the output to the joystick steering left-right EPC solenoid.
Action of • Stops the output to the joystick steering cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the monitoring
function (Code: 40953, D-OUT-8).
Related
• Machine with joystick steering only
information
• Method of reproducing failure code: Turn the starting switch ON and joystick steering operation (engine
stopped state).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective joystick steering L118 (male) Resistance
1 cut relay (L118) (Internal
short circuit) Between (1) and (2) 200 – 400 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Ground fault in wiring harness carry out troubleshooting.
2
value in normal (Contact with ground circuit) Wiring harness between L07 (female) (26) –
state Voltage Max. 1 V
L118 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment • Operate the joystick steering lever.
3
controller L07 Voltage
Between (26) and
20 – 30 V
chassis ground

40-286 ➁ WA500-6
TROUBLESHOOTING D193KY
Related Circuit Diagram

WA500-6 40-287 ➁
TROUBLESHOOTING D5ZHKA

D5ZHKA
Terminal C Signal: Disconnection
Action Code Failure Code Terminal C signal: Disconnection
Trouble
E01 D5ZHKA (Transmission controller system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground. (Engine speed is above 500 rpm
trouble and no starting switch terminal C signal has been input.)
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Engine does not start easily.
machine
• The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked with
Related
the monitoring function (Code: 40905, D-IN-7).
information
• Method of reproducing failure code: START position of starting switch

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 2 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
box A (See cause 4.)
★ Prepare with starting switch OFF, then turn starting switch ON, OFF
or START and carry out troubleshooting
Defective starting switch LS4 Starting switch Resistance
2
(Internal disconnection)
START Max. 1 Ω
Between (1) and (3)
OFF, ON Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between LS4 (female) (3) –
Resistance Max. 1 Ω
Disconnection in wiring L120 (female) (3)
harness Wiring harness between L120 (female) (6) –
3 Resistance Max. 1 Ω
(Disconnection or defective L103 (female) (5)
Possible causes contact in connector)
Wiring harness between L103 (female) (3) –
and standard Resistance Max. 1 Ω
L104 (female) (6)
value in normal
state Wiring harness between L104 (female) (3) –
Resistance Max. 1 Ω
L02(female) (6)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between LS4 (female) (3) –
L120 (female) (3), – circuit branch end and Resistance Min. 1 MΩ
chassis ground
Grounding fault in wiring Wiring harness between L120 (female) (6) –
Resistance Min. 1 MΩ
4 harness L103 (female) (5) and chassis ground
(Contact with ground circuit) Wiring harness between L103 (female) (3) –
L104 (female) (6), – circuit branch end and Resistance Min. 1 MΩ
chassis ground
Wiring harness between L104 (female) (3) –
L02 (female) (6), – circuit branch end and Resistance Min. 1 MΩ
chassis ground

40-288 ➁ WA500-6
TROUBLESHOOTING D5ZHKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON, OFF
Possible causes or START and carry out troubleshooting
and standard Defective transmission L02 Starting switch Voltage
5
value in normal controller
state Between (6) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V

WA500-6 40-289 ➁
TROUBLESHOOTING D5ZHKA
Related Circuit Diagram

40-290 ➁ WA500-6
TROUBLESHOOTING D5ZHKA

MEMORANDUM

WA500-6 40-291 ➁
TROUBLESHOOTING D5ZHKB

D5ZHKB
Terminal C Signal: Short Circuit
Action Code Failure Code Terminal C signal: Short circuit
Trouble
E01 D5ZHKB (Transmission controller system)
Contents of • Terminal C system is shorted with the power source. (Engine speed is above 500 rpm and starting
trouble switch terminal C signal has been input.)
Action of • Engine start assistance is not working.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Engine does not start easily.
machine
• The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked with
Related
the monitoring function (Code: 40905, D-IN-7).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON, OFF
or START and carry out troubleshooting
Defective starting switch LS4 Starting switch Resistance
1
(Internal disconnection)
START Max. 1 Ω
Between (1) and (3)
OFF, ON Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting after
engine starts and during engine operation
Wiring harness between LS4 (female) (3) –
L120 (female) (3), – circuit branch end and Voltage Max. 1 V
chassis ground
Possible causes
Wiring harness between L120 (female) (6) –
and standard Hot short in wiring harness Voltage Max. 1 V
2 L103 (female) (5) and chassis ground
value in normal (Contact with 24 V circuit)
state Wiring harness between L103 (female) (3) –
L104 (female) (6), – circuit branch end and Voltage Max. 1 V
chassis ground
Wiring harness between L104 (female) (3) –
L02 (female) (6), – circuit branch end and Voltage Max. 1 V
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON, OFF,
or START and carry out troubleshooting
Defective transmission L02 Starting switch Voltage
3
controller
Between (6) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V

40-292 ➁ WA500-6
TROUBLESHOOTING D5ZHKB
Related Circuit Diagram

WA500-6 40-293 ➁
TROUBLESHOOTING D5ZHKZ

D5ZHKZ
Terminal C Signal: Disconnection or Short Circuit
Action Code Failure Code Terminal C signal: Disconnection or short circuit
Trouble
E01 D5ZHKZ (Work equipment controller system)
Contents of • Terminal C system is disconnected. (Engine speed is above 500 rpm and no starting switch terminal C
trouble signal has been input.)
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
• Engine starts when work equipment control lever is not at Neutral (disconnection).
appears on
machine • While engine is stopped, residual pressure in work equipment cannot be released (short circuit).

• The input state (ON/OFF) from starting switch terminal C to work equipment controller can be checked
Related
with the monitoring function (Code: 40912, D-IN-17).
information
• Method of reproducing failure code: Set the starting switch to START position.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 2 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
box A (See cause 4.)
★ Prepare with starting switch OFF, then turn starting switch ON, OFF
or START and carry out troubleshooting
Defective starting switch LS4 Starting switch Resistance
2
(Internal disconnection)
START Max. 1 Ω
Between (1) and (3)
OFF, ON Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between LS4 (female) (3) –
Resistance Max. 1 Ω
harness L120 (female) (3)
3
(Disconnection or defective Wiring harness between L120 (female) (6) –
contact in connector) Resistance Max. 1 Ω
L103 (female) (5)
Wiring harness between L103 (female) (3) –
Resistance Max. 1 Ω
L06 (female) (25)
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Wiring harness between LS4 (female) (3) –
L120 (female) (3), – circuit branch end and Resistance Min. 1 MΩ
Grounding fault in wiring chassis ground
4 harness
(Contact with ground circuit) Wiring harness between L120 (female) (6) –
Resistance Min. 1 MΩ
L103 (female) (5) and chassis ground
Wiring harness between L103 (female) (3) –
L06 (female) (25), – circuit branch end and Resistance Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between LS4 (female) (3) –
Voltage Max. 1 V
Hot short in wiring harness L120 (female) (3) and chassis ground
5
(Contact with 24 V circuit) Wiring harness between L120 (female) (6) –
Voltage Max. 1 V
L103 (5) and chassis ground
Wiring harness between L103 (female) (3) –
Voltage Max. 1 V
L06 (female) (25) and chassis ground

40-294 ➁ WA500-6
TROUBLESHOOTING D5ZHKZ

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON, OFF
Possible causes or START and carry out troubleshooting
and standard Defective work equipment L06 Starting switch Voltage
6
value in normal controller
state Between (25) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V

WA500-6 40-295 ➁
TROUBLESHOOTING D5ZHKZ
Related Circuit Diagram

40-296 ➁ WA500-6
TROUBLESHOOTING D5ZHKZ

MEMORANDUM

WA500-6 40-297 ➁
TROUBLESHOOTING D5ZHL6

D5ZHL6
Terminal C Signal: Signal Does Not Match Engine Running or Stopped State
Action Code Failure Code Terminal C signal: Signal does not match engine running or stopped
Trouble state
E01 D5ZHL6 (Machine monitor system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground. (Engine speed is above 500 rpm
trouble and alternator terminal R voltage has been checked.)
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The engine does not start.
machine
• The input state (ON/OFF) from starting switch terminal C to machine monitor can be checked with the
Related
monitoring function (Code: 40900, D-IN-2).
information
• Method of reproducing failure code: Set the starting switch to START position.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON, OFF,
or START and carry out troubleshooting
Defective starting switch LS4 Starting switch Voltage
1
(Internal disconnection)
Between (3) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between LS4 (female) (3) –
Resistance Max. 1 Ω
Disconnection in wiring L120 (female) (3)
harness Wiring harness between L120 (female) (6) –
2 Resistance Max. 1 Ω
(Disconnection or defective L103 (female) (5)
contact in connector) Wiring harness between L103 (female) (3) –
Resistance Max. 1 Ω
L104 (female) (6)
Wiring harness between L104 (female) (3) –
Resistance Max. 1 Ω
L52 (female) (2)
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Wiring harness between LS4 (female) (3) –
L120 (female) (3), – circuit branch end and Resistance Min. 1 MΩ
chassis ground
Grounding fault in wiring Wiring harness between L120 (female) (6) –
Resistance Min. 1 MΩ
3 harness L103 (female) (5) and chassis ground
(Contact with ground circuit) Wiring harness between L103 (female) (3) –
L104 (female) (6), – circuit branch end and Resistance Min. 1 MΩ
chassis ground
Wiring harness between L104 (female) (3) –
L52 (female) (2), – circuit branch end and Resistance Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON, OFF
or START and carry out troubleshooting
4 Defective machine monitor L52 Starting switch Voltage
Between (2) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V

40-298 ➁ WA500-6
TROUBLESHOOTING D5ZHL6
Related Circuit Diagram

WA500-6 40-299 ➁
TROUBLESHOOTING DA80L4

DA80L4
Auto-Grease Controller: ON/OFF Signals Disagree
Action Code Failure Code Auto-grease controller: ON/OFF signals disagree
Trouble
— DA80L4 (Machine monitor system)
Contents of
• Both auto-grease sensor input circuits A and B are in the same signal (+24 V).
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
• Auto-grease does not work.
appears on
machine • Auto-grease lamp goes off.

• The input state (ON/OFF) from the auto-grease controller can be checked with the monitoring function
Related (Code: 40900, D-IN-4, D-IN-5).
information • Applicable only to machines equipped with auto-grease function (if equipped).
• Method of reproducing failure code: Turn the starting switch ON (auto-grease install).

Cause Standard value in normal state/Remarks on troubleshooting

Defective auto grease
controller (Internal
1 Refer to and carry out troubleshootings for auto-grease system.
disconnection or short
circuit)
• Fill up grease to the tank.
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short in wiring harness
2 carry out troubleshooting.
(Contact with 24 V circuit)
Wiring harness between L52 (female) (3) -R38
Voltage Max. 1 V
(female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Real-time monitor Auto-grease
Auto- grease L52
(Code: 40900) lamp
Possible causes Between (3) – ground
and standard D-IN-4 0
(0 V)
value in normal Operating ON
state Between (12) –
D-IN-5 1
ground (24 V)
Between (3) – ground
D-IN-4 0
(0 V) Blink
3 Defective machine monitor Abnormal
Between (12) – (2 Hz)
D-IN-5 0
ground (0 V)
Between (3) – ground
D-IN-4 1
(24 V) Blink
Tank empty
Between (12) – (1 Hz)
D-IN-5 0
ground (0 V)
Between (3) – ground
D-IN-4 1
(24 V)
Abnormal OFF
Between (12) –
D-IN-5 1
ground (24 V)

40-300 ➁ WA500-6
TROUBLESHOOTING DA80L4
Related Circuit Diagram

WA500-6 40-301 ➁
TROUBLESHOOTING DAF3KK

DAF3KK
Machine Monitor: Low Source Voltage (input)
Action Code Failure Code Machine monitor: Low source voltage (input)
Trouble
E03 DAF3KK (Machine monitor system)
Contents of • When the voltage of the SW power supply (power supply for operation) is above 17 V, the voltage of the
trouble constant power supply (power supply for operation) is below 17 V.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The service meter reading is abnormal; the odometer does not advance; and failure history data is not
appears on
saved.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 8 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
box A (See cause 5.)
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between LR1 (male) (1) –
2 Resistance Max. 1 Ω
(Disconnection or defective fuse No. 8 of fuse box A
Possible causes contact) Wiring harness between fuse No. 8 of fuse
and standard Resistance Max. 1 Ω
box A – L51 (female) (4), (5)
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
3 harness Wiring harness between fuse No. 8 of fuse
(Contact with ground circuit) box A – L51 (female) (4), (5) Resistance Min. 1 MΩ
and chassis ground
If machine monitor is replaced and condition becomes normal, machine
4 Defective machine monitor
monitor is defective.

40-302 ➁ WA500-6
TROUBLESHOOTING DAF3KK
Related Circuit Diagram

WA500-6 40-303 ➁
TROUBLESHOOTING DAF5KP

DAF5KP
Machine Monitor: Low Output Voltage
Action Code Failure Code Machine monitor: Low output voltage
Trouble
E01 DAF5KP (Machine monitor system)
Contents of • When the voltage of the switch power supply (power supply for operation) of the machine monitor is
trouble above 17 V, the voltage of the sensor is below 5 V.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until it is restarted.
Problem that
appears on • Machine monitor does not display load.
machine
Related • Only for load meter (if equipped)
information • Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshootin

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L51 (female) (16) –
Resistance Min. 1 MΩ
JF3 (female) (1) and chassis ground
Grounding fault in wiring
Wiring harness between JF3 (female) (2) –
1 harness Resistance Min. 1 MΩ
F13 (female) (C) and chassis ground
(Contact with ground circuit)
Wiring harness between JF3 (female) (7) –
Resistance Min. 1 MΩ
F14 (female) (B) and chassis ground
Wiring harness between JF3 (female) (8) –
Resistance Min. 1 MΩ
F15 (female) (B) and chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal
state F13 (male) Resistance
Between (C) and (A) 5 kΩ ±20%
Between (A), (B), (C) and
Min. 1 MΩ
chassis ground
Defective lift arm angle sensor ★ Prepare with starting switch OFF, then turn starting switch ON and
2
(Internal short circuit) carry out troubleshooting.
F13 Lift arm cylinder Voltage
Between (C) and (A) Constant 4.85 – 5.15 V
Constant 0.83 – 4.17 V
Between (B) and (A) At max. length 3.50 – 4.17 V
At min. length 0.83 – 1.88 V

40-304 ➁ WA500-6
TROUBLESHOOTING DAF5KP

Cause Standard value in normal state/Remarks on troubleshootin

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F14 (male) Resistance
Between (A), (B), (C) and
Min. 1 MΩ
chassis ground

Defective lift arm bottom ★ Prepare with starting switch OFF, then turn starting switch ON and
3 pressure sensor carry out troubleshooting.
(Internal short circuit) Lift arm bottom
F14 (male) Voltage
pressure
Between (C) and (B) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Between (C) and (A) When released 0.50 – 0.90 V
When relieved 3.02 – 3.42 V

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal F15 (male) Resistance
state
Between (A), (B), (C) and
Min. 1 MΩ
chassis ground
Defective lift arm rod pressure ★ Prepare with starting switch OFF, then turn starting switch ON and
4 sensor carry out troubleshooting.
(Internal short circuit)
F15 (male) Lift arm rod pressure Voltage
Between (C) and (B) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Between (C) and (A) When released 0.50 – 0.90 V
When relieved 3.02 – 3.42 V
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective machine monitor L51 Lift arm cylinder Voltage
Between (16) and
Constant 4.85 – 5.15 V
chassis ground

WA500-6 40-305 ➁
TROUBLESHOOTING DAF5KP
Related Circuit Diagram

40-306 ➁ WA500-6
TROUBLESHOOTING DAF5KP

MEMORANDUM

WA500-6 40-307 ➁
TROUBLESHOOTING DAFRKR

DAFRKR
Machine Monitor: CAN Defective Communication
Action Code Failure Code CAN communication with machine monitor: Defective communication
Trouble (Abnormality in target component system)
E03 DAFRKR (Transmission controller system)
Contents of • Communication via CAN signal line between the machine monitor and transmission controller is
trouble defective.
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Uses CAN information that was sent from machine monitor before the occurrence of the error.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on • The monitor does not display normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Disconnection in wiring
harness
1 Resistance
(Disconnection or defective
contact in connector)
Grounding fault in wiring
2 harness
(Contact with ground circuit)
Possible causes
Hot short in wiring harness
and standard 3 Voltage
(Contact with 24 V circuit)
value in normal
state
★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring harness
4
(with another wiring harness) Wiring harness between L56 (female) (3) –
Defective end point
5
resistance
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L56 (female) (3) –
Max. 1 Ω
L03 (female) (32)
Wiring harness between L56 (female) (8) –
Resistance Max. 1 Ω
L03 (female) (22)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L56 (female) (3) –
Resistance Min. 1 MΩ
L03 (female) (32) and chassis ground
Wiring harness between L56 (female) (8) –
Resistance Min. 1 MΩ
L03 (female) (22) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L56 (female) (3) –
Max. 1 V
L03 (female) (32) and chassis ground
Wiring harness between L56 (female) (8) –
Voltage Max. 1 V
L03 (female) (22) and chassis ground
without turning starting switch ON.
Resistance Min. 1 MΩ
(8)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CAN1 (male) Resistance
Between (A) and (B) 120 ±12 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
E21 (male) Resistance
Between (A) and (B) 120 ±12Ω

40-308 ➁ WA500-6
TROUBLESHOOTING DAFRKR

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
If causes 1 – 5 are not the cause of the problem, the machine monitor
and standard
6 Defective machine monitor may be defective. (Since problem is in system, troubleshooting cannot be
value in normal
carried out.)
state

Related Circuit Diagram

WA500-6 40-309 ➁
TROUBLESHOOTING DAQ0KK

DAQ0KK
Transmission Controller: Low Source Voltage
Action Code Failure Code Transmission controller: Low source voltage
Trouble
E03 DAQ0KK (Transmission controller system)

• Voltage of constant power supply (battery direct power supply) of the transmission controller is low.
Contents of
trouble • Voltage of constant power supply (battery direct power supply) is below 18 V and engine speed is above
500 rpm.
• Cannot sense the input signals normally.
Action of
controller • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine cannot operate normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective slow blow fuse If the slow blow fuse is shut down, the circuit probably has a grounding
1
(SBF1) fault, etc. (See cause 4.)
Defective fuse No.6 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
2
box A (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between battery relay BTR1
Resistance Max. 1 Ω
harness D03 – slow blow fuse SBF1 R01
3
(Disconnection or defective Wiring harness between slow blow fuse
contact in connector) Resistance Max. 1 Ω
SBF1 R02 – fuse No.6 of fuse box A
Wiring harness between fuse No.6 of fuse
Resistance Max. 1 Ω
box A – L04 (female) (1), (11)
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between battery relay BTR1
state D03 – slow blow fuse SBF1 R01 and chassis Resistance Min. 1 MΩ
Grounding fault in wiring ground
4 harness Wiring harness between slow blow fuse
(Contact with ground circuit) SBF1 R02 – fuse No.6 of fuse box A and Resistance Min. 1 MΩ
chassis ground
Wiring harness between fuse No.6 of fuse
box A – L04 (female) (1), (11), – circuit Resistance Min. 1 MΩ
branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective transmission
5 L04 Voltage
controller
Between (1), (11) and (21), (31),
20 – 30 V
(32), (33)

40-310 ➁ WA500-6
TROUBLESHOOTING DAQ0KK
Related Circuit Diagram

WA500-6 40-311 ➁
TROUBLESHOOTING DAQ0KT

DAQ0KT
Transmission Controller: Abnormality in Controller
Action Code Failure Code Transmission controller: Abnormality in controller
Trouble
E01 DAQ0KT (Transmission controller system)

• The information in the ROM (non-volatile memory) of the transmission controller is abnormal.
Contents of
trouble • Just after starting switch was turned OFF, battery direct power source was lost and finishing operation
was not carried out normally.
• Sets the internal adjustment values to the default values.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The feel of the transmission gear shift may be bad.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Since problem is in system, troubleshooting cannot be carried out.
and standard Defective transmission
1 If there is not any visible problem in machine, controller may be used as
value in normal controller
it is after initial setting and adjustment.
state

40-312 ➁ WA500-6
TROUBLESHOOTING DAQ0KT

MEMORANDUM

WA500-6 40-313 ➁
TROUBLESHOOTING DAQ2KK

DAQ2KK
Transmission Controller Load Power Supply Line: Low Source Voltage
(input)
Action Code Failure Code Transmission controller load power supply line: Low source voltage
Trouble (input)
E03 DAQ2KK (Transmission controller system)
• The voltage of the 24 V solenoid power supply system is low.
Contents of
trouble • Detection conditions: Terminal C input turned OFF, constant power supply (battery direct power supply)
above 20 V, and solenoid power supply below 18 V
• Turns the centralized warning lamp and alarm buzzer ON.
• Strains itself not to display failure codes that may be falsely detected due to low 24 V solenoid source
Action of
voltage.
controller
• Even if cause of failure disappears, system does not reset itself until directional lever, joystick steering
FNR (directional) switch, or directional selector switch is set to N (Neutral).
Problem that
• Transmission is stuck in Neutral.
appears on
machine • The fan rotates forward if reversed.

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective fan motor relay L114 (male) Resistance

(L114) (Internal Between (1) and (2) 200 – 400 Ω
1
disconnection or short
★ Prepare with starting switch OFF, then turn starting switch ON and
circuit)
carry out troubleshooting.
If fan motor relay (L114) is replaced with a relay of the same type (5-pin
type) and the condition becomes normal, the fan motor relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between L04 (female) (2),
2 Resistance Max. 1 Ω
(Disconnection or defective (12), (22) – L114 (female) (5)
Possible causes contact in connector) Wiring harness between L114 (female) (3) –
and standard Resistance Max. 1 Ω
value in normal fuse No.6 of fuse box A
state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L04 (female) (2),
Grounding fault in wiring
(12), (22) – L114 (female) (5) and chassis Resistance Min. 1 MΩ
3 harness
ground
(Contact with ground circuit)
Wiring harness between L114 (female) (3) –
fuse No. 6 of fuse box A, – circuit branch end Resistance Min. 1 MΩ
and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective transmission
4 L04 Voltage
controller
Between (2), (12), (22) and
20 – 30 V
(21), (31), (32), (33)

40-314 ➁ WA500-6
TROUBLESHOOTING DAQ2KK
Related Circuit Diagram

WA500-6 40-315 ➁
TROUBLESHOOTING DAQ9KQ

DAQ9KQ
Transmission Controller: Disagreement of Model Selection Signals
Action Code Failure Code Transmission controller model selection: Disagreement of model
Trouble selection signals
E03 DAQ9KQ (Machine monitor system)
Contents of
• The transmission controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of
Action of the failure code is still used.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Does not display failure codes which may be falsely detected.
Problem that
appears on • If machine travels in this state, transmission may be broken.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

• Select the model using the machine monitor and Service mode
Possible causes Improper machine monitor adjustment function.
and standard 1
model selection • See Machine Monitor System: Service Mode: Model Selection
value in normal
Function in the Testing and Adjusting section.
state
2 Transmission controller Check controller part number. If it is wrong, replace controller.

40-316 ➁ WA500-6
TROUBLESHOOTING DAQ9KQ

MEMORANDUM

WA500-6 40-317 ➁
TROUBLESHOOTING DAQRKR

DAQRKR
Transmission Controller: CAN Defective Communication
Action Code Failure Code CAN communication with transmission controller: Defective
Trouble communication (Abnormality in target component system)
E03 DAQRKR (Machine monitor system)
Contents of
• Machine monitor cannot get information from transmission controller.
trouble
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on • The monitor does not display normally.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then disconnect CAN1 and E21
Defective CAN terminal and carry out troubleshooting.
1
resistor Between CAN1 (male) (A) – (B) Resistance 120 Ω
Between E21 (male) (A) – (B) Resistance 120 Ω
★ Prepare with starting switch OFF, then disconnect CAN1, E21, L56,
L03, L06 and E18 and carry out troubleshooting.
Wiring harness between L56 (female) (8), (3)
Resistance Max. 1 Ω
– E21 (female) (A), (B)
Wiring harness between L56 (female) (8), (3)
Possible causes Resistance Max. 1 Ω
and standard – L03 (female) (32), (22)
value in normal Disconnection in wiring Wiring harness between L56 (female) (8), (3)
Resistance Max. 1 Ω
state harness – L06 (female) (32), (22)
2 (Disconnection in wiring or Wiring harness between L56 (female) (8), (3)
defective contact in Resistance Max. 1 Ω
– E18 (female) (46), (47)
connector)
Wiring harness between L56 (female) (8), (3)
Resistance Max. 1 Ω
– CAN1 (female) (A), (B)
Wiring harness between L56 (female) (8), (3)
Resistance Max. 1 Ω
– L80 (female) (7), (8)
Wiring harness between E18 (female) (46),
(47) – CAN1 (female) (A), (B) or E21 Resistance Max. 1 Ω
(female) (A), (B)

40-318 ➁ WA500-6
TROUBLESHOOTING DAQRKR

Cause Standard value in normal state/Remarks on troubleshooting

Ground fault in wiring
3 harness
Possible causes
(Contact with GND circuit)
and standard
value in normal
state
Defective machine monitor,
engine controller,
4 transmission controller, or work equipment controller may be defective.
transmission controller, or
work equipment controller
★ Prepare with starting switch OFF, then disconnect CAN1, E21, L56,
L03, L06 and E18 and carry out troubleshooting.
Wiring harness between L56 (female) (3) –
Resistance Min. 1 MΩ
E21 (female) (A)
Wiring harness between L56 (female) (3) –
Resistance Min. 1 MΩ
L03 (female) (32)
Wiring harness between L56 (female) (3) –
Resistance Min. 1 MΩ
E18 (female) (46)
Wiring harness between L56 (female) (3) –
Resistance Min. 1 MΩ
CAN1 (female) (A)
Wiring harness between L56 (female) (3) –
Resistance Min. 1 MΩ
L80 (female) (3)
Wiring harness between E18 (female) (46) –
Resistance Min. 1 MΩ
CAN1 (female) (A) – E21 (female) (A)
If causes 1 – 3 are not detected, machine monitor, engine controller,
(Since problem is in system, troubleshooting cannot be carried out.)

Related Circuit Diagram

WA500-6 40-319 ➁
TROUBLESHOOTING DAQRMA

DAQRMA
Transmission Controller Option Setting: Malfunction
Action Code Failure Code Transmission controller option setting: Malfunction
Trouble
E03 DAQRMA (Machine monitor – transmission controller)
Contents of
• Optional setting of the machine monitor disagrees with its recognition in the transmission controller.
trouble
Action of • The transmission controller complies with its optional setting recognition.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Optional components do not operate normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes 1 Defective machine monitor Since problem is in system, troubleshooting cannot be carried out.
and standard
value in normal Defective transmission
2 Since problem is in system, troubleshooting cannot be carried out.
state controller

40-320 ➁ WA500-6
TROUBLESHOOTING DAQRMA

MEMORANDUM

WA500-6 40-321 ➁
TROUBLESHOOTING DB2RKR

DB2RKR
Engine Controller: CAN Defective Communication
Action Code Failure Code CAN communication with engine controller: Defective communication
Trouble (Abnormality in target component system)
E03 DB2RKR (Transmission controller system)
Contents of • Communication via CAN signal line between the transmission controller and engine controller is
trouble defective.
• Uses CAN information that was sent from engine controller before the occurrence of the error.
• Keeps recognizing engine speed at 2,100 rpm.
Action of
• Holds recognized position of accelerator at 80%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on • The monitor does not display normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Disconnection in wiring
harness
1 Resistance
(Disconnection or defective
contact in connector)
Grounding fault in wiring
2 harness
(Contact with ground circuit)
Possible causes
Hot short in wiring harness
and standard 3 Voltage
(Contact with 24 V circuit)
value in normal
state
★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring harness
4
(with another wiring harness) Wiring harness between E18 (female) (46) –
Defective end point
5
resistance
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between E18 (female) (47) –
Max. 1 Ω
L03 (female) (22)
Wiring harness between E18 (female) (46) –
Resistance Max. 1 Ω
L03 (female) (32)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between E18 (female) (47) –
Resistance Min. 1 MΩ
L03 (female) (22) and chassis ground
Wiring harness between E18 (female) (46) –
Resistance Min. 1 MΩ
L03 (female) (32) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between E18 (female) (47) –
Max. 1 V
L03 (female) (22) and chassis ground
Wiring harness between E18 (female) (46) –
Voltage Max. 1 V
L03 (female) (32) and chassis ground
without turning starting switch ON.
Resistance Min. 1 MΩ
(47)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CAN1 (male) Resistance
Between (A) and (B) 120 ±12 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
E21 (male) Resistance
Between (A) and (B) 120 ±12 Ω

40-322 ➁ WA500-6
TROUBLESHOOTING DB2RKR

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
If causes 1 – 5 are not the cause of the problem, the engine controller
and standard
6 Defective engine controller may be defective. (Since problem is in system, troubleshooting cannot be
value in normal
carried out.)
state

Related Circuit Diagram

WA500-6 40-323 ➁
TROUBLESHOOTING DB90KK

DB90KK
Work Equipment Controller: Low Source Voltage (input)
Action Code Failure Code Work equipment controller: Low source voltage (input)
Trouble
E03 DB90KK (Work equipment controller system)

Contents of • Voltage of work equipment controller UNSW power supply (battery direct power supply) is low.
trouble • Voltage of constant power supply (battery direct power supply) is 18 V or less.
• Does not display failure codes other than this code if voltage of constant power supply (battery direct
power supply) remains under 18 V for more than two seconds.
Action of • Even if cause of failure disappears, system does not reset itself until joystick steering lever and work
controller equipment lever are set to N (Neutral).
• Turns the centralized warning lamp and alarm buzzer ON.
• Cannot operate normally since it cannot sense the input signals properly.
Problem that
appears on • The machine cannot operate normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective slow blow fuse If the slow blow fuse is shut down, the circuit probably has a grounding
1
(SBF1) fault, etc. (See cause 4.)
Defective fuse No.7 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
2
box A (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between battery relay BTR1
Resistance Max. 1 Ω
harness D03 – slow blow fuse SBF1 R01
3
(Disconnection or defective Wiring harness between slow blow fuse
contact in connector) Resistance Max. 1 Ω
SBF1 R02 – fuse No.7 of fuse box A
Wiring harness between fuse No.7 of fuse
Resistance Max. 1 Ω
box A – L07 (female) (1), (11)
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal
Wiring harness between battery relay BTR1
state
D03 – slow blow fuse SBF1 R01 and chassis Resistance Min. 1 MΩ
Grounding fault in wiring ground
4 harness Wiring harness between slow blow fuse
(Contact with ground circuit) SBF1 R02 – fuse No.7 of fuse box A and Resistance Min. 1 MΩ
chassis ground
Wiring harness between fuse No.7 of fuse
box A – L07 (female) (1), (11) Resistance Min. 1 MΩ
and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment
5 L07 Voltage
controller
Between (1), (11) and (21), (31),
20 – 30 V
(32), (33)

40-324 ➁ WA500-6
TROUBLESHOOTING DB90KK
Related Circuit Diagram

WA500-6 40-325 ➁
TROUBLESHOOTING DB90KT

DB90KT
Work Equipment Controller: Abnormality in Controller
Action Code Failure Code Work equipment controller: Abnormality in controller
Trouble
E01 DB90KT (Work equipment controller system)
Contents of
• The information in the ROM (non-volatile memory) of the work equipment controller system is abnormal.
trouble
• Sets the internal adjustment values to the default values.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The machine may falsely detect errors.
appears on
machine • Performance degrades since the machine is controlled with improper data.

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard Defective work equipment • Since problem is in system, troubleshooting cannot be carried out.
1
value in normal controller • Replace the work equipment controller.
state

40-326 ➁ WA500-6
TROUBLESHOOTING DB90KT

MEMORANDUM

WA500-6 40-327 ➁
TROUBLESHOOTING DB92KK

DB92KK
Work Equipment Controller Load Power Supply Line: Low Source Voltage
(input)
Action Code Failure Code Work equipment controller load power supply line: Low source voltage
Trouble (input)
E03 DB92KK (Work equipment controller system)
• The voltage of the 24V solenoid power supply system is low.
Contents of
trouble • Detection conditions: Terminal C input turned OFF, constant power supply (battery direct power supply)
above 20 V, and solenoid power supply below 18 V
• Cannot supply voltage to the solenoid. (If the voltage is below 18 V, all outputs are turned OFF.)
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering lever and work
equipment lever are set to N (Neutral).
Problem that
appears on • Work equipment does not move.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective slow blow fuse If the slow blow fuse is shut down, the circuit probably has a grounding
1
(SBF2) fault, etc. (See cause 4.)
Defective fuse No. 7 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
2
box B (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between battery relay BTR1
Resistance Max. 1 Ω
harness D04 – slow blow fuse SBF2 R03
3
(Disconnection or defective Wiring harness between slow blow fuse
contact in connector) Resistance Max. 1 Ω
SBF2 R05 – fuse No.7 of fuse box B
Wiring harness between fuse No.7 of fuse
Resistance Max. 1 Ω
box B – L07 (female) (2), (12), (22)
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting
and standard
without turning starting switch ON.
value in normal
state Wiring harness between battery relay BTR1
D04 – slow blow fuse SBF2 R03 and chassis Resistance Min. 1 MΩ
Grounding fault in wiring ground
4 harness Wiring harness between slow blow fuse
(Contact with ground circuit) SBF2 R05 – fuse No.7 of fuse box B and Resistance Min. 1 MΩ
chassis ground
Wiring harness between fuse No.7 of fuse
box B – L07 (female) (2), (12), (22), – circuit Resistance Min. 1 MΩ
branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment
5 L07 Voltage
controller
Between (2), (12), (22) and
20 – 30 V
(21), (31), (32), (33)

40-328 ➁ WA500-6
TROUBLESHOOTING DB92KK
Related Circuit Diagram

WA500-6 40-329 ➁
TROUBLESHOOTING DD95KX

DD95KX
Work Equipment Controller Power Supply Output: Out-of-Input Signal
Range
Action Code Failure Code Work equipment controller power supply output: Out-of-input signal
Trouble range
E03 DB95KX (Work equipment controller system)
Contents of
• Normal voltage output of 5 V sensor power supply system is out of range (outside 4.7 – 5.3 V).
trouble
• Cannot sense the input signals normally due to abnormal potentiometer signal.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The operator cannot operate the work equipment (all stop).
appears on
machine • The following potentiometer errors occur.

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective joystick steering
lever potentiometer JS3 (male) Resistance
1
(Internal disconnection or Between (4) and (1) 4 – 6 kΩ
short circuit)
Between (1), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 3-spool valve EPC
lever potentiometer S25 (male) Resistance
2
(Internal disconnection or Between (4) and (1) 2.5 – 3.9 kΩ
short circuit)
Between (1), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
Defective lift arm EPC lever
and standard S03 (male) Resistance
potentiometer
value in normal 3
(Internal disconnection or Between (4) and (1) 2.5 – 3.9 kΩ
state
short circuit)
Between (1), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket EPC lever
potentiometer S02 (male) Resistance
4
(Internal disconnection or Between (4) and (1) 2.5 – 3.9 kΩ
short circuit)
Between (1), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective oil pressure sensor F16 (male) Resistance
5
of work equipment pump Between (B) and (A)
Between (A), (B) and
Min. 1 MΩ
chassis ground

40-330 ➁ WA500-6
TROUBLESHOOTING DD95KX

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
6 harness
Possible causes (Contact with ground circuit) Wiring harness between L05 (female) (22) –
Resistance Min. 1 MΩ
and standard chassis ground
value in normal ★ Prepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
Defective work equipment
7
controller L05 Voltage
Between (22) and (21) 4.85 – 5.15 V

Related Circuit Diagram

WA500-6 40-331 ➁
TROUBLESHOOTING DB99KQ

DB99KQ
Work Equipment Controller: Disagreement of Model Selection Signals
Action Code Failure Code Work equipment controller model selection: Disagreement of model
Trouble selection signals
E03 DB99KQ (Machine monitor system)
Contents of
• Work equipment 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.
controller • Does not display failure codes which may be false detected.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Work equipment may not operate normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

• Set the model with the service mode adjustment function of the
Possible causes Improper machine monitor machine monitor.
1
and standard model selection • See Machine Monitor System: Service Mode: Model Selection
value in normal Function in the Testing and Adjusting section.
state • Check if work equipment controller has the correct part number.
2 Work equipment controller
• If the part number is not correct, replace it.

40-332 ➁ WA500-6
TROUBLESHOOTING DB99KQ

MEMORANDUM

WA500-6 40-333 ➁
TROUBLESHOOTING DB9RKR

DB9RKR
Work Equipment Controller: CAN Defective Communication
Action Code Failure Code CAN communication with work equipment controller: Defective
Trouble communication (Abnormality in target component system)
E03 DB9RKR (Transmission controller system)
Contents of • Communication via CAN signal line between the work equipment controller and transmission controller
trouble is defective.
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Uses CAN information that was sent from work equipment controller before the occurrence of the error.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Disconnection in wiring
harness
1 Resistance
(Disconnection or defective
contact in connector)
Grounding fault in wiring
2 harness
(Contact with ground circuit)
Possible causes
Hot short in wiring harness
and standard 3 Voltage
(Contact with 24 V circuit)
value in normal
state
★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring harness
4
(with another wiring harness) Wiring harness between L06 (female) (22) –
Defective end point
5
resistance
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L06 (female) (22) –
Max. 1 Ω
L03 (female) (22)
Wiring harness between L06 (female) (32) –
Resistance Max. 1 Ω
L03 (female) (32)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L06 (female) (22) –
Resistance Min. 1 MΩ
L03 (female) (22) and chassis ground
Wiring harness between L06 (female) (32) –
Resistance Min. 1 MΩ
L03 (female) (32) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L06 (female) (22) –
Max. 1 V
L03 (female) (22) and chassis ground
Wiring harness between L06 (female) (32) –
Voltage Max. 1 V
L03 (female) (32) and chassis ground
without turning starting switch ON.
Resistance Min. 1 MΩ
(32)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CAN1 (male) Resistance
Between (A) and (B) 120 ±12 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
E21 (male) Resistance
Between (A) and (B) 120 ±12 Ω

40-334 ➁ WA500-6
TROUBLESHOOTING DB9RKR

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
If causes 1 – 5 are not the cause of the problem, the work equipment
and standard Defective work equipment
6 controller may be defective. (Since problem is in system, troubleshooting
value in normal controller
cannot be carried out.)
state

Related Circuit Diagram

WA500-6 40-335 ➁
TROUBLESHOOTING DB9RMA

DB9RMA
Work Equipment Controller Option Setting: Malfunction
Action Code Failure Code Work equipment controller option setting: Malfunction
Trouble
E03 DB9RMA (Machine monitor system)
Contents of
• Optional setting of the machine monitor disagrees with its recognition in the work equipment controller.
trouble
Action of • The work equipment controller complies with its optional setting recognition.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Optional components do not operate normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Defective work equipment
1 Since trouble is in system, troubleshooting cannot be carried out.
and standard controller
value in normal
state 2 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.

40-336 ➁ WA500-6
TROUBLESHOOTING DB9RMA

MEMORANDUM

WA500-6 40-337 ➁
TROUBLESHOOTING DB9RMC

DB9RMC
Work Equipment Controller: CAN Communication Defective Operation
Action code Failure code CAN communication with work equipment controller: Defective operation
Trouble
E03 DB9RMC (Work equipment controller system)
• Communication via CAN signal line between the work equipment controller and transmission controller is
defective.
Contents of
• The travel speed signal cannot be transmitted from the transmission controller.
trouble
• The engine start prohibition signal cannot be transmitted from the transmission controller.
• If cause of failure disappears, system resets itself.
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Judges that the travel speed is at 0 km/h.
controller
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
Problem that • The operator cannot use semi-automatic digging occasionally or cannot use it at any time.
appears on • The engine can start when the joystick steering lever is not in neutral.
machine • Swing speed increases because joystick steering cannot sense travel speed properly.
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Disconnection in wiring
harness
1 Resistance
(Disconnection or defective
contact in connector)
Grounding fault in wiring
2 harness
(Contact with ground circuit)
Possible causes
Hot short in wiring harness
and standard 3 Voltage
(Contact with 24 V circuit)
value in normal
state
Short circuit in wiring harness
4
(with another wiring harness) Wiring harness between L06 (female) (22) –
Defective end point
5
resistance
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L06 (female) (22) –
Max. 1 Ω
L03 (female) (22)
Wiring harness between L06 (female) (32) –
Resistance Max. 1 Ω
L03 (female) (32)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L06 (female) (22) –
Resistance Min. 1 MΩ
L03 (female) (22) and chassis ground
Wiring harness between L06 (female) (32) –
Resistance Min. 1 MΩ
L03 (female) (32) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L06 (female) (22) –
Max. 1 V
L03 (female) (22) and chassis ground
Wiring harness between L06 (female) (32) –
Voltage Max. 1 V
L03 (female) (32) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Resistance Min. 1 MΩ
(32)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CAN1 (male) Resistance
Between (A) and (B) 120 ±12 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
E21 (male) Resistance
Between (A) and (B) 120 ±12 Ω

40-338 ➁ WA500-6
TROUBLESHOOTING DB9RMC

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard If causes 1 – 5 are not the cause of the problem, the transmission
Defective transmission
value in normal 6 controller may be defective. (Since problem is in system, troubleshooting
controller
state cannot be carried out.)

Related Circuit Diagram

WA500-6 40-339 ➁
TROUBLESHOOTING DD15LD

DD15LD
Switch (Panel Switch 1 ■): Switch is Kept Pressed for Long Time
Action Code Failure Code ■ Switch (Panel switch 1): Switch is kept pressed for long time
Trouble
E01 DD15LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 1 ■ (panel switch 1) is kept CLOSED
trouble continuously for more than one minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot operate the monitor (cannot enter the Service mode).
appears on
machine • Character display may not display letters.

• The input state (ON/OFF) from the machine monitor mode selector switch 1 ■ (panel switch 1) can be
Related checked with the monitoring function (Code: 40901 D-IN-15).
information • The operator may not be able to use the monitoring function because of the ■ switch problem.
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective ■ switch ■ switch
1 (Panel switch 1) L66 (male) Resistance
(Panel switch 1)
(Internal short circuit)
ON Max. 1Ω
Between (4) and (5)
Other than above Min. 1 MΩ
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L52 (female) (17) and
state Voltage Max. 1 V
L66 (female) (4) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
■ switch
3 Defective machine monitor L52 Voltage
(Panel switch 1)
Between (17) and ON 20 – 30 V
chassis ground Other than above Max. 1 V

40-340 ➁ WA500-6
TROUBLESHOOTING DD15LD
Related Circuit Diagram

WA500-6 40-341 ➁
TROUBLESHOOTING DD16LD

DD16LD
Switch (Panel Switch 2 ◊): Switch is Kept Pressed for Long Time
Action Code Failure Code ◊ Switch (Panel switch 2): Switch is kept pressed for long time
Trouble
E01 DD16LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 2 ◊ (panel switch 2) is kept CLOSED
trouble continuously for more than one minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot operate the monitor.
appears on
machine • Character display may not display letters.

• The input state (ON/OFF) from the machine monitor mode selector switch 2 ◊ (panel switch 2) can be
Related checked with the monitoring function (Code: 40901 D-IN-14).
information • The operator may not be able to use the monitoring function because of the ◊ switch problem.
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective ◊ switch ◊ switch
1 (Panel switch 2) L66 (male) Resistance
(Panel switch 2)
(Internal short circuit)
ON Max. 1 Ω
Between (5) and (6)
Other than above Min. 1 MΩ
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L52 (female) (8) and
state Voltage Max. 1 V
L66 (female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
◊ switch
3 Defective machine monitor L52 Voltage
(Panel switch 2)
Between (8) and ON 20 – 30 V
chassis ground Other than above Max. 1 V

40-342 ➁ WA500-6
TROUBLESHOOTING DD16LD
Related Circuit Diagram

WA500-6 40-343 ➁
TROUBLESHOOTING DD17LD

DD17LD
Switch (Panel Switch 3 <): Switch is Kept Pressed for Long Time
Action Code Failure Code < Switch (Panel switch 3): Switch is kept pressed for long time (Machine
Trouble
E01 DD17LD monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 3 < (panel switch 3) is kept CLOSED
trouble continuously for more than one minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot operate the monitor.
appears on
machine • Character display may not display letters.

• The input state (ON/OFF) from the machine monitor mode selector switch 3 < (panel switch 3) can be
Related checked with the monitoring function (Code: 40904 D-IN-38).
information • The operator may not be able to use the monitoring function because of the < switch problem.
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective < switch < switch
1 (Panel switch 3) L65 (female) Resistance
(Panel switch 3)
(Internal short circuit)
ON Max. 1 Ω
Between (4) and (5)
Other than above Min. 1 MΩ
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L54 (female) (7)
(Contact with ground circuit) Resistance Min. 1 MΩ
state and L65 (female) (4) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
< switch
3 Defective machine monitor L54 (female) Voltage
(Panel switch 3)
Between (7) and ON Max. 1 V
chassis ground Other than above 20 – 30 V

40-344 ➁ WA500-6
TROUBLESHOOTING DD17LD
Related Circuit Diagram

WA500-6 40-345 ➁
TROUBLESHOOTING DD18LD

DD18LD
Switch (Panel Switch 4 >): Switch is Kept Pressed for Long Time
Action Code Failure Code > Switch (Panel switch 4): Switch is kept pressed for long time
Trouble
E01 DD18LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 4 > (panel switch 4) is kept CLOSED
trouble continuously for more than one minute.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the monitor.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 4 > (panel switch 4) can be
Related checked with the monitoring function (Code: 40904 D-IN-37).
information • The operator may not be able to use the monitoring function because of the > switch problem.
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective > switch > switch
1 (Panel switch 4) L65 (female) Resistance
(Panel switch 4)
(Internal short circuit)
ON Max. 1 Ω
Between (5) and (6)
Other than above Min. 1 MΩ
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L54 (female) (15)
(Contact with ground circuit) Resistance Min. 1 MΩ
state and L65 (female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
> switch
3 Defective machine monitor L54 (female) Voltage
(Panel switch 4)
Between (15) and ON Max. 1 V
chassis ground Other than above 20 – 30 V

40-346 ➁ WA500-6
TROUBLESHOOTING DD18LD
Related Circuit Diagram

WA500-6 40-347 ➁
TROUBLESHOOTING DD1ALD

DD1ALD
Remote Positioner Raise/Lower Set Switch (raise): Switch is Kept Pressed
for Long Time
Action Code Failure Code Remote positioner raise/lower set switch (raise): Switch is kept pressed
Trouble for long time
E01 DD1ALD (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (raise) system has a grounding fault, operator cannot
trouble set raising.
• Stops setting the lift arm raise set position.
Action of • Stops the remote raise stop operation.
controller • Turns the lift arm raise set indicator OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The operator cannot set the lift arm raise set position.
appears on
machine • The remote positioner raise stop control does not operate.

• The input state (ON/OFF) from the remote positioner raise/lower set switch (raise) can be checked with
Related
the monitoring function (Code: 40913 D-IN-28).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Remote positioner
Defective remote positioner S13 (male) Resistance
raise/lower set switch
1 raise/lower set switch (raise)
Raise Max. 1 Ω
(Internal short circuit) Between (5) and (6)
Other than above Min. 1 MΩ
Between (5), (6) and
Constant Min. 1 MΩ
Possible causes chassis ground
and standard
★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L06 (female) (13) –
Resistance Min. 1 MΩ
S13 (female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment Remote positioner
3 L06 (male) Voltage
controller raise/lower set switch
Between (13) and Raise Max. 1 V
chassis ground Other than above 7 – 10 V

40-348 ➁ WA500-6
TROUBLESHOOTING DD1ALD
Related Circuit Diagram

WA500-6 40-349 ➁
TROUBLESHOOTING DD1BLD

DD1BLD
Remote Positioner Raise/Lower Set Switch (lower): Switch is Kept Pressed
for Long Time
Action Code Failure Code Remote positioner raise/lower set switch (lower): Switch is kept pressed
Trouble for long time
E01 DD1BLD (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (lower) system has a grounding fault, operator cannot
trouble set lowering.
• Stops setting the lift arm lower set position.
Action of • Stops the remote lower stop operation.
controller • Turns the lift arm lower set indicator OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The operator cannot set the lower set position.
appears on
machine • The remote positioner lower stop control does not operate.

• The input state (ON/OFF) from the remote positioner raise/lower set switch (lower) can be checked with
Related
the monitoring function (Code: 40913 D-IN-29).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Remote positioner
Defective remote positioner S13 (male) Resistance
raise/lower set switch
1 raise/lower set switch
Lower Max. 1 Ω
(Internal short circuit) Between (4) and (5)
Other than above Min. 1 MΩ
Between (4), (5) and
Constant Min. 1 MΩ
Possible causes chassis ground
and standard
★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L06 (female) (3) –
Resistance Min. 1 MΩ
S13 (female) (4) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment Remote positioner
3 L06 (male) Voltage
controller raise/lower set switch
Between (3) and Lower Max. 1 V
chassis ground Other than above 7 – 10 V

40-350 ➁ WA500-6
TROUBLESHOOTING DD1BLD
Related Circuit Diagram

WA500-6 40-351 ➁
TROUBLESHOOTING DD1CLD

DD1CLD
Load Meter Subtotal Switch: Switch is Kept Pressed for Long Time
Action Code Failure Code Load meter subtotal switch: Switch is kept pressed for long time
Trouble
E01 DD1CLD (Machine monitor system)
Contents of • The load meter subtotal switch may not operate because of grounding fault in load meter subtotal switch
trouble system.
Action of
• None in particular.
controller
Problem that
• The total amount of load cannot be set to 0 on the screen.
appears on
machine • Data cannot be output to printer (if equipped).

• The input state (ON/OFF) from the load meter subtotal switch can be checked with the monitoring
Related function (Code: 40904 D-IN-32).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Load meter subtotal
S08 (male) Resistance
Defective load meter subtotal switch
1
switch (Internal short circuit) ON Max. 1 Ω
Between (3) and (4)
OFF Min. 1 MΩ
Between (3), (4) and
Constant Min. 1 MΩ
chassis ground
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L54 (female) (4) –
Resistance Min. 1 MΩ
S08 (female) (3) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Load meter subtotal
3 Defective machine monitor L54 (male) Voltage
switch
Between (4) and ON Max. 1 V
chassis ground OFF 20 – 30 V

40-352 ➁ WA500-6
TROUBLESHOOTING DD1CLD
Related Circuit Diagram

WA500-6 40-353 ➁
TROUBLESHOOTING DD1FLD

DD1FLD
Load Meter Mode Selector Switch (A/B): Switch is Kept Pressed for Long
Time
Action Code Failure Code Load meter mode selector switch (A/B): Switch is kept pressed for long
Trouble
E01 DD1FLD time (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (A/B) is kept CLOSED continuously for more
trouble than one minute
Action of
• None in particular.
controller
Problem that
• The working object cannot be changed.
appears on
machine • Character display may not display letters.

• The input state (ON/OFF) from the load meter mode selector switch (A/B) can be checked with the
Related monitoring function (Code: 40901 D-IN-10).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Load meter mode
Defective load meter mode L69 (male) Resistance
selector switch (A/B)
1 selector switch (A/B)
ON Max. 1 Ω
(Internal short circuit) Between (5) and (6)
OFF Min. 1 MΩ
Between (5), (6) and
Constant Min. 1 MΩ
Possible causes chassis ground
and standard
★ Prepare with starting switch OFF, then turn starting switch ON and
value in normal
Hot short in wiring harness carry out troubleshooting.
state 2
(Contact with 24 V circuit) Wiring harness between L52 (female) (6) and
Voltage Max. 1 V
L69 (female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Load meter mode
3 Defective machine monitor L52 (female) Voltage
selector switch (A/B)
Between (6) and ON 20 – 30 V
chassis ground OFF Max. 1 V

40-354 ➁ WA500-6
TROUBLESHOOTING DD1FLD
Related Circuit Diagram

WA500-6 40-355 ➁
TROUBLESHOOTING DD1GLD

DD1GLD
Load Meter Mode Selector Switch (+/-): Switch is Kept Pressed for Long
Time
Action Code Failure Code Load meter mode selector switch (+/–): Switch is kept pressed for long
Trouble time
E01 DD1GLD (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (+/–) is kept CLOSED continuously for more
trouble than one minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot use settings of load meter addition mode.
appears on
machine • Character display may not display letters.

• The input state (ON/OFF) from the load meter mode selector switch (+/–) can be checked with the
Related monitoring function (Code: 40901 D-IN-11).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Load meter mode
Defective load meter mode L69 (male) Resistance
selector switch (+/–)
1 selector switch (+/–)
ON Max. 1 Ω
(Internal short circuit) Between (4) and (5)
OFF Min. 1 MΩ
Between (4), (5) and
Constant Min. 1 MΩ
Possible causes chassis ground
and standard Prepare with starting switch OFF, then turn starting switch ON and carry
value in normal Hot short in wiring harness out troubleshooting.
state 2
(Contact with 24 V circuit) Wiring harness between L52 (female) (15)
Voltage Max. 1 V
and L69 (female) (4) and chassis ground
Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Load meter mode
3 Defective machine monitor L52 (female) Voltage
selector switch (+/–)
Between (15) and ON 20 – 30 V
chassis ground OFF Max. 1 V

40-356 ➁ WA500-6
TROUBLESHOOTING DD1GLD
Related Circuit Diagram

WA500-6 40-357 ➁
TROUBLESHOOTING DD1HLD

DD1HLD
Load Meter Display Selector Switch: Switch is Kept Pressed for Long Time
Action Code Failure Code Load meter display selector switch: Switch is kept pressed for long time
Trouble
E01 DD1HLD (Machine monitor system)
Contents of • The load meter display selector switch does not operate because of grounding fault in the load meter
trouble display selector switch system.
Action of
• None in particular.
controller
Problem that
• Unable to display cumulative data.
appears on
machine • Character display may not display letters.

• The input state (weight) from the load meter display selector switch can be checked with the monitoring
Related function (Code: 40902 D-IN-23).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Load meter display
Defective load meter display L70 (male) Resistance
selector switch
1 selector switch
ON Max. 1 Ω
(Internal short circuit) Between (5) and (6)
OFF Min. 1 MΩ
Between (5), (6) and
Constant Min. 1 MΩ
Possible causes chassis ground
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L53 (female) (10)
Resistance Min. 1 MΩ
and L70 (female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Load meter display
3 Defective machine monitor L53 (male) Voltage
selector switch
Between (10) and ON Max. 1 V
chassis ground OFF 20 – 30 V

40-358 ➁ WA500-6
TROUBLESHOOTING DD1HLD
Related Circuit Diagram

WA500-6 40-359 ➁
TROUBLESHOOTING DDA7L4

DDA7L4
RPM Set ON/OFF Switch: ON/OFF Signals Disagree
Action Code Failure Code RPM set ON/OFF switch: ON/OFF signals disagree
Trouble
E01 DDA7L4 (Transmission controller system)
Contents of
• RPM set does not function because of a hot short circuit in RPM set ON/OFF switch system.
trouble
Action of • Turns RPM set function OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • RPM setting is disabled.
machine
• The input state (ON/OFF) from the RPM set ON/OFF switch (pressed upward) can be checked with the
monitoring function (Code: 95500 THROT LOCK A).
Related
• The input state (ON/OFF) from the RPM set ON/OFF switch (pressed downward) can be checked with
information
the monitoring function (Code: 95501 THROT LOCK B).
• Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
RPM set ON/OFF
S11 (male) Resistance
switch
ON Ι, OFF Min. 1 MΩ
Defective RPM set ON/OFF Between (4) and (5)
1
switch (Internal short circuit) ON ΙΙ Max. 1 Ω
ON Ι Max. 1 Ω
Between (5) and (6)
ON ΙΙ, OFF Min. 1 MΩ
Between (4), (5), (6)
Constant Min. 1 MΩ
and chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
value in normal Hot short in wiring harness Wiring harness between L02 (female) (13) – S11
state 2 Voltage Max. 1 V
(Contact with 24 V circuit) (female) (4) and chassis ground
Wiring harness between L02 (female) (19) – S11
Voltage Max. 1 V
(female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
RPM set ON/OFF
L02 Voltage
switch
3 Defective machine monitor
Between (13) and ON Ι, OFF Max. 1 V
chassis ground ON ΙΙ 20 – 30 V

Between (19) and ON Ι 20 – 30 V

chassis ground ON ΙΙ, OFF Max. 1 V

40-360 ➁ WA500-6
TROUBLESHOOTING DDA7L4
Related Circuit Diagram

WA500-6 40-361 ➁
TROUBLESHOOTING DDA8KB

DDA8KB
RPM Set Idle UP/DOWN Selector Switch (idle UP): Short Circuit
Action Code Failure Code RPM set idle UP/DOWN selector switch (idle UP): Short circuit
Trouble
E01 DDA8KB (Transmission controller system)
Contents of • Idle-up switch is misjudged to be ON due to ground fault in RPM set idle UP/DOWN selector switch
trouble (idle UP) system.
Action of • Turns RPM set function OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • RPM setting is disabled.
machine
• The input state (ON/OFF) from the RPM set idle UP/DOWN selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON and
operate the RPM set idle UP/DOWN selector switch (idle UP)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
RPM set idle UP/
S12 (male) DOWN selector Resistance
switch

Defective RPM set idle UP/ Idle UP position or

Min. 1 MΩ
1 DOWN selector switch Between (4) and (5) neutral
(Internal short circuit) Idle DOWN position Max. 1 Ω
Idle UP position Max. 1 Ω
Between (5) and (6) Idle DOWN position
Min. 1 MΩ
or neutral
Between (4), (5), (6)
Constant Min. 1 MΩ
and chassis ground
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L04 (female) (19) –
Resistance Min. 1 MΩ
S12 (female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
RPM set idle UP/
L04 DOWN selector Voltage
switch
Defective transmission Idle UP position or
3 20 – 30 V
controller Between (29) and neutral
chassis ground
Idle DOWN position Max. 1 V
Idle UP position Max. 1 V
Between (19) and
chassis ground Idle DOWN position
20 – 30 V
or neutral

40-362 ➁ WA500-6
TROUBLESHOOTING DDA8KB
Related Circuit Diagram

WA500-6 40-363 ➁
TROUBLESHOOTING DDA9KB

DDA9KB
RPM Set Idle UP/DOWN Selector Switch (idle DOWN): Short Circuit
Action Code Failure Code RPM set idle UP/DOWN selector switch (idle-down): Short circuit
Trouble
E01 DDA9KB (Transmission controller system)
Contents of • Idle DOWN switch is misjudged to be ON due to ground fault in RPM set idle UP/DOWN switch
trouble (idle DOWN) system.
Action of • Turns RPM set function OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • RPM setting is disabled.
machine
• The input state (ON/OFF) from the RPM set idle UP/DOWN selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON and
operate the RPM set idle UP/DOWN selector switch (idle DOWN).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
RPM set idle UP/
S12 (male) DOWN selector Resistance
switch

Defective RPM set idle UP/ Idle UP position or

Min. 1 MΩ
1 DOWN selector switch Between (4) and (5) neutral
(Internal short circuit) Idle DOWN position Max. 1 Ω
Idle UP position Max. 1 Ω
Between (5) and (6) Idle DOWN position
Min. 1 MΩ
or neutral
Between (4), (5), (6)
Constant Min. 1 MΩ
and chassis ground
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L04 (female) (29) –
Resistance Min. 1 MΩ
S12 (female) (4) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
RPM set idle UP/
L04 DOWN selector Voltage
switch
Defective transmission Idle UP position or
3 20 – 30 V
controller Between (29) and neutral
chassis ground
Idle DOWN position Max. 1 V
Idle UP position Max. 1 V
Between (19) and
chassis ground Idle DOWN position
20 – 30 V
or neutral

40-364 ➁ WA500-6
TROUBLESHOOTING DDA9KB
Related Circuit Diagram

WA500-6 40-365 ➁
TROUBLESHOOTING DDB6L4

DDB6L4
Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree
Action Code Failure Code Parking brake switch (Neutralizer): ON/OFF signals disagree
Trouble
E03 DDB6L4 (Transmission controller system)

• Controller outputs a failure signal when all the following conditions are satisfied:
Contents of • Parking brake switch signal ON (neutralizer signal OPEN)
trouble • Parking brake released (by CAN communication from the machine monitor)
• Hydraulic oil temperature under 25°C (77°F)
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Forward-reverse cannot be operated, or parking brake indicator lamp remains turned off.
machine
• The input state (ON/OFF) from the parking indicator switch to the machine monitor can be checked with
the monitoring function (Code: 40903 D-IN-26).
• The input state (ON/OFF) from the parking brake switch can be checked with the monitoring function
(Code: 40907 D-IN-23).
• If failure code [DGH2KX] (Hydraulic oil temperature sensor: Out-of-input signal range) is displayed, carry
Related
out troubleshooting for it first.
information
• If failure code [DAFRKR] (Machine monitor CAN communication: Defective communication (Abnormality
in target component system) is displayed, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch and parking brake switch ON.
• If emergency parking brake reset switch is turned ON (set to release position) while parking brake switch
is ON (set to parking position), this error may be detected.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Parking brake oil
PB.SW (male) Resistance
pressure
Defective parking brake When parking brake is
released,
1 indicator switch Max. 1 Ω
(Internal disconnection) Min. 0.61 MPa
(Min. 88.47 psi)
Between (1) and (2)
When parking brake
Possible causes applied,
and standard Min. 1 MΩ
Max. 0.34 MPa
value in normal (Max. 49.31 psi)
state
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L58 (male) Parking brake switch Resistance
Defective parking brake ON Min. 1 MΩ
2 switch Between (3) and (4)
OFF Max. 1 Ω
(Internal disconnection)
ON Max. 1 Ω
Between (5) and (6)
OFF Min. 1 MΩ
Between (3) and (6) Constant Min. 1 MΩ

40-366 ➁ WA500-6
TROUBLESHOOTING DDB6L4

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between L54 (female) (1) –
Resistance Max. 1 Ω
harness PB.SW (female) (1)
3
(Disconnection or defective Wiring harness between PB.SW (female) (2)
contact) Resistance Max. 1 Ω
– chassis ground
Possible causes Wiring harness between L58 (female) (3) –
Resistance Max. 1 Ω
and standard L03 (female) (6)
value in normal ★ Prepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
L03 Parking brake switch Voltage
Defective transmission ON Max. 1 V
4
controller
Between (6) and Turn starting switch
chassis ground ON and then turn
20 – 30 V
parking brake switch
ON and OFF.

WA500-6 40-367 ➁
TROUBLESHOOTING DDB6L4
Related Circuit Diagram

40-368 ➁ WA500-6
TROUBLESHOOTING DDB6L4

MEMORANDUM

WA500-6 40-369 ➁
TROUBLESHOOTING DDD1LD

DDD1LD
Remote Positioner Bucket Angle Set Switch: Switch is Kept Pressed for
Long Time
Action Code Failure Code Remote positioner bucket angle set switch: Switch is kept pressed for
Trouble long time
E01 DDD1LD (Work equipment controller system)
• Unable to set the bucket to a specified angle due to ground fault in the remote positioner bucket angle
Contents of
set switch system.
trouble
• Detected continuous operation for 30 seconds and longer.
Action of • Judged that remote positioner bucket angle set switch is turned ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Remote positioner raise set signal: Setting is changed to upward by 1° (degree) and the monitor displays
Problem that the changed angle.
appears on • Remote positioner lower set signal: Setting is changed to downward by 1° (degree) and the monitor
machine displays the changed angle.
• Cannot be changed to upward or downward.
• The input state (ON/OFF) from the remote positioner bucket angle set switch can be checked with the
monitoring function (Code: 40911 D-IN-10, D-IN-11).
Related
• Only for load meter (if equipped)
information
• Method of reproducing failure code: Turn the starting switch and remote positioner bucket angle set
switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Remote positioner
S14 (male) bucket angle set Resistance
switch
Defective remote positioner
1 bucket angle set switch Downward ON Max. 1 Ω
Between (4) and (5)
(Internal short circuit) OFF Min. 1 MΩ
Upward ON Max. 1 Ω
Between (5) and (6)
OFF Min. 1 MΩ
Between (4), (5), (6)
Constant Min. 1 MΩ
and chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Grounding fault in wiring
Wiring harness between L07 (female) (30) –
state 2 harness Resistance Min. 1 MΩ
S14 (female) (6) and chassis ground
(Contact with ground circuit)
Wiring harness between L07 (female) (40) –
Resistance Min. 1 MΩ
S14 (female) (4) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Remote positioner
L07 (female) bucket angle set Voltage
Defective work equipment switch
3
controller Downward ON Max. 1 V
Between (40) and
chassis ground OFF 7 – 10 V
Between (30) and Upward ON Max. 1 V
chassis ground OFF 7 – 10 V

40-370 ➁ WA500-6
TROUBLESHOOTING DDD1LD
Related Circuit Diagram

WA500-6 40-371 ➁
TROUBLESHOOTING DDE5MA

DDE5MA
Emergency Steering Drive Switch: Malfunction
Action Code Failure Code Emergency steering drive switch: Malfunction
Trouble
E01 DDE5MA (Machine monitor system)
Contents of • When engine stopped, steering pump pressure detected because of ground fault in the emergency
trouble steering drive switch system.
Action of
• None in particular.
controller
Problem that
appears on —
machine
• The input state (ON/OFF) from the emergency steering motor can be checked with the monitoring
Related
function (Code: 40903 D-IN-30).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Relieve the steering circuit.
Defective emergency steering Steering relief oil
T04 (male) Resistance
1 drive switch pressure
(Internal defect) Low Min. 1 MΩ
Between (1) and (2)
Normal Max. 1 Ω
Between (1), (2) and
Constant Min. 1 MΩ
Possible causes chassis ground
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L54 (female) (3) –
Resistance Min. 1 MΩ
T04 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Relieve the steering circuit.
3 Defective machine monitor Steering relief oil
L54 (female) Voltage
pressure
Between (3) and Low 20 – 30 V
chassis ground Normal Max. 1 V

40-372 ➁ WA500-6
TROUBLESHOOTING DDE5MA
Related Circuit Diagram

WA500-6 40-373 ➁
TROUBLESHOOTING DDK3KA

DDK3KA
Right FNR Switch: Disconnection
Action Code Failure Code Right FNR switch: Disconnection
Trouble
E03 DDK3KA (Transmission controller system)
Contents of • Right FNR (directional) switch signal cannot be recognized due to disconnection or hot short circuit in
trouble right FNR (directional) switch input signal system.
• Sets to neutral.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until right FNR (directional) switch is set
to N (Neutral).
Problem that • Machine cannot be moved with FNR switch.
appears on • Machine can be moved with directional lever.
machine • Shift lever position pilot lamp turns out.
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional) switch
can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or Code: 40942 D-IN-32).
Related
• Only for right FNR (directional) switch (If equipped)
information
• Method of reproducing failure code: Turn the starting switch and directional selector ON/OFF switch ON
+ Operate right FNR (directional) switch.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Right FNR
S09 (male) Resistance
(directional) switch
F (Forward) Max. 1 Ω
Between (1) and (2)
Defective right FNR Other than above Min. 1 MΩ
(directional) switch
1 N (Neutral). Max. 1 Ω
(Internal disconnection or Between (1) and (3)
short circuit) Other than above Min. 1 MΩ
R (Reverse) Max. 1 Ω
Between (1) and (4)
Possible causes Other than above Min. 1 MΩ
and standard Between (1), (2), (3),
value in normal (4) and chassis Constant Min. 1 MΩ
state ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (28) –
Resistance Max. 1 Ω
Disconnection in wiring S09 (female) (3)
harness Wiring harness between L03 (female) (37) –
2 Resistance Max. 1 Ω
(Disconnection or defective S09 (female) (2)
contact in connector) Wiring harness between L03 (female) (38) –
Resistance Max. 1 Ω
S09 (female) (4)
Wiring harness between S09 (female) (1) –
Resistance Max. 1 Ω
chassis ground

40-374 ➁ WA500-6
TROUBLESHOOTING DDK3KA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L03(female) (28) –
Voltage Max. 1 V
Hot short in wiring harness S09 (female) (3) and chassis ground
3
(Contact with 24 V circuit) Wiring harness between L03 (female) (37) –
Voltage Max. 1 V
S09 (female) (2) and chassis ground
Wiring harness between L03 (female) (38) –
Voltage Max. 1 V
S09 (female) (4) and chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
value in normal • Directional selector ON/OFF switch ON
state
Right FNR
L03 Voltage
(directional) switch
Defective transmission Between (37) and F (Forward) Max. 1 V
4
controller chassis ground Other than above 7 – 10 V
Between (28) and N (Neutral). Max. 1 V
chassis ground Other than above 7 – 10 V
Between (38) and R (Reverse) Max. 1 V
chassis ground Other than above 7 – 10 V

WA500-6 40-375 ➁
TROUBLESHOOTING DDK3KA
Related Circuit Diagram

40-376 ➁ WA500-6
TROUBLESHOOTING DDK3KB

DDK3KB
Right FNR Switch: Short Circuit
Action Code Failure Code Right FNR switch: Short circuit
Trouble
E03 DDK3KB (Transmission controller system)
Contents of • Multiple right FNR (directional) switch signals are input due to grounding fault in right FNR (directional)
trouble switch input signal system.
• Sets to neutral.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until right FNR (directional) switch is set
to N (Neutral).
Problem that • Machine cannot be moved with FNR switch.
appears on • Machine can be moved with directional lever.
machine • Multiple shift lever position pilot lamps light up.
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional) switch
can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or D-IN-32).
Related
• Only for right FNR (directional) switch (If equipped)
information
• Method of reproducing failure code: Turn the starting switch and directional selector ON/OFF switch ON
+ Operate right FNR (directional) switch.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Right FNR
S09 (male) Resistance
(directional) switch
F (Forward) Max. 1 Ω
Between (1) and (2)
Defective right FNR Other than above Min. 1 MΩ
1 (directional) switch N (Neutral). Max. 1 Ω
(Internal short circuit) Between (1) and (3)
Other than above Min. 1 MΩ
R (Reverse) Max. 1 Ω
Possible causes Between (1) and (4)
and standard Other than above Min. 1 MΩ
value in normal Between (1), (2), (3),
state (4) and chassis Constant Min. 1 MΩ
ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (28) –
Grounding fault in wiring Resistance Min. 1 MΩ
S09 (female) (3) and chassis ground
2 harness
(Contact with ground circuit) Wiring harness between L03 (female) (37) –
Resistance Min. 1 MΩ
S09 (female) (2) and chassis ground
Wiring harness between L03 (female) (38) –
Resistance Min. 1 MΩ
S09 (female) (4) and chassis ground

WA500-6 40-377 ➁
TROUBLESHOOTING DDK3KB

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Directional selector ON/OFF switch ON
Right FNR
L03 Voltage
Possible causes (directional) switch
and standard Defective transmission Between (37) and F (Forward) Max. 1 V
3
value in normal controller chassis ground Other than above 7 – 10 V
state
Between (28) and N (Neutral). Max. 1 V
chassis ground Other than above 7 – 10 V
Between (38) and R (Reverse) Max. 1 V
chassis ground Other than above 7 – 10 V

40-378 ➁ WA500-6
TROUBLESHOOTING DDK3KB
Related Circuit Diagram

WA500-6 40-379 ➁
TROUBLESHOOTING DDK4KA

DDK4KA
Joystick Steering FNR Switch: Disconnection
Action Code Failure Code Joystick steering FNR switch: Disconnection
Trouble
E03 DDK4KA (Transmission controller system)
Contents of • Joystick steering FNR (directional) switch signal is not input due to disconnection or hot short circuit in
trouble joystick steering FNR (directional) switch input signal system.
• Sets to neutral.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering FNR (directional)
switch is set to N (Neutral).
Problem that • Machine cannot be moved with FNR switch.
appears on • Machine can be moved with directional lever.
machine • Shift lever position pilot lamp turns out.
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional) switch
can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or D-IN-32).
Related
• Only for joystick steering (If equipped)
information
• Method of reproducing failure code: Turn the starting switch and joystick ON/OFF switch ON + Operate
joystick steering FNR (directional) switch.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Joystick steering FNR
JL2 (male) Resistance
(directional) switch
F (Forward) Max. 1 Ω
Between (1) and (2)
Defective joystick steering Other than above Min. 1 MΩ
FNR (directional) switch
1 N (Neutral). Max. 1 Ω
(Internal disconnection or Between (1) and (3)
short circuit) Other than above Min. 1 MΩ
R (Reverse) Max. 1 z
Between (1) and (4)
Possible causes Other than above Min. 1 Mz
and standard Between (1), (2), (3),
value in normal (4) and chassis Constant Min. 1 Mz
state ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (28) –
Resistance Max. 1 Ω
Disconnection in wiring JL2 (female) (3)
harness Wiring harness between L03 (female) (37) –
2 Resistance Max. 1 Ω
(Disconnection or defective JL2 (female) (2)
contact in connector) Wiring harness between L03 (female) (38) –
Resistance Max. 1 Ω
JL2 (female) (4)
Wiring harness between JL2 (female) (1) –
Resistance Max. 1 Ω
chassis ground

40-380 ➁ WA500-6
TROUBLESHOOTING DDK4KA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L03 (female) (28) –
Voltage Max. 1 V
Hot short in wiring harness JL2 (female) (3) and chassis ground
3
(Contact with 24 V circuit) Wiring harness between L03 (female) (37) –
Voltage Max. 1 V
JL2 (female) (2) and chassis ground
Wiring harness between L03 (female) (38) –
Voltage Max. 1 V
JL2 (female) (4) and chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
value in normal • Joystick selector ON/OFF switch ON.
state
Joystick steering FNR
L03 Voltage
(directional) switch
Defective transmission Between (37) and F (Forward) Max. 1 V
4
controller chassis ground Other than above 7 – 10 V
Between (28) and N (Neutral). Max. 1 V
chassis ground Other than above 7 – 10 V
Between (38) and R (Reverse) Max. 1 V
chassis ground Other than above 7 – 10 V

WA500-6 40-381 ➁
TROUBLESHOOTING DDK4KA
Related Circuit Diagram

40-382 ➁ WA500-6
TROUBLESHOOTING DDK4KB

DDK4KB
Joystick Steering FNR Switch: Short Circuit
Action Code Failure Code Joystick steering FNR switch: Short circuit
Trouble
E03 DDK4KB (Transmission controller system)
Contents of • Multiple signals are input due to grounding fault in joystick steering FNR (directional) switch input signal
trouble system.
• Sets to neutral.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering FNR (directional)
switch is set to N (Neutral).
Problem that • Machine cannot be moved with FNR switch.
appears on • Machine can be moved with directional lever.
machine • Multiple shift lever position pilot lamps light up.
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional) switch
can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or Code: 40942 D-IN-32).
Related
• Only for joystick steering (If equipped)
information
• Method of reproducing failure code: Turn the starting switch and joystick ON/OFF switch ON + Operate
joystick steering FNR (directional) switch.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Joystick steering FNR
JL2 (male) Resistance
(directional) switch
F (Forward) Max. 1 Ω
Between (1) and (2)
Defective joystick steering Other than above Min. 1 MΩ
1 FNR (directional) switch N (Neutral). Max. 1 Ω
(Internal short circuit) Between (1) and (3)
Other than above Min. 1 MΩ
R (Reverse) Max. 1 Ω
Possible causes Between (1) and (4)
and standard Other than above Min. 1 MΩ
value in normal Between (1), (2), (3),
state (4) and chassis Constant Min. 1 MΩ
ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (28) –
Grounding fault in wiring Resistance Min. 1 MΩ
JL2 (female) (3) and chassis ground
2 harness
(Contact with ground circuit) Wiring harness between L03 (female) (37) –
Resistance Min. 1 MΩ
JL2 (female) (2) and chassis ground
Wiring harness between L03 (female) (38) –
Resistance Min. 1 MΩ
JL2 (female) (4) and chassis ground

WA500-6 40-383 ➁
TROUBLESHOOTING DDK4KB

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Joystick ON/OFF switch ON
Joystick steering FNR
L03 Voltage
Possible causes (directional) switch
and standard Defective transmission Between (37) and F (Forward) Max. 1 V
3
value in normal controller chassis ground Other than above 7 – 10 V
state
Between (28) and N (Neutral). Max. 1 V
chassis ground Other than above 7 – 10 V
Between (38) and R (Reverse) Max. 1 V
chassis ground Other than above 7 – 10 V

40-384 ➁ WA500-6
TROUBLESHOOTING DDK4KB
Related Circuit Diagram

WA500-6 40-385 ➁
TROUBLESHOOTING DDK5L4

DDK5L4
Joystick Steering with Shift UP/DOWN Switch: ON/OFF Signals Disagree
Action Code Failure Code Joystick steering shift UP/DOWN switch: ON/OFF signals disagree
Trouble
E01 DDK5L4 (Transmission controller system)
Contents of
• Multiple signals are input due to grounding fault in joystick steering shift UP/DOWN switch system.
trouble
Action of • Turns the joystick steering shift UP/DOWN function OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Shift UP/DOWN cannot be performed by joystick steering.
machine
• The input signal (ON/OFF) from the joystick steering shift UP/DOWN switch can be checked with the
Related monitoring function (Code: 40905 D-IN-1 or D-IN-2).
information • Method of reproducing failure code: Turn the starting switch ON + Joystick ON/OFF switch ON +
Joystick steering shift UP/DOWN switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Joystick steering shift
JL2 (male) Resistance
UP/DOWN switch
Shift DOWN ON Min. 1 MΩ
Between (1) and (5)
Shift DOWN OFF Max. 1 Ω

Defective joystick steering Shift DOWN ON Max. 1 Ω

Between (1) and (6)
1 shift UP/DOWN switch Shift DOWN OFF Min. 1 MΩ
(Internal short circuit)
Shift UP ON Min. 1 MΩ
Between (1) and (7)
Shift UP OFF Max. 1 Ω
Shift UP ON Max. 1 Ω
Between (1) and (8)
Shift UP OFF Min. 1 MΩ
Between (5), (6), (7),
Possible causes (8) and chassis Constant Min. 1 MΩ
and standard ground
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting
state
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L02 (female) (11) –
2 harness Resistance Min. 1 MΩ
JL2 (female) (6) and chassis ground
(Contact with ground circuit)
Wiring harness between L02 (female) (17) –
Resistance Min. 1 MΩ
JL2 (female) (8) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Joystick ON/OFF switch ON
Joystick steering shift
L02 Resistance
Defective transmission UP/DOWN switch
3
controller
Between (11) and Shift DOWN ON Max. 1 Ω
chassis ground Shift DOWN OFF Min. 1 MΩ
Between (17) and Shift UP ON Max. 1 Ω
chassis ground Shift UP OFF Min. 1 MΩ

40-386 ➁ WA500-6
TROUBLESHOOTING DDK5L4
Related Circuit Diagram

WA500-6 40-387 ➁
TROUBLESHOOTING DDK6KA

DDK6KA
FNR Lever Switch: Disconnection
Action Code Failure Code FNR lever switch: Disconnection
Trouble
E03 DDK6KA (Transmission controller system)
Contents of • Since the FNR (directional) lever switch signal system is disconnected or in ground fault, all the lever
trouble signals are not input.
• Sets to Neutral when joystick steering ON/OFF switch is OFF.
• When joystick steering ON/OFF switch is ON:
• Follows right FNR switch or joystick steering FNR switch.
Action of
controller • Assumes FNR lever switch to be set to Neutral for control operation.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to N
(Neutral).
Problem that • Machine cannot be moved with FNR switch.
appears on • Machine can be moved with right FNR switch or joystick FNR switch.
machine • Shift lever position pilot lamp turns out.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No.5 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
box B (See cause 4.)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
FNR (directional)
L63 Voltage
lever
Defective FNR (directional) Between (1) and (10) Constant 20 – 30 V
lever switch N (Neutral). 20 – 30 V
2 Between (2) and (10)
(Internal disconnection or
Other than above Max. 1 V
short circuit)
F (Forward) 20 – 30 V
Between (3) and (10)
Other than above Max. 1 V
Possible causes
and standard R (Reverse) 20 – 30 V
Between (4) and (10)
value in normal Other than above Max. 1 V
state
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 5 of fuse
Resistance Max. 1 Ω
box B – L63 (female) (1)
Disconnection in wiring Wiring harness between L03 (female) (16) –
Resistance Max. 1 Ω
harness L63 (female) (4)
3
(Disconnection or defective Wiring harness between L03 (female) (26) –
contact in connector) Resistance Max. 1 Ω
L63 (female) (3)
Wiring harness between L03 (female) (36) –
Resistance Max. 1 Ω
L63 (female) (2)
Wiring harness between L63 (female) (10) –
Resistance Max. 1 Ω
chassis ground

40-388 ➁ WA500-6
TROUBLESHOOTING DDK6KA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 5 of fuse
box B – L63 (female) (1) Resistance Min. 1 MΩ
Grounding fault in wiring and chassis ground
4 harness Wiring harness between L03 (female) (16) –
Resistance Min. 1 MΩ
(Contact with ground circuit) L63 (female) (4) and chassis ground
Wiring harness between L03 (female) (26) –
Resistance Min. 1 MΩ
L63 (female) (3) and chassis ground
Possible causes Wiring harness between L03 (female) (36) –
Resistance Min. 1 MΩ
and standard L63 (female) (2) and chassis ground
value in normal ★ Prepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
FNR (directional)
L03 Voltage
lever
Between (26) and N (Neutral). 20 – 30 V
Defective transmission
5 chassis ground Other than above Max. 1 V
controller
Between (36) and F (Forward) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (16) and R (Reverse) 20 – 30 V
chassis ground Other than above Max. 1 V

WA500-6 40-389 ➁
TROUBLESHOOTING DDK6KA
Related Circuit Diagram

40-390 ➁ WA500-6
TROUBLESHOOTING DDK6KB

DDK6KB
FNR Lever Switch: Short Circuit
Action Code Failure Code FNR lever switch: Short circuit
Trouble
E03 DDK6KB (Transmission controller system)
Contents of • FNR (directional) lever switch signals are input due to hot short circuit in FNR (directional) lever switch
trouble signal system.
• Sets to neutral.
• Turns the centralized warning lamp and alarm buzzer ON.
Action of • Follows right FNR (directional) switch or joystick steering FNR (directional) switch when joystick steering
controller ON/OFF switch is turned ON → OFF→ ON.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
Problem that • Machine cannot be moved with FNR switch.
appears on • Machine can be moved with right FNR switch or joystick FNR switch.
machine • Multiple shift lever position pilot lamps light up.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information • Only for steering wheel specification (Standard)
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L63 FNR (directional) lever Voltage
Between (1) and (10) Constant 20 – 30 V
Defective FNR (directional) F (Forward) 20 – 30 V
1 lever switch Between (2) and (10)
Other than above Max. 1 V
(Internal short circuit)
N (Neutral). 20 – 30 V
Between (3) and (10)
Possible causes Other than above Max. 1 V
and standard R (Reverse) 20 – 30 V
value in normal Between (4) and (10)
state Other than above Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (16) – L63
Voltage Max. 1 V
Hot short in wiring harness (female) (4) and chassis ground
2
(Contact with 24 V circuit) Wiring harness between L03 (female) (26) – L63
Voltage Max. 1 V
(female) (3) and chassis ground
Wiring harness between L03 (female) (36) – L63
Voltage Max. 1 V
(female) (2) and chassis ground

WA500-6 40-391 ➁
TROUBLESHOOTING DDK6KB

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L03 FNR (directional) lever Voltage
Possible causes Between (26) and N (Neutral). 20 – 30 V
and standard Defective transmission chassis ground Other than above Max. 1 V
3
value in normal controller
state Between (36) and F (Forward) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (16) and R (Reverse) 20 – 30 V
chassis ground Other than above Max. 1 V

40-392 ➁ WA500-6
TROUBLESHOOTING DDK6KB
Related Circuit Diagram

WA500-6 40-393 ➁
TROUBLESHOOTING DDT0L4

DDT0L4
Shift Mode Selector Switch: ON/OFF Signals Disagree
Action Code Failure Code Shift mode selector switch: ON/OFF signals disagree
Trouble
E01 DDT0L4 (Transmission controller system)
Contents of • The signals input from the transmission manual/auto-shift selector switch are combined in an impossible
trouble manner.
Action of • Selects the manual shift mode.
controller • If cause of failure disappears, system resets itself.
Problem that
• The position of the transmission manual/auto-shift selector switch does not match the shift mode during
appears on
auto-shift.
machine
• The input state (H/L) from the transmission manual/auto-shift selector switch can be checked with the
Related monitoring function (Code: 40905 D-IN-4, D-IN-5).
information • The operator can check the current shift mode with the automatic shift pilot lamp.
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S16 (male) Shift mode Resistance
Manual shift Min. 1 MΩ
Between (2) and (4) Auto shift (L) Min. 1 MΩ
Defective transmission
manual/auto-shift selector Auto shift (H) Max. 1 Ω
1
switch Manual shift Min. 1 MΩ
(Internal defect). Between (1) and (2) Auto shift (L) Max. 1 Ω
Auto shift (H) Max. 1 Ω
Manual shift Min. 1 MΩ
Between (1) and (4) Auto shift (L) Min. 1 MΩ
Auto shift (H) Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes
Disconnection in wiring without turning starting switch ON.
and standard
value in normal harness Wiring harness between L02 (female) (18) –
2 Resistance Max. 1 Ω
state (Disconnection or defective S16 (female) (4)
contact in connector) Wiring harness between L02 (female) (24) –
Resistance Max. 1 Ω
S16 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L02 (female) (18) –
3 harness Resistance Min. 1 MΩ
S16 (female) (4) and chassis ground
(Contact with ground circuit)
Wiring harness between L02 (female) (24) –
Resistance Min. 1 MΩ
S16 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness Wiring harness between L02 (female) (18) –
4 Voltage Max. 1 V
(Contact with 24 V circuit) S16 (female) (4) and chassis ground
Wiring harness between L02 (female) (24) –
Voltage Max. 1 V
S16 (female) (2) and chassis ground

40-394 ➁ WA500-6
TROUBLESHOOTING DDT0L4

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L02 Shift mode Voltage
Possible causes
Manual shift Max. 1 V
and standard Between (18) and
Defective transmission Auto shift (L) Max. 1 V
value in normal 5 chassis ground
controller
state Auto shift (H) 20 – 30 V
Manual shift Max. 1 V
Between (24) and
Auto shift (L) 20 – 30 V
chassis ground
Auto shift (H) 20 – 30 V

Related Circuit Diagram

WA500-6 40-395 ➁
TROUBLESHOOTING DDT4LD

DDT4LD
Transmission Cutoff Set Switch: Switch is Kept Pressed for Long Time
Action Code Failure Code Transmission cutoff set switch: Switch is kept pressed for long time
Trouble
E01 DDT4LD (Transmission controller system)
Contents of • Transmission cutoff is not performed normally due to grounding fault in transmission cutoff set switch
trouble system.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Transmission cutoff is performed at unintended position.
machine
• The input state (ON/OFF) from the transmission cutoff set switch can be checked with the monitoring
Related
function (Code: 40906 D-IN-9).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Transmission cut-off
Defective transmission cut-off S19 (male) Resistance
set switch
1 set switch
ON Max. 1 Ω
(Internal short circuit) Between (5) and (6)
OFF Min. 1 MΩ
Between (5), (6) and
Constant Min. 1 MΩ
chassis ground
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L04 (female) (20) –
Resistance Min. 1 MΩ
S19 (female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective transmission Transmission cut-off
3 L04 (female) Resistance
controller set switch
Between (20) and ON Max. 1 Ω
chassis ground OFF Min. 1 MΩ

40-396 ➁ WA500-6
TROUBLESHOOTING DDT4LD
Related Circuit Diagram

WA500-6 40-397 ➁
TROUBLESHOOTING DDW9LD

DDW9LD
Kickdown Switch: Switch is Kept Pressed for Long Time
Action Code Failure Code Kickdown switch: Switch is kept pressed for long time
Trouble
E01 DDW9LD (Transmission controller system)
Contents of
• The kickdown does not function due to grounding fault in kickdown switch system.
trouble
Action of • Turns the kickdown ON when a grounding fault is detected then does not control the kickdown.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When ground fault occurs, kickdown is turned ON once but is not turned ON again.
machine
• The input state (ON/OFF) from the kickdown switch can be checked with the monitoring function (Code:
Related
40906 D-IN-10).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S07 (male) Kickdown switch Resistance
Defective kickdown switch
1 ON Max. 1 Ω
(Internal short circuit) Between (1) and (2)
OFF Min. 1 MΩ
Between (1), (2) and
Constant Min. 1 MΩ
chassis ground
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L04 (female) (30) –
Resistance Min. 1 MΩ
S07 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective transmission L04 Kickdown switch Voltage
3
controller
Between (30) and ON Max. 1 V
chassis ground OFF 20 – 30 V

40-398 ➁ WA500-6
TROUBLESHOOTING DDW9LD
Related Circuit Diagram

WA500-6 40-399 ➁
TROUBLESHOOTING DDWLLD

DDWLLD
Hold Switch: Switch is Kept Pressed Down for Long Time
Action Code Failure Code Hold switch: Switch is kept pressed for long time
Trouble
E01 DDWLLD (Transmission controller system)
Contents of
• Since the hold switch system is in ground fault, the hold switch does not function.
trouble
Action of • Holds once when a grounding fault occurs then does not control holding.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When ground fault occurs, turn the hold switch once.
machine
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function
Related
(Code: 40906 D-IN-11).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S07 (male) Hold switch Resistance
Defective hold switch
1 ON Max. 1 Ω
(Internal short circuit) Between (3) and (4)
OFF Min. 1 MΩ
Between (3), (4) and
Constant Min. 1 MΩ
chassis ground
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L04 (female) (40) –
Resistance Min. 1 MΩ
S07 (female) (3) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective transmission L04 Hold switch Voltage
3
controller
Between (40) and ON Max. 1 V
chassis ground OFF 20 – 30 V

40-400 ➁ WA500-6
TROUBLESHOOTING DDWLLD
Related Circuit Diagram

WA500-6 40-401 ➁
TROUBLESHOOTING DDY0LD

DDY0LD
Load Meter Cancel Switch: Switch is Kept Pressed for Long Time
Action Code Failure Code Load meter cancel switch: Switch is kept pressed for long time
Trouble
E01 DDY0LD (Machine monitor system)
Contents of
• The load meter cancel switch is in ground fault and load meter cancel switch does not function.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Unable to cancel calculated load weight.
machine
• The input state (ON/OFF) from the load meter cancel switch can be checked with the monitoring
Related function (Code: 40904 D-IN-33).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Load meter cancel
S08 (male) Resistance
Defective load meter cancel switch
1
switch (Internal short circuit) ON Max. 1 Ω
Between (1) and (2)
OFF Min. 1 MΩ
Between (1), (2) and
Possible causes Constant Min. 1 MΩ
chassis ground
and standard
★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
(Contact with ground circuit) Wiring harness between L54 (female) (13) –
Resistance Min. 1 MΩ
S08 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Load meter cancel
3 Defective machine monitor L54 (male) Voltage
switch
Between (13) and ON Max. 1 V
chassis ground OFF 20 – 30 V

40-402 ➁ WA500-6
TROUBLESHOOTING DDY0LD
Related Circuit Diagram

WA500-6 40-403 ➁
TROUBLESHOOTING DF10KA

DF10KA
Transmission Shift Lever Switch: Disconnection
Action Code Failure Code Transmission shift lever switch: Disconnection
Trouble
E01 DF10KA (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is disconnected or in ground fault, the signal
trouble is not input.
Action of • Fixed to the shift range before the abnormality occurred.
controller • If cause of failure disappears, system resets itself.
Problem that
• The transmission is not set to the selected gear speed.
appears on
machine • Shift indicator displays the shift range before the abnormality occurred.

• The input state (ON/OFF) from each shift switch can be checked with the monitoring function
Related
(Code: 40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19).
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L63 Shift range Voltage
Between (1) and (10) Constant 20 – 30 V
1st (1st speed) 20 – 30 V
Between (5) and (10)
Defective transmission shift Other than above Max. 1 V
1 lever switch
2nd (2nd speed) 20 – 30 V
(Internal disconnection) Between (6) and (10)
Other than above Max. 1 V
3rd (3rd speed) 20 – 30 V
Between (7) and (10)
Other than above Max. 1 V
4th (4th speed) 20 – 30 V
Possible causes Between (8) and (10)
Other than above Max. 1 V
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Wiring harness between fuse No. 5 of fuse
Resistance Max. 1 Ω
box B – L63 (female) (1)
Wiring harness between L03 (female) (5) –
Resistance Max. 1 Ω
Disconnection in wiring L63 (female) (8)
harness Wiring harness between L03 (female) (15) –
2 Resistance Max. 1 Ω
(Disconnection or defective L63 (female) (7)
contact in connector) Wiring harness between L03 (female) (25) –
Resistance Max. 1 Ω
L63 (female) (6)
Wiring harness between L03 (female) (35) –
Resistance Max. 1 Ω
L63 (female) (5)
Wiring harness between L63 (female) (10) –
Resistance Max. 1 Ω
chassis ground

40-404 ➁ WA500-6
TROUBLESHOOTING DF10KA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 5 of fuse
Resistance Min. 1 MΩ
box B – L63 (female) (1) and chassis ground
Wiring harness between L03 (female) (5) –
Grounding fault in wiring Resistance Min. 1 MΩ
L63 (female) (8) and chassis ground
3 harness
(Contact with ground circuit) Wiring harness between L03 (female) (15) –
Resistance Min. 1 MΩ
L63 (female) (7) and chassis ground
Wiring harness between L03 (female) (25) –
Resistance Min. 1 MΩ
L63 (female) (6) and chassis ground
Possible causes Wiring harness between L03 (female) (35) –
and standard Resistance Min. 1 MΩ
L63 (female) (5) and chassis ground
value in normal
★ Prepare with starting switch OFF, then turn starting switch ON and
state
carry out troubleshooting.
L03 Shift range Voltage
Between (35) and 1st (1st speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Defective transmission 2nd (2nd speed) 20 – 30 V
4 Between (25) and
controller
chassis ground Other than above Max. 1 V
Between (15) and 3rd (3rd speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (5) and 4th (4th speed) 20 – 30 V
chassis ground Other than above Max. 1 V

WA500-6 40-405 ➁
TROUBLESHOOTING DF10KA
Related Circuit Diagram

40-406 ➁ WA500-6
TROUBLESHOOTING DF10KB

DF10KB
Transmission Shift Lever Switch: Short Circuit
Action Code Failure Code Transmission shift lever switch: Short circuit
Trouble
E01 DF10KB (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is in hot short circuit, multiple transmission
trouble shift lever switch signals are input.
Action of • Uses the shift range input to the higher gear speed.
controller • If cause of failure disappears, system resets itself.
Problem that • The relevant gear speed is not set. (The transmission does not shift into 1st or 2nd even if the
appears on transmission shift lever is used.)
machine • Shift indicator indicates the shift range input to the higher gear speed.
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function
Related
(Code: 40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19).
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L63 Shift range Voltage
1st (1st speed) 20 – 30 V
Between (5) and (10)
Other than above Max. 1 V
Defective transmission shift
1 lever switch 2nd (2nd speed) 20 – 30 V
Between (6) and (10)
(Internal short circuit) Other than above Max. 1 V
3rd (3rd speed) 20 – 30 V
Between (7) and (10)
Other than above Max. 1 V
Possible causes
and standard 4th (4th speed) 20 – 30 V
Between (8) and (10)
value in normal Other than above Max. 1 V
state
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (5) – L63
Voltage Max. 1 V
(female) (8) and chassis ground
Hot short in wiring harness Wiring harness between L03 (female) (15) – L63
2 Voltage Max. 1 V
(Contact with 24 V circuit) (female) (7) and chassis ground
Wiring harness between L03 (female) (25) – L63
Voltage Max. 1 V
(female) (6) and chassis ground
Wiring harness between L03 (female) (35) – L63
Voltage Max. 1 V
(female) (5) and chassis ground

WA500-6 40-407 ➁
TROUBLESHOOTING DF10KB

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L03 Shift range Voltage
Between (35) and 1st (1st speed) 20 – 30 V
Possible causes chassis ground Other than above Max. 1 V
and standard Defective transmission 2nd (2nd speed) 20 – 30 V
3 Between (25) and
value in normal controller
chassis ground Other than above Max. 1 V
state
Between (15) and 3rd (3rd speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (5) and 4th (4th speed) 20 – 30 V
chassis ground Other than above Max. 1 V

40-408 ➁ WA500-6
TROUBLESHOOTING DF10KB
Related Circuit Diagram

WA500-6 40-409 ➁
TROUBLESHOOTING DGF1KA

DGF1KA
Transmission Oil Temperature Sensor: Disconnection
Action Code Failure Code Transmission oil temperature sensor: Disconnection
Trouble
E01 DGF1KA (Transmission controller system)

• Due to disconnection in transmission oil temperature sensor signal system, the signal level is higher
Contents of than normal range.
trouble • Transmission oil temperature sensor signal voltage: Min. 4.56 V (Max. 15°C [59°F]); torque converter
oil temperature sensor signal voltage: Min. 3.7 V (Max. 5.5°C [41.9°F]).
Action of • Cannot judge transmission oil temperature normally.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Gear shift shock may occur.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with the
monitoring function (Code: 93600 T/M OIL TEMP).
• The input state (voltage) from the transmission oil temperature sensor can be checked with the
monitoring function (Code: 93601 T/M OIL TEMP).
Related
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked with
information
the monitoring function (Code: 40100 TC OIL TEMP).
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
monitoring function (Code: 40101 TC OIL TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission oil Transmission oil
temperature sensor TM.T (male) Resistance
1 temperature
(Internal disconnection or
short circuit) 25°C
35 – 50 kΩ
Between (1) and (2) (Normal temperature)
100°C 3.1 – 4.5 kΩ
Possible causes Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard harness without turning starting switch ON.
2
value in normal (Disconnection or defective Wiring harness between L02 (female) (9) –
state contact in connector) Resistance Max. 1 Ω
TM.T (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Transmission oil
Defective transmission L02 (female) Resistance
3 temperature
controller
25°C
35 – 50 kΩ
Between (9) and (21) (Normal temperature)
100°C 3.1 – 4.5 kΩ

40-410 ➁ WA500-6
TROUBLESHOOTING DGF1KA
Related Circuit Diagram

WA500-6 40-411 ➁
TROUBLESHOOTING DGF1KB

DGF1KB
Transmission Oil Temperature Sensor: Short Circuit
Action Code Failure Code Transmission oil temperature sensor: Short circuit
Trouble
E01 DGF1KB (Transmission controller system)

• Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower
Contents of
than normal range.
trouble
• Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C [302°F])
Action of • Judges that the transmission oil temperature is higher.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Gear shift shock may occur.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with the
monitoring function (Code: 93600 T/M OIL TEMP).
Related
• The input state (voltage) from the transmission oil temperature sensor can be checked with the
information
monitoring function (Code: 93601 T/M OIL TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission oil Transmission oil
TM.T (male) Resistance
1 temperature sensor temperature
(Internal short circuit) 25°C (77°F)
35 – 50 kΩ
Between (1) and (2) (Normal temperature)
100°C (212°F) 3.1 – 4.5 kΩ
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L02 (female) (9) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state TM.T (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Transmission oil
Defective transmission L02 (female) Resistance
3 temperature
controller
25°C (77°F)
35 – 50 kΩ
Between (9) and (21) (Normal temperature)
100°C (212°F) 3.1 – 4.5 kΩ

40-412 ➁ WA500-6
TROUBLESHOOTING DGF1KB
Related Circuit Diagram

WA500-6 40-413 ➁
TROUBLESHOOTING DGH2KX

DGH2KX
Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range
Action Code Failure Code Hydraulic oil temperature sensor: Out-of-input signal range
Trouble
E01 DGH2KX (Machine monitor system)

• Due to grounding fault in hydraulic oil temperature sensor signal system, the signal level is lower than
Contents of
normal range.
trouble
• Hydraulic oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C [302°F])
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • The hydraulic oil temperature gauge reads MAX position.
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitoring
information
function (Code: 04404 HYD TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission oil Hydraulic oil
T03 (male) Resistance
1 temperature sensor temperature
(Internal short circuit) 25°C
35 – 50 kΩ
Between (1) and (2) (Normal temperature)
100°C 3.1 – 4.5 kΩ
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L55 (female) (7) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state T03 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Hydraulic oil
L55 (female) Resistance
3 Defective machine monitor temperature
25°C
Between (7) and 35 – 50 kΩ
(Normal temperature)
chassis ground
100°C 3.1 – 4.5 kΩ

40-414 ➁ WA500-6
TROUBLESHOOTING DGH2KX
Related Circuit Design

WA500-6 40-415 ➁
TROUBLESHOOTING DGR2KA

DGR2KA
Rear Brake Oil Temperature Sensor: Disconnection
Action CCode Failure Code Rear brake oil temperature sensor: Disconnection
Trouble
E01 DGR2KA (Machine monitor system)
Contents of
• Rear brake oil temperature sensor signal system disconnection.
trouble
Action of • Judges that the rear brake oil temperature is lower.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the monitoring
information
function (Code: 30205 R BRAKE OIL).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective rear brake oil Rear brake oil
R17 (male) Resistance
1 temperature sensor temperature
(Internal disconnection) 25°C (77°F)
35 – 50 kΩ
Between (1) and (2) (Normal temperature)
100°C (212°F) 3.1 – 4.5 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L55 (female) (8) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective R17 (female) (1)
state contact in connector)
Wiring harness between R17 (female) (2) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Rear brake oil
L55 (female) Resistance
3 Defective machine monitor temperature
25°C (77°F)
Between (8) and 35 – 50 kΩ
(Normal temperature)
chassis ground
100°C (212°F) 3.1 – 4.5 kΩ

40-416 ➁ WA500-6
TROUBLESHOOTING DGR2KA
Related Circuit Diagram

WA500-6 40-417 ➁
TROUBLESHOOTING DGR2KX

DGR2KX
Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range
Action Code Failure Code Rear brake oil temperature sensor: Out-of-input signal range
Trouble
E01 DGR2KX (Machine monitor system)

• Due to grounding fault in rear brake oil temperature sensor signal system, the signal level is lower than
Contents of
normal range.
trouble
• Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C [302°F])
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the monitoring
information
function (Code: 30205 R BRAKE OIL).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective rear brake oil Rear brake oil
R17 (male) Resistance
1 temperature sensor temperature
(Internal short circuit) 25°C (77°F)
35 – 50 kΩ
Between (1) and (2) (Normal temperature)
100°C (212°F) 3.1 – 4.5 kΩ
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L55 (female) (8) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state R17 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Rear brake oil
L55 (female) Resistance
3 Defective machine monitor temperature
25°C (77°F)
Between (8) and 35 – 50 kΩ
(Normal temperature)
chassis ground
100°C (212°F) 3.1 – 4.5 kΩ

40-418 ➁ WA500-6
TROUBLESHOOTING DGR2KX
Related Circuit Diagram

WA500-6 40-419 ➁
TROUBLESHOOTING DGT1KX

DGT1KX
Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range
Action Code Failure Code Torque converter oil temperature sensor: Out-of-input signal range
Trouble
E01 DGT1KX (Machine monitor system)
Contents of • Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower
trouble than normal range. (Transmission oil temperature voltage: max. 0.97 V; min. 150°C [302°F])
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • The torque converter oil temperature gauge reads MAX position.
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked with
the monitoring function (Code: 40100 TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101 TC OIL TEMP).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective torque converter Torque converter oil
T05 (male) Resistance
1 oil temperature sensor temperature
(Internal short circuit) 25°C (F)
35 – 50 kΩ
Between (1) and (2) (Normal temperature)
100°C (212F) 3.1 – 4.5 kΩ
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L55 (female) (2) –
state
(Contact with ground circuit) Resistance Max. 1 Ω
T05 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Torque converter oil
L55 (female) Resistance
3 Defective machine monitor temperature
25°C (F)
Between (2) and 35 – 50 kΩ
(Normal temperature)
chassis ground
100°C (212F) 3.1 – 4.5 kΩ

40-420 ➁ WA500-6
TROUBLESHOOTING DGT1KX
Related Circuit Diagram

WA500-6 40-421 ➁
TROUBLESHOOTING DH21KA

DH21KA
Work Equipment Pump Oil Pressure Sensor: Disconnection
Action Code Failure Code Work equipment pump oil pressure sensor: Disconnection
Trouble
E01 DH21KA (Work equipment controller system)

• Due to disconnection or grounding fault in the work equipment oil pressure sensor system, the signal
Contents of
voltage is lower than normal range.
trouble
(Work equipment pump oil pressure sensor signal voltage: Max. 0.3 V)
Action of • Judges that work equipment pump oil pressure reads 0.
controller • If cause of failure disappears, system resets itself.
Problem that
• Remote positioner inaccuracy of stopping
appears on
machine • When work equipment is relieved, cut-off does not function

• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked with
the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the
information
monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve bucket tilt.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F16 (male) Resistance
Between (A), (B), (C) and
Min. 1 MΩ
chassis ground
Defective work equipment ★ Prepare with starting switch OFF, then start engine, tilt the bucket and
pump oil pressure sensor carry out troubleshooting.
1
(Internal disconnection or
F16 Work equipment Voltage
short circuit)
Between (B) and (A) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (C) and (A)
Possible causes When bucket tilt
3.02 – 3.42 V
and standard relieved
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Disconnection in wiring Wiring harness between L05 (female) (2) –
Resistance Max. 1 Ω
harness F16 (female) (C)
2
(Disconnection or defective Wiring harness between L05 (female) (21) –
contact in connector) Resistance Max. 1 Ω
F16 (female) (A)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
F16 (female) (B)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L05 (female) (2) –
3 harness Resistance Min. 1 MΩ
F16 (female) (C) and chassis ground
(Contact with ground circuit)
Wiring harness between L05 (female) (22) -
Resistance Min. 1 MΩ
F16 (female) (B) and chassis ground

40-422 ➁ WA500-6
TROUBLESHOOTING DH21KA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine, tilt the bucket and
carry out troubleshooting.
L05 Work equipment Voltage
Possible causes Between
and standard Constant 4.85 – 5.15 V
4 Work equipment controller (22) and (21)
value in normal
state Constant 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (2) and (21)
When bucket tilt
3.02 – 3.42 V
relieved

Related Circuit Diagram

WA500-6 40-423 ➁
TROUBLESHOOTING DH21KB

DH21KB
Work Equipment Pump Oil Pressure Sensor: Short Circuit
Action Code Failure Code Work equipment pump oil pressure sensor: Short circuit
Trouble
E01 DH21KB (Work equipment controller system)

• Due to a hot short circuit in the work equipment pump oil pressure sensor signal system, the signal
Contents of
voltage is higher than normal range.
trouble
(Work equipment pump oil pressure sensor signal voltage: Min. 4.7 V)
Action of • Judges that work equipment pump oil pressure is higher.
controller • If cause of failure disappears, system resets itself.
Problem that
• Remote positioner inaccurate stopping
appears on
machine • When work equipment is relieved, cutoff does not function

• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked with
the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the
information
monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve bucket tilt.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F16 (male) Resistance
Between (A), (B), (C) and
Min. 1 MΩ
chassis ground

Defective work equipment ★ Prepare with starting switch OFF, then start engine, tilt the
1 pump oil pressure sensor bucket and carry out troubleshooting.
(Internal short circuit) F16 Bucket Voltage
Between (B) and (A) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (C) and (A)
When bucket tilt
3.02 – 3.42 V
Possible causes relieved
and standard ★ Prepare with starting switch OFF, then turn starting switch ON
value in normal and carry out troubleshooting.
state
Hot short in wiring harness Wiring harness between L05 (female) (2) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) F16 (female) (C) and chassis ground
Wiring harness between L05 (female) (22) –
Voltage Max. 1 V
F16 (female) (B) and chassis ground
★ Prepare with starting switch OFF, then start engine, tilt the
bucket and carry out troubleshooting.
L05 Bucket Voltage
Between
Defective work equipment Constant 4.85 – 5.15 V
3 (22) and (21)
controller
Constant 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (2) and (21)
When bucket tilt
3.02 – 3.42 V
relieved

40-424 ➁ WA500-6
TROUBLESHOOTING DH21KB
Related Circuit Diagram

WA500-6 40-425 ➁
TROUBLESHOOTING DHPCKX

DHPCKX
Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range
Action Code Failure Code Lift arm cylinder bottom pressure sensor: Out-of-input signal range
Trouble
E01 DHPCKX (Machine monitor system)

• Due to disconnection or grounding fault in the lift arm cylinder bottom pressure sensor signal, the lift arm
cylinder bottom pressure sensor voltage is lower than normal range.
Contents of (Lift arm cylinder bottom pressure sensor signal voltage: Less than 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder bottom pressure sensor signal, the lift arm cylinder bottom
pressure sensor voltage is higher than normal range.
(Lift arm cylinder bottom pressure sensor signal voltage: Min. 4.7 V)
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (oil pressure) from the lift arm cylinder bottom pressure sensor can be checked with the
monitoring function (Code: 40400 BOOM BTM PRESS).
Related • The input state (voltage) from the lift arm cylinder bottom pressure sensor can be checked with the
information monitoring function (Code: 40402 BOOM BTM PRESS).
• Only for load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation.

Standard value in normal state/Remarks on troubleshooting

★ Replace sensor and check if error is reset.
★ Prepare with starting switch OFF; then start engine; raise the lift arm;
and carry out troubleshooting.

Defective lift arm cylinder F14 Lift arm Voltage

1
bottom pressure sensor Between (B) and (A) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Between (C) and (A) Neutral 0.50 – 0.90 V
Lift arm bottom relief 3.02 – 3.42 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes
Disconnection in wiring Wiring harness between L51 (female) (16) –
and standard Resistance Max. 1 Ω
value in normal harness F14 (female) (B)
2
state (Disconnection in wiring Wiring harness between L55 (female) (9) –
harness or defective contact) Resistance Max. 1 Ω
F14 (female) (C)
Wiring harness between F14 (female) (A) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L51 (female) (16) –
Grounding fault in wiring
F14 (female) (B), – circuit branch end and Resistance Min. 1 MΩ
3 harness
chassis ground
(Contact with ground circuit)
Wiring harness between L55 (female) (9) –
F14 (female) (C), – circuit branch end and Resistance Min. 1 MΩ
chassis ground

40-426 ➁ WA500-6
TROUBLESHOOTING DHPCKX

Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L51 (female) (16) –
Hot short in wiring harness F14 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24 V circuit) chassis ground
Wiring harness between L55 (female) (9) –
F14 (female) (C), – circuit branch end and Voltage Max. 1 V
Possible causes chassis ground
and standard
value in normal ★ Prepare with starting switch OFF, then start engine, raise the lift arm
state and carry out troubleshooting.
L51, L55 Lift arm Voltage
Between L51 (16)
5 Defective machine monitor Constant 4.85 – 5.15 V
and chassis ground
Constant 0.50 – 4.50 V
Between L55 (9) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm bottom relief 3.02 – 3.42 V

Related Circuit Diagram

WA500-6 40-427 ➁
TROUBLESHOOTING DHPDKX

DHPDKX
Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range
Action Code Failure Code Lift arm cylinder bottom head pressure sensor: Out-of-input signal
Trouble range
E01 DHPDKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder head pressure sensor signal, the lift arm
cylinder head pressure sensor voltage is lower than normal range.
Contents of (Lift arm cylinder head pressure sensor signal voltage: Less than 0.3 V)
trouble • Due to a hot short circuit in the lift arm cylinder head pressure sensor signal, the lift arm cylinder head
pressure sensor voltage is higher than normal range. (Lift arm cylinder head pressure sensor signal
voltage: Min. 4.7 V)
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (oil pressure) from the lift arm cylinder head pressure sensor can be checked with the
monitoring function (Code: 40500 BOOM HEAD PRESS).
Related • The input state (voltage) from the lift arm cylinder head pressure sensor can be checked with the
information monitoring function (Code: 40501 BOOM HEAD PRESS).
• Only for load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation.

Cause Standard value in normal state/Remarks on troubleshooting

★ Replace sensor and check if error is reset.
★ Prepare with starting switch OFF; start engine; lower the lift arm; and
carry out troubleshooting.
Defective lift arm cylinder F15 (male) Lift arm Voltage
1
head pressure sensor Between (B) and (A) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Between (C) and (A) Neutral 0.50 – 0.90 V
Lift arm head relief 3.02 – 3.42 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes
Disconnection in wiring Wiring harness between L51 (female) (16) –
and standard Resistance Max. 1 Ω
value in normal harness F15 (female) (B)
2
state (Disconnection in wiring Wiring harness between L55 (female) (4) –
harness or defective contact) Resistance Max. 1 Ω
F15 (female) (C)
Wiring harness between F15 (female) (A) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L51 (female) (16) –
Grounding fault in wiring
F15 (female) (B), – circuit branch end and Resistance Min. 1 MΩ
3 harness
chassis ground
(Contact with ground circuit)
Wiring harness between L55 (female) (4) –
F15 (female) (C), – circuit branch end and Resistance Min. 1 MΩ
chassis ground

40-428 ➁ WA500-6
TROUBLESHOOTING DHPDKX

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L51 (female) (16) –
Hot short in wiring harness F15 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24 V circuit) chassis ground
Wiring harness between L55 (female) (4) –
Possible causes F15 (female) (C), – circuit branch end and Voltage Max. 1 V
and standard chassis ground
value in normal ★ Prepare with starting switch OFF, then start engine, raise the lift arm
state and carry out troubleshooting.
L51, L55 Lift arm Voltage
Between L51 (16)
5 Defective machine monitor Constant 4.85 – 5.15 V
and chassis ground
Constant 0.50 – 4.50 V
Between L55 (4) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm head relief 3.02 – 3.42 V

Related Circuit Diagram

WA500-6 40-429 ➁
TROUBLESHOOTING DHT1KX

DHT1KX
Left Brake Pressure Sensor: Out-of-Input Signal
Action Code Failure Code Left brake pressure sensor: Out-of-input signal range
Trouble
E01 DHT1KX (Transmission controller system)
Contents of • Due to grounding fault in left brake pressure sensor signal system, the signal level is lower than normal
trouble range.
• Turns the transmission cutoff function OFF.
• Disables the change of transmission cutoff setting.
Action of
controller • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral), or the
transmission cutoff switch is turned OFF.
Problem that
appears on • The transmission cutoff indicator goes off.
machine
• Left brake pressure sensor input voltage: Max. 0.3 V
• The input state (oil pressure) from the left brake pressure sensor can be checked with the monitoring
Related function (Code: 41201 T/M CUT OFF P).
information • The input state (voltage) from the left brake pressure sensor can be checked with the monitoring function
(Code: 41202 T/M CUT OFF P).
• Method of reproducing failure code: Turn the starting switch and transmission cutoff switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Turn transmission cutoff switch ON.

Defective left brake pressure B01 Brake Voltage

1 sensor When brake released 0.9 – 1.1 V
(Internal short circuit) When left brake pressed 1.1 – 5.1 V
Between (C) and (A) When right brake
1.1 – 5.1 V
pressed
Other than above 0.9 – 5.1 V
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Wiring harness between L02 (female) (8) – B01 Resistance Min. 1 MΩ
(female) (C)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L02 Brake Voltage
Defective transmission When brake released 0.9 – 1.1 V
3
controller When left brake pressed 1.1 – 5.1 V
Between (8) and (21) When right brake
1.1 – 5.1 V
pressed
Other than above 0.9 – 5.1 V

40-430 ➁ WA500-6
TROUBLESHOOTING DHT1KX
Related Circuit Diagram

WA500-6 40-431 ➁
TROUBLESHOOTING DHT2L6

DHT2L6
Transmission Filter Clogging Sensor: Signal Disagrees with Operating and
Stopped States of Engine
Action Code Failure Code Transmission filter clogging sensor: Signal disagrees with operating and
Trouble
E01 DHT2L6 stopped states of engine (Machine monitor system)
Contents of • Due to disconnection or hot short circuit in transmission filter clogging sensor signal, transmission filter
trouble clogging sensor signal voltage does not agree with the engine operation or stopping in normal condition.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • The transmission filter clogging caution lamp does not light up.
machine
• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the
Related
monitoring function (Code: 40903 D-IN-24).
information
• Method of reproducing failure code: Start engine and drive the machine in high idle.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective transmission filter
1 clogging sensor R12 (male) Transmission filter Resistance
(Internal disconnection) Normal Max. 1 Ω
Between (1) and (2)
Clogging Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between L53 (female) (5) –
2 Resistance Max. 1 Ω
Possible causes (Disconnection or defective R12 (female) (1)
and standard contact in connector) Wiring harness between R12 (male) (2) –
Resistance Max. 1 Ω
value in normal chassis ground
state
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short in wiring harness carry out troubleshooting.
3
(Contact with 24 V circuit) Wiring harness between L53 (female) (5) –
Voltage Max. 1 V
R12 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
4 Defective machine monitor L53 (female) Transmission filter Resistance
Between (5) and Normal Max. 1 Ω
chassis ground Clogging Min. 1 MΩ

40-432 ➁ WA500-6
TROUBLESHOOTING DHT2L6
Related Circuit Diagram

WA500-6 40-433 ➁
TROUBLESHOOTING DK59KA

DK59KA
Lift Arm EPC Lever Potentiometer (Main): Disconnection
Action Code Failure Code Lift arm EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK59KA (Work equipment controller system)

• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer system, the signal
Contents of
voltage is lower than normal range.
trouble
(Lift arm EPC lever potentiometer (Main) signal voltage: Max. 0.3 V)
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to
N (Neutral).
Problem that
appears on —
machine

Cause Standard value in normal state/Remarks on troubleshooting

Defective lift arm EPC lever
potentiometer
1 S03
(Internal disconnection or
short circuit)
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection in wiring
harness or defective contact)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
Lift arm EPC lever Voltage
Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Raise operation
3.64 – 4.14 V
(Before detent)
Raise operation
Between (3) and (1) 3.86 – 4.36 V
(Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
Float operation 0.64 – 1.14 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (19) –
Resistance Max. 1 Ω
S03 (female) (3)
Wiring harness between L05 (female) (21) –
Resistance Max. 1 Ω
S03 (female) (1)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
S03 (female) (4)

40-434 ➁ WA500-6
TROUBLESHOOTING DK59KA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L05 (female) (19) –
3 harness Resistance Min. 1 MΩ
S03 (female) (3) and chassis ground
(Contact with ground circuit)
Between L05 (female) (22) – S03 (female)
Resistance Min. 1 MΩ
(4), – circuit branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
Possible causes
and standard L05 Lift arm EPC lever Voltage
value in normal Between
state Constant 4.85 – 5.15 V
(22) and (21)
Defective work equipment Lever in neutral 2.40 – 2.60 V
4
controller Raise operation
3.64 – 4.14 V
(Before detent)
Between Raise operation
3.86 – 4.36 V
(19) and (21) (Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
Float operation 0.64 – 1.14 V

WA500-6 40-435 ➁
TROUBLESHOOTING DK59KA
Related Circuit Diagram

40-436 ➁ WA500-6
TROUBLESHOOTING DK59KY

DK59KY
Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply
Line
Action Code Failure Code Lift arm EPC lever potentiometer (Main): Short circuit with power supply
Trouble line
E03 DK59KY (Work equipment controller system)
• Due to hot short circuit in the lift arm EPC lever potentiometer (Main) system, the signal voltage is higher
Contents of
than normal range.
trouble
(Lift arm EPC lever potentiometer (Main) signal voltage: Min. 4.7 V)
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to
N (Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 Resistance
Between (1) and (4) 3.2 ± 0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective lift arm EPC lever • Work equipment lock lever: Lock
1 potentiometer S03 Lift arm EPC lever Voltage
(Internal short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes
and standard Lever in neutral 2.40 – 2.60 V
value in normal Raise operation
3.64 – 4.14 V
state (Before detent)
Raise operation
Between (3) and (1) 3.86 – 4.36 V
(Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
Float operation 0.64 – 1.14 V
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness Wiring harness between L05 (female) (19) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S03 (female) (3) and chassis ground
Between L05 (female) (22) – S03 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground

WA500-6 40-437 ➁
TROUBLESHOOTING DK59KY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Work equipment lock lever: Lock
L05 Lift arm EPC lever Voltage
Between
Constant 4.85 – 5.15 V
Possible causes (22) and (21)
and standard
Defective work equipment Lever in neutral 2.40 – 2.60 V
value in normal 3
controller Raise operation
state 3.64 – 4.14 V
(Before detent)
Between Raise operation
3.86 – 4.36 V
(19) and (21) (Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
Float operation 0.64 – 1.14 V

40-438 ➁ WA500-6
TROUBLESHOOTING DK59KY
Related Circuit Diagram

WA500-6 40-439 ➁
TROUBLESHOOTING DK59L8

DK59L8
Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree
Action Code Failure Code Lift arm EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK59L8 (Work equipment controller system)

• Lift arm EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Lift arm EPC lever potentiometer signal voltage (Total of Main and Sub): Max. 4.7 V) or
trouble
(Lift arm EPC lever potentiometer signal voltage (Total of Main and Sub): Min. 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detects a position within neutrality ±5% as
the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within
Action of
neutrality ±5%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to
N (Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, lift arm does not move.
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Possible causes Defective lift arm EPC lever • Work equipment lock lever: Lock
and standard potentiometer
1 S03 Lift arm EPC lever Voltage
value in normal (Internal disconnection or
state short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Raise operation
3.64 – 4.14 V
(Before detent)
Raise operation
Between (3) and (1) 3.86 – 4.36 V
(Detent position)
Float operation 0.64 – 1.14 V
Lower operation
0.86 – 1.36 V
(Before detent)

40-440 ➁ WA500-6
TROUBLESHOOTING DK59L8

Cause Standard value in normal state/Remarks on troubleshooting

Lever in neutral 2.40 – 2.60 V
Raise operation
0.86 – 1.36 V
Defective lift arm EPC lever (Before detent)
potentiometer Raise operation
1 Between (2) and (1) 0.64 – 1.14 V
(Internal disconnection or (Detent position)
short circuit) Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (13) –
Resistance Max. 1 Ω
Disconnection in wiring S03 (female) (2)
harness Wiring harness between L05 (female) (19) –
2 Resistance Max. 1 Ω
(Disconnection in wiring S03 (female) (3)
harness or defective contact) Wiring harness between L05 (female) (21) –
Resistance Max. 1 Ω
Possible causes S03 (female) (1)
and standard Wiring harness between L05 (female) (22) –
value in normal Resistance Max. 1 Ω
S03 (female) (4)
state
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (13) –
Grounding fault in wiring Resistance Min. 1 MΩ
S03 (female) (2) and chassis ground
3 harness
(Contact with ground circuit) Wiring harness between L05 (female) (19) –
Resistance Min. 1 MΩ
S03 (female) (3) and chassis ground
Between L05 (female) (22) – S03 (female) (4), –
Resistance Min. 1 MΩ
circuit branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L05 (female) (13) –
Voltage Max. 1 V
Hot short in wiring harness S03 (female) (2) and chassis ground
4
(Contact with 24 V circuit) Wiring harness between L05 (female) (19) –
Voltage Max. 1 V
S03 (female) (3) and chassis ground
Between L05 (female) (22) – S03 (female) (4), –
Voltage Max. 1 V
circuit branch end and chassis ground

WA500-6 40-441 ➁
TROUBLESHOOTING DK59L8

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
L05 Lift arm EPC lever Voltage
Between
Constant 4.85 – 5.15 V
(22) and (21)
Lever in neutral 2.40 – 2.60 V
Raise operation
3.64 – 4.14 V
(Before detent)
Possible causes Between Raise operation
3.86 – 4.36 V
and standard Defective work equipment (19) and (21) (Detent position)
5
value in normal controller Float operation 0.64 – 1.14 V
state
Lower operation
0.86 – 1.36 V
(Before detent)
Lever in neutral 2.40 – 2.60 V
Raise operation
0.86 – 1.36 V
(Before detent)
Between Raise operation
0.64 – 1.14 V
(13) and (21) (Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V

40-442 ➁ WA500-6
TROUBLESHOOTING DK59L8
Related Circuit Diagram

WA500-6 40-443 ➁
TROUBLESHOOTING DK5AKA

DK5AKA
Lift Arm EPC Lever Potentiometer (Sub): Disconnection
Action Code Failure Code Lift arm EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5AKA (Work equipment controller system)
Contents of • Due to disconnection or grounding fault in the lift arm EPC lever potentiometer (Sub) system, the signal
trouble voltage is lower than normal range. (Lift arm EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V)
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on • —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.

Cause Standard value in normal state/Remarks on troubleshooting

Defective lift arm EPC lever
potentiometer
1 S03 (male)
(Internal disconnection or
short circuit)
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection in wiring
harness or defective contact)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
Lift arm EPC lever Voltage
Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Raise operation
0.86 – 1.36 V
(Before detent)
Raise operation
Between (2) and (1) 0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (13) –
Resistance Max. 1 Ω
S03 (female) (2)
Wiring harness between L05 (female) (21) –
Resistance Max. 1 Ω
S03 (female) (1)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
S03 (female) (4)

40-444 ➁ WA500-6
TROUBLESHOOTING DK5AKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L05 (female) (13) –
3 harness Resistance Min. 1 MΩ
S03 (female) (2) and chassis ground
(Contact with ground circuit)
Between L05 (female) (22) – S03 (female)
Resistance Min. 1 MΩ
(4), – circuit branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
Possible causes
and standard L05 Lift arm EPC lever Voltage
value in normal Between
state Constant 4.85 – 5.15 V
(22) and (21)
Defective work equipment Lever in neutral 2.40 – 2.60 V
4
controller Raise operation
0.86 – 1.36 V
(Before detent)
Between Raise operation
0.64 – 1.14 V
(13) and (21) (Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V

WA500-6 40-445 ➁
TROUBLESHOOTING DK5AKA
Related Circuit Diagram

40-446 ➁ WA500-6
TROUBLESHOOTING DK5AKY

DK5AKY
Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply
LIne
Action Code Failure Code Lift arm EPC lever potentiometer (Sub): Short circuit with power supply
Trouble line
E03 DK5AKY (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm EPC lever potentiometer (Sub) system, the signal voltage is higher
trouble than normal range. (Lift arm EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V)
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to
N (Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective lift arm EPC lever • Work equipment lock lever: Lock
1 potentiometer S03 (male) Lift arm EPC lever Voltage
(Internal short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes
and standard Lever in neutral 2.40 – 2.60 V
value in normal Raise operation
0.86 – 1.36 V
state (Before detent)
Raise operation
Between (2) and (1) 0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness Wiring harness between L05 (female) (13) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S03 (female) (2) and chassis ground
Between L05 (female) (22) – S03 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground

WA500-6 40-447 ➁
TROUBLESHOOTING DK5AKY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
L05 Lift arm EPC lever Voltage
Between
Constant 4.85 – 5.15 V
Possible causes (22) and (21)
and standard Defective work equipment Lever in neutral 2.40 – 2.60 V
3
value in normal controller Raise operation
state 0.86 – 1.36 V
(Before detent)
Between Raise operation
0.64 – 1.14 V
(13) and (21) (Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V

40-448 ➁ WA500-6
TROUBLESHOOTING DK5AKY
Related Circuit Diagram

WA500-6 40-449 ➁
TROUBLESHOOTING DK5BKA

DK5BKA
Bucket EPC Lever Potentiometer (Main): Disconnection
Action Code Failure Code Bucket EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5BKA (Work equipment controller system)

• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Main) system, the signal
Contents of
voltage is lower than normal range.
trouble
(Bucket EPC lever potentiometer (Main) signal voltage: Max. 0.3 V)
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to
N (Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective bucket EPC lever carry out troubleshooting.
potentiometer • Work equipment lock lever: Lock
1
(Internal disconnection or
short circuit) S02 Bucket EPC lever Voltage
Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes
and standard Lever in neutral 2.40 – 2.60 V
value in normal Tilt operation
3.64 – 4.14 V
state (Before detent)
Between (3) and (1)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between L05 (female) (7) –
Resistance Max. 1 Ω
harness S02 (female) (3)
2
(Disconnection in wiring Wiring harness between L05 (female) (21) –
harness or defective contact) Resistance Max. 1 Ω
S02 (female) (1)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
S02 (female) (4)

40-450 ➁ WA500-6
TROUBLESHOOTING DK5BKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L05 (female) (7) –
3 harness Resistance Min. 1 MΩ
S02 (female) (3) and chassis ground
(Contact with ground circuit)
Between L05 (female) (22) – S02 (female)
Resistance Min. 1 MΩ
(4), – circuit branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Possible causes
and standard • Work equipment lock lever: Lock
value in normal L05 Bucket EPC lever Voltage
state Between
Constant 4.85 – 5.15 V
Defective work equipment (22) and (21)
4
controller Lever in neutral 2.40 – 2.60 V
Tilt operation
3.64 – 4.14 V
(Before detent)
Between (7) and (21)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V

WA500-6 40-451 ➁
TROUBLESHOOTING DK5BKA
Related Circuit Diagram

40-452 ➁ WA500-6
TROUBLESHOOTING DK5BKY

DK5BKY
Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply
Line
Action Code Failure Code Bucket EPC lever potentiometer (Main): Short circuit with power supply
Trouble line
E03 DK5BKY (Work equipment controller system)
• Due to hot short circuit in the bucket EPC lever potentiometer (Main) system, the signal voltage is
Contents of
higher than normal range.
trouble
(Bucket EPC lever potentiometer (Main) signal voltage: Min. 4.7 V)
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to
N (Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective bucket EPC lever carry out troubleshooting.
1 potentiometer • Work equipment lock lever: Lock
(Internal short circuit) S02 Bucket EPC lever Voltage
Possible causes
Between (4) and (1) Constant 4.85 – 5.15 V
and standard
value in normal Lever in neutral 2.40 – 2.60 V
state Tilt operation
3.64 – 4.14 V
(Before detent)
Between (3) and (1)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness Wiring harness between L05 (female) (7) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S02 (female) (3) and chassis ground
Between L05 (female) (22) – S02 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground

WA500-6 40-453 ➁
TROUBLESHOOTING DK5BKY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
L05 Bucket EPC lever Voltage
Possible causes Between
Constant 4.85 – 5.15 V
and standard Defective work equipment (22) and (21)
3
value in normal controller Lever in neutral 2.40 – 2.60 V
state
Tilt operation
3.64 – 4.14 V
(Before detent)
Between (7) and (21)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V

40-454 ➁ WA500-6
TROUBLESHOOTING DK5BKY
Related Circuit Diagram

WA500-6 40-455 ➁
TROUBLESHOOTING DK5BL8

DK5BL8
Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree
Action Code Failure Code Bucket EPC lever potentiometer (Main): Analog signals disagree (Work
Trouble
E03 DK5BL8 equipment controller system)

• Bucket EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Bucket EPC lever potentiometer signal voltage (Total of Main and Sub): Max. 4.7 V) or (Bucket EPC
trouble
lever potentiometer signal voltage (Total of Main and Sub): Min 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detects a position within neutrality ±5% as
the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within
Action of
neutrality ±5%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to
N (Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, bucket does not move.
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
S02 Bucket EPC lever Voltage
Possible causes Defective bucket EPC lever Between (4) and (1) Constant 4.85 – 5.15 V
and standard potentiometer
1 Lever in neutral 2.40 – 2.60 V
value in normal (Internal disconnection or
state short circuit) Tilt operation
3.64 – 4.14 V
(Before detent)
Between (3) and (1)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V
Lever in neutral 2.40 – 2.60 V
Tilt operation
0.86 – 1.36 V
(Before detent)
Between (2) and (1)
Tilt operation
0.64 – 1.14 V
(Detent position)
Full dump operation 3.86 – 4.36 V

40-456 ➁ WA500-6
TROUBLESHOOTING
Cause
Disconnection in wiring
harness
2 Resistance
(Disconnection in wiring
harness or defective contact)
Grounding fault in wiring
3 harness
(Contact with ground circuit)
Possible causes
Hot short in wiring harness
and standard 4
(Contact with 24 V circuit)
value in normal
state
Defective work equipment
5 Between (7) and (21)
controller
WA500-6
DK5BL8
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (1) –
Resistance Max. 1 Ω
S02 (female) (2)
Wiring harness between L05 (female) (7) –
Max. 1 Ω
S02 (female) (3)
Wiring harness between L05 (female) (21) –
Resistance Max. 1 Ω
S02 (female) (1)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
S02 (female) (4)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (1) –
Resistance Min. 1 MΩ
S02 (female) (2) and chassis ground
Wiring harness between L05 (female) (7) –
Resistance Min. 1 MΩ
S02 (female) (3) and chassis ground
Between L05 (female) (22) – S02 (female)
Resistance Min. 1 MΩ
(4), – circuit branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L05 (female) (1) –
Voltage Max. 1 V
S02 (female) (2) and chassis ground
Wiring harness between L05 (female) (7) –
Voltage Max. 1 V
S02 (female) (3) and chassis ground
Between L05 (female) (22) – S02 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
L05 Bucket EPC lever Voltage
Between
Constant 4.85 – 5.15 V
(22) and (21)
Lever in neutral 2.40 – 2.60 V
Tilt operation
3.64 – 4.14 V
(Before detent)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V
Lever in neutral 2.40 – 2.60 V
Tilt operation
0.86 – 1.36 V
(Before detent)
Between (1) and (21)
Tilt operation
0.61 – 1.14 V
(Detent position)
Full dump operation 3.96 – 4.36 V
40-457 ➁
TROUBLESHOOTING DK5BL8
Related Circuit Diagram

40-458 ➁ WA500-6
TROUBLESHOOTING DK5CKA

DK5CKA
Bucket EPC Lever Potentiometer (Sub): Disconnection
Action Code Failure Code Bucket EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5CKA (Work equipment controller system)

• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Sub) system,
Contents of
(Sub) signal voltage is lower than normal range.
trouble
(Bucket EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V)
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective bucket EPC lever carry out troubleshooting.
potentiometer • Work equipment lock lever: Lock
1
(Internal disconnection or
short circuit) S02 Bucket EPC lever Voltage
Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes
and standard Lever in neutral 2.40 – 2.60 V
value in normal Tilt operation
0.86 – 1.36 V
state (Before detent)
Between (2) and (1)
Tilt operation
0.64 – 1.14 V
(Detent position)
Full dump operation 3.96 – 4.36 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between L05 (female) (1) –
Resistance Max. 1 Ω
harness S02 (female) (2)
2
(Disconnection in wiring Wiring harness between L05 (female) (21) –
harness or defective contact) Resistance Max. 1 Ω
S02 (female) (1)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
S02 (female) (4)

WA500-6 40-459 ➁
TROUBLESHOOTING DK5CKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L05 (female) (1) –
3 harness Resistance Min. 1 MΩ
S02 (female) (2) and chassis ground
(Contact with ground circuit)
Between L05 (female) (22) – S02 (female)
Resistance Min. 1 MΩ
(4), – circuit branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Possible causes
and standard • Work equipment lock lever: Lock
value in normal L05 Bucket EPC lever Voltage
state Between (22) and
Constant 4.85 – 5.15 V
Defective work equipment (21)
4
controller Lever in neutral 2.40 – 2.60 V
Tilt operation
0.86 – 1.36 V
(Before detent)
Between (1) and (21)
Tilt operation
0.64 – 1.14 V
(Detent position)
Full dump operation 3.86 – 4.36 V

40-460 ➁ WA500-6
TROUBLESHOOTING DK5CKA
Related Circuit Diagram

WA500-6 40-461 ➁
TROUBLESHOOTING DK5CKY

DK5CKY
Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply
Line
Action Code Failure Code Bucket EPC lever potentiometer (Sub): Short circuit with power supply line
Trouble
E03 DK5CKY (Work equipment controller system)

• Due to hot short circuit in the bucket EPC lever potentiometer (Sub) system, (Sub) signal voltage is
Contents of
lower than normal range.
trouble
(Bucket EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V)
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to
N (Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective bucket EPC lever carry out troubleshooting.
1 potentiometer (Internal short • Work equipment lock lever: Lock
circuit) S02 Bucket EPC lever Voltage
Possible causes
Between (4) and (1) Constant 4.85 -5.15 V
and standard
value in normal Lever in neutral 2.40 – 2.60 V
state Tilt operation
0.86 – 1.36 V
(Before detent)
Between (2) and (1)
Tilt operation
0.64 – 1.14 V
(Detent position)
Full dump operation 3.86 – 4.36 V
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness Wiring harness between L05 (female) (1) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S02 (female) (2) and chassis ground
Between L05 (female) (22) – S02 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground

40-462 ➁ WA500-6
TROUBLESHOOTING DK5CKY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
L05 Bucket EPC lever Voltage
Possible causes Between
Constant 4.85 – 5.15 V
and standard Defective work equipment (22) and (21)
3
value in normal controller Lever in neutral 2.40 – 2.60 V
state
Tilt operation
0.86 – 1.36 V
(Before detent)
Between (1) and (21)
Tilt operation
0.64 – 1.14 V
(Detent position)
Full dump operation 3.86 – 4.36 V

WA500-6 40-463 ➁
TROUBLESHOOTING DK5CKY
Related Circuit Diagram

40-464 ➁ WA500-6
TROUBLESHOOTING DK5DKA

DK5DKA
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Disconnection
Action Code Failure Code 3-spool valve (attachment) EPC lever potentiometer (Main):
Trouble Disconnection
E03 DK5DKA (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer
Contents of
(Main), the signal voltage is lower than normal range.
trouble
(3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 0.3 V)
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in
control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional setting
of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment)
lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S25 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground

Defective 3-spool valve ★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes carry out troubleshooting.
(attachment) EPC lever
and standard
1 potentiometer • Work equipment lock lever: Lock
value in normal
(Internal disconnection or 3-spool valve
state S25 (male) Voltage
short circuit) (attachment) EPC lever
Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Full extension
3.86 – 4.36 V
Between (3) and (1) operation
Full retraction
0.64 – 1.14 V
operation

WA500-6 40-465 ➁
TROUBLESHOOTING DK5DKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between L05 (female) (20) –
Resistance Max. 1 Ω
harness S25 (female) (3)
2
(Disconnection in wiring Wiring harness between L05 (female) (21) –
harness or defective contact) Resistance Max. 1 Ω
S25 (female) (1)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
S25 (female) (4)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring Wiring harness between L05 (female) (20) –
Resistance Min. 1 MΩ
3 harness S25 (female) (3) and chassis ground
(Contact with ground circuit) Wiring harness between L05 (female) (22) –
Possible causes
and standard S25 (female) (4), – circuit branch end and Resistance Min. 1 MΩ
value in normal chassis ground
state ★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
3-spool valve
L05 (attachment) Voltage
EPC lever
Defective work equipment
4 Between
controller Constant 4.85 – 5.15 V
(22) and (21)
Lever in neutral 2.40 – 2.60 V
Full extension
Between 3.86 – 4.36 V
operation
(20) and (21)
Full retraction
0.64 – 1.14 V
operation

40-466 ➁ WA500-6
TROUBLESHOOTING DK5DKA
Related Circuit Diagram

WA500-6 40-467 ➁
TROUBLESHOOTING DK5DKY

DK5DKY
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Short Circuit
with Power Supply Line
Action Code Failure Code 3-spool valve (attachment) EPC lever potentiometer (Main): Short
Trouble circuit with power supply line
E03 DK5DKY (Work equipment controller system)
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Main) system the
Contents of
signal voltage is higher than normal range.
trouble
(3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 4.7 V)
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in
control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional
setting of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment)
lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S25 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes Defective 3-spool valve carry out troubleshooting.
and standard (attachment) EPC lever • Work equipment lock lever: Lock
1
value in normal potentiometer 3-spool valve
state (Internal short circuit) S25 (male) (attachment) Voltage
EPC lever
Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Full extension
3.86 – 4.36 V
Between (3) and (1) operation
Full retraction
0.64 – 1.14 V
operation

40-468 ➁ WA500-6
TROUBLESHOOTING DK5DKY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (20) –
Hot short in wiring harness Voltage Max. 1 V
2 S25 (female) (3) and chassis ground
(Contact with 24 V circuit)
Wiring harness between L05 (female) (22) –
S25 (female) (4), – circuit branch end and Voltage Max. 1 V
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes carry out troubleshooting.
and standard • Work equipment lock lever: Lock
value in normal 3-spool valve
state L05 (attachment) Voltage
EPC lever
Defective work equipment
3 Between
controller Constant 4.85 – 5.15 V
(22) and (21)
Lever in neutral 2.40 – 2.60 V
Full extension
Between 3.64 – 4.36 V
operation
(20) and (21)
Full retraction
0.64 – 1.14 V
operation

Related Circuit Diagram

WA500-6 40-469 ➁
TROUBLESHOOTING DK5DL8

DK5DL8
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Analog Signals
Disagree
Action Code Failure Code 3-spool valve (attachment) EPC lever potentiometer (Main): Analog
Trouble signals disagree
E03 DK5DL8 (Work equipment controller system)
• The 3-spool valve (attachment) EPC lever potentiometer (Main and Sub) input signals disagree with
Contents of each other. (3-spool valve (attachment) EPC lever potentiometer signal voltage (Total of Main and Sub):
trouble Max. 4.7 V) or (3-spool valve (attachment) EPC lever potentiometer signal voltage (Total of Main and
Sub): Min. 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detects a position within neutrality ±5% as
the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within
Action of
neutrality ±5%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, 3-spool valve (attachment) cylinder does not move.
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional setting
of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment)
lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S25 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective 3-spool valve carry out troubleshooting.
Possible causes
(attachment) EPC lever
and standard • Work equipment lock lever: Lock
1 potentiometer
value in normal 3-spool valve
(Internal disconnection or
state S25 (male) (attachment) Voltage
short circuit)
EPC lever
Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Full extension
3.86 – 4.36 V
Between (3) and (1) operation
Full retraction
0.64 – 1.14 V
operation

40-470 ➁ WA500-6
TROUBLESHOOTING DK5DL8

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve Lever in neutral 2.40 – 2.60 V

(attachment) EPC lever Full extension
0.64 – 1.14 V
1 potentiometer Between (2) and (1) operation
(Internal disconnection or Full retraction
short circuit) 3.86 – 4.36 V
operation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (14) –
Resistance Max. 1 Ω
Disconnection in wiring S25 (female) (2)
harness Wiring harness between L05 (female) (20) –
2 Resistance Max. 1 Ω
(Disconnection in wiring S25 (female) (3)
harness or defective contact) Wiring harness between L05 (female) (21) –
Resistance Max. 1 Ω
S25 (female) (1)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
S25 (female) (4)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (14) –
Resistance Min. 1 MΩ
Grounding fault in wiring S25 (female) (2) and chassis ground
3 harness Wiring harness between L05 (female) (20) –
(Contact with ground circuit) Resistance Min. 1 MΩ
S25 (female) (3) and chassis ground
Wiring harness between L05 (female) (22) –
S25 (female) (4), – circuit branch end and Resistance Min. 1 MΩ
chassis ground
Possible causes
★ Prepare with starting switch OFF, then turn starting switch ON and
and standard
carry out troubleshooting.
value in normal
state Wiring harness between L05 (female) (14) –
Voltage Max. 1 V
S25 (female) (2) and chassis ground
Hot short in wiring harness
4 Wiring harness between L05 (female) (20) –
(Contact with 24 V circuit) Voltage Max. 1 V
S25 (female) (3) and chassis ground
Wiring harness between L05 (female) (22) –
S25 (female) (4), – circuit branch end and Voltage Max. 1 V
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
3-spool valve
L05 (attachment) Voltage
EPC lever
Between
Constant 4.85 – 5.15 V
(22) and (21)
Defective work equipment Lever in neutral 2.40 – 2.60 V
5
controller Full extension
Between 3.86 – 4.36 V
operation
(20) and (21)
Full retraction
0.64 – 1.14 V
operation
Lever in neutral 2.40 – 2.60 V
Full extension
Between 0.64 – 1.14 V
operation
(14) and (21)
Full retraction
3.86 – 4.36 V
operation

WA500-6 40-471 ➁
TROUBLESHOOTING DK5DL8
Related Circuit Diagram

40-472 ➁ WA500-6
TROUBLESHOOTING DK5DL8

MEMORANDUM

WA500-6 40-473 ➁
TROUBLESHOOTING DK5EKA

DK5EKA
3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Disconnection
Action Code Failure Code 3-spool valve (attachment) EPC lever potentiometer (Sub):
Trouble Disconnection
E03 DK5EKA (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer
Contents of
(Sub), the signal voltage is lower than normal range.
trouble
(3-spool valve (attachment) EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V)
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer is in
Action of control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed.
(If this failure code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the
optional setting of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment)
lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S25 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective 3-spool valve carry out troubleshooting.
Possible causes
(attachment) EPC lever
and standard • Work equipment lock lever: Lock
1 potentiometer
value in normal 3-spool valve
(Internal disconnection or
state S25 (attachment) Voltage
short circuit)
EPC lever
Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Full extension
0.64 – 1.14 V
Between (2) and (1) operation
Full retraction
3.86 – 4.36 V
operation

40-474 ➁ WA500-6
TROUBLESHOOTING DK5EKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between L05 (female) (14) –
Resistance Max. 1 Ω
harness S25 (female) (2)
2
(Disconnection in wiring Wiring harness between L05 (female) (21) –
harness or defective contact) Resistance Max. 1 Ω
S25 (female) (1)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
S25 (female) (4)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring Wiring harness between L05 (female) (14) –
Resistance Min. 1 MΩ
3 harness S25 (female) (2) and chassis ground
(Contact with ground circuit) Wiring harness between L05 (female) (22) –
Possible causes
and standard S25 (female) (4), – circuit branch end and Resistance Min. 1 MΩ
value in normal chassis ground
state ★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Work equipment lock lever: Lock
3-spool valve
L05 (attachment) Voltage
EPC lever
Defective work equipment
4 Between
controller Constant 4.85 – 5.15 V
(22) and (21)
Lever in neutral 2.40 – 2.60 V
Full extension
Between 0.64 – 1.14 V
operation
(14) and (21)
Full retraction
3.86 – 4.36 V
operation

Related Circuit Diagram

WA500-6 40-475 ➁
TROUBLESHOOTING DK5EKY

DK5EKY
3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Short Circuit
with Power Supply Line
Action Code Failure Code 3-spool valve (attachment) EPC lever potentiometer (Sub): Short circuit
Trouble with power supply line
E03 DK5EKY (Work equipment controller system)
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Sub) system, the
Contents of
signal voltage is higher than normal range.
trouble
(3-spool valve (attachment) EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V)
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer is in
control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional setting
of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment)
lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S25 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes Defective 3-spool valve carry out troubleshooting.
and standard (attachment) EPC lever • Work equipment lock lever: Lock
1
value in normal potentiometer 3-spool valve
state (Internal short circuit) S25 (attachment) Voltage
EPC lever
Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Full extension
0.64 – 1.14 V
Between (2) and (1) operation
Full retraction
3.86 – 4.36 V
operation

40-476 ➁ WA500-6
TROUBLESHOOTING DK5EKY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L05 (female) (14) – S25
Hot short in wiring harness Voltage Max. 1 V
2 (female) (2) and chassis ground
(Contact with 24 V circuit)
Wiring harness between L05 (female) (22) – S25
(female) (4), – circuit branch end and chassis Voltage Max. 1 V
ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes carry out troubleshooting.
and standard • Work equipment lock lever: Lock
value in normal 3-spool valve
state L05 (attachment) Voltage
EPC lever
Defective work equipment
3 Between
controller Constant 4.85 – 5.15 V
(22) and (21)
Lever in neutral 2.40 – 2.60 V
Full extension
Between 0.64 – 1.14 V
operation
(14) and (21)
Full retraction
3.86 – 4.36 V
operation

Related Circuit Diagram

WA500-6 40-477 ➁
TROUBLESHOOTING DK5FKA

DK5FKA
Joystick Steering EPC Lever Potentiometer (Main): Disconnection
Action Code Failure Code Joystick steering EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5FKA (Work equipment controller system)

• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer system (main),
Contents of
the signal voltage is lower than normal range.
trouble
(Joystick steering EPC lever potentiometer (Main) signal voltage: Max. 0.3 V)
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is set to
N (Neutral).
Problem that
appears on —
machine
• This failure code is not displayed when joystick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked with
Related the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked with
the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS3 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
Defective joystick steering
EPC lever potentiometer ★ Prepare with starting switch OFF, then turn starting switch ON and
1 carry out troubleshooting.
(Internal disconnection or
short circuit) Joystick steering EPC
JS3 (male) Voltage
lever
Possible causes
and standard Between (4) and (1) Constant 4.85 – 5.15 V
value in normal Lever in neutral 2.40 – 2.60 V
state
Between (3) and (1) Full steering to left 1.09 – 1.59 V
Full steering to right 3.41 – 3.91 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between L05 (female) (9) –
Resistance Max. 1 Ω
harness JS3 (female) (3)
2
(Disconnection in wiring Wiring harness between L05 (female) (22) –
harness or defective contact) Resistance Max. 1 Ω
JS3 (female) (4)
Wiring harness between JS3 (female) (1) –
Resistance Max. 1 Ω
chassis ground

40-478 ➁ WA500-6
TROUBLESHOOTING DK5FKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L05 (female) (9) –
3 harness Resistance Min. 1 MΩ
JS3 (female) (3) and chassis ground
(Contact with ground circuit)
Wiring harness between L05 (female) (22) –
Resistance Min. 1 MΩ
JS3 (female) (4) and chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
value in normal
Joystick steering EPC
state L05 Voltage
lever
Defective work equipment Between (22) and
4 Constant 4.85 – 5.15 V
controller chassis ground
Lever in neutral 2.40 – 2.60 V
Between (9) and
Full steering to left 1.09 – 1.59 V
chassis ground
Full steering to right 3.41 – 3.91 V

Related Circuit Diagram

WA500-6 40-479 ➁
TROUBLESHOOTING DK5FKY

DK5FKY
Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power
Supply Line
Action Code Failure Code Joystick steering EPC lever potentiometer (Main): Short circuit with the
Trouble power supply line
E03 DK5FKY (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Main) system, the signal voltage
Contents of
is higher than normal range.
trouble
(Joystick steering EPC lever potentiometer (Main) signal voltage: Max. 4.7 V)
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is set to
N (Neutral).
Problem that
appears on —
machine
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked with
Related the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked with
the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS3 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
Defective joystick steering ★ Prepare with starting switch OFF, then turn starting switch ON and
1 EPC lever potentiometer carry out troubleshooting.
(Internal short circuit)
Possible causes Joystick steering EPC
JS3 (male) Voltage
and standard lever
value in normal Between (4) and (1) Constant 4.85 – 5.15 V
state Lever in neutral 2.40 – 2.60 V
Between (3) and (1) Full steering to left 1.09 – 1.59 V
Full steering to right 3.41 – 3.91 V
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness Wiring harness between L05 (female) (9) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) JS3 (female) (3) and chassis ground
Wiring harness between L05 (female) (22) –
Voltage Max. 1 V
JS3 (female) (4) and chassis ground

40-480 ➁ WA500-6
TROUBLESHOOTING DK5FKY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Joystick steering EPC
L05 Voltage
Possible causes lever
and standard Defective work equipment Between (22) and
3 Constant 4.85 – 5.15 V
value in normal controller chassis ground
state
Lever in neutral 2.40 – 2.60 V
Between (9) and
Full steering to left 1.09 – 1.59 V
chassis ground
Full steering to right 3.41 – 3.91 V

Related Circuit Diagram

WA500-6 40-481 ➁
TROUBLESHOOTING DK5GKA

DK5GKA
Joystick Steering EPC Lever Potentiometer (Sub): Disconnection
Action Code Failure Code Joystick steering EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5GKA (Work equipment controller system)

• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer system (Sub),
Contents of
the signal voltage is lower than normal range.
trouble
(Joystick steering EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V)
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked with
Related the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked with
the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.

Cause Standard value in normal state/Remarks on troubleshooting

Defective joystick steering
EPC lever potentiometer
1 carry out troubleshooting.
(Internal disconnection or
short circuit)
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection in wiring
harness or defective contact)
Grounding fault in wiring
3 harness
(Contact with ground circuit)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS3 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Joystick steering EPC
JS3 (male) Voltage
lever
Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Between (2) and (1) Full steering to left 3.41 – 3.91 V
Full steering to right 1.09 – 1.59 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (3) –
Resistance Max. 1 Ω
JS3 (female) (2)
Wiring harness between L05 (female) (22) –
Resistance Max. 1 Ω
JS3 (female) (4)
Wiring harness between JS3 (female) (1) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (3) –
Resistance Min. 1 MΩ
JS3 (female) (2) and chassis ground
Wiring harness between L05 (female) (22) –
Resistance Min. 1 MΩ
JS3 (female) (4) and chassis ground

40-482 ➁ WA500-6
TROUBLESHOOTING DK5GKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Joystick steering EPC
L05 Voltage
Possible causes lever
and standard Defective work equipment Between (22) and
4 Constant 4.85 – 5.15 V
value in normal controller chassis ground
state
Lever in neutral 2.40 – 2.60 V
Between (3) and
Full steering to left 3.41 – 3.91 V
chassis ground
Full steering to right 1.09 – 1.59 V

Related Circuit Diagram

WA500-6 40-483 ➁
TROUBLESHOOTING DK5GKY

DK5GKY
Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power
Supply Line
Action Code Failure Code Joystick steering EPC lever potentiometer (Sub): Short circuit with
Trouble the power supply line
E03 DK5GKY (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Sub) system, the signal
Contents of
voltage is higher than normal range.
trouble
(Joystick steering EPC lever potentiometer (Sub) signal voltage: Max. 4.7 V)
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in
control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is
set to N (Neutral).
Problem that
appears on —
machine
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked
with the monitoring function (Code: 42004, J/S POT1).
Related
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked
with the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering
lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS3 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
Defective joystick steering
EPC lever potentiometer ★ Prepare with starting switch OFF, then turn starting switch ON
1 and carry out troubleshooting.
(Internal disconnection or
short circuit) Joystick steering EPC
Possible causes JS3 (male) Voltage
and standard lever
value in normal Between (4) and (1) Constant 4.85 – 5.15 V
state Lever in neutral 2.40 – 2.60 V
Between (2) and (1) Full steering to left 3.41 – 3.91 V
Full steering to right 1.09 – 1.59 V
★ Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short in wiring harness Wiring harness between L05 (female) (3) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) JS3 (female) (2) and chassis ground
Wiring harness between L05 (female) (22) –
Voltage Max. 1 V
JS3 (female) (4) and chassis ground

40-484 ➁ WA500-6
TROUBLESHOOTING DK5GKY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Joystick steering EPC
L05 Voltage
Possible causes lever
and standard Defective work equipment Between (22) and
3 Constant 4.85 – 5.15 V
value in normal controller chassis ground
state
Lever in neutral 2.40 – 2.60 V
Between (3) and
Full steering to left 3.41 – 3.91 V
chassis ground
Full steering to right 1.09 – 1.59 V

Related Circuit Diagram

WA500-6 40-485 ➁
TROUBLESHOOTING DK5FL8

DK5FL8
Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree
Action Code Failure Code Joystick steering EPC lever potentiometer (Main): Analog signals
Trouble
E03 DK5FL8 disagree (Work equipment controller system)

• Joystick steering EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Joystick steering EPC lever potentiometer signal voltage (both Main and Sub): Max. 4.7 V) or (Joystick
trouble
steering EPC lever potentiometer signal voltage (both Main and Sub): Min 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±5% as
the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within
Action of
neutrality ±5%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is set to
N (Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the joystick steering
appears on EPC lever is set to neutral.
machine • If both Main and Sub potentiometers are abnormal, steering cylinder does not move.
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked with
Related the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked with
the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS3 (male) Resistance
Between (1) and (4) 3.2 ±0.64 kΩ
Between (1), (2), (3), (4) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes Defective joystick steering carry out troubleshooting.
and standard EPC lever potentiometer Joystick steering EPC
1 JS3 (male) Voltage
value in normal (Internal disconnection or lever
state short circuit)
Between (4) and (1) Constant 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Between (3) and (1) Full steering to left 1.09 – 1.59 V
Full steering to right 3.41 – 3.91 V
Lever in neutral 2.40 – 2.60 V
Between (2) and (1) Full steering to left 3.41 – 3.91 V
Full steering to right 1.09 – 1.59 V

40-486 ➁ WA500-6
TROUBLESHOOTING
Cause
Disconnection in wiring
harness Wiring harness between L05 (female) (9) – JS3
2 Resistance
(Disconnection in wiring
harness or defective contact) Wiring harness between L05 (female) (22) –
Grounding fault in wiring
3 harness
(Contact with ground circuit) Wiring harness between L05 (female) (9) – JS3 Resistance Min. 1 MΩ
Possible causes
and standard
value in normal
state
Hot short in wiring harness
4
(Contact with 24 V circuit)
Defective work equipment
5 Lever in neutral
controller
WA500-6
DK5FL8
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (3) – JS3
Resistance Max. 1 Ω
(female) (2)
Max. 1 Ω
(female) (3)
Resistance Max. 1 Ω
JS3 (female) (4)
Wiring harness between JS3 (female) (1) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (3) – JS3
Resistance Min. 1 MΩ
(female) (2) and chassis ground
(female) (3) and chassis ground
Wiring harness between L05 (female) (22) –
Resistance Min. 1 MΩ
JS3 (female) (4) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L05 (female) (3) – JS3
Voltage Max. 1 V
(female) (2) and chassis ground
Wiring harness between L05 (female) (9) – JS3
Voltage Max. 1 V
(female) (3) and chassis ground
Wiring harness between L05 (female) (22) –
Voltage Max. 1 V
JS3 (female) (4) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Joystick steering EPC
L05 Voltage
lever
Between (22) and
Constant 4.85 – 5.15 V
chassis ground
2.40 – 2.60 V
Between (9) and
Full steering to left 1.09 – 1.59 V
chassis ground
Full steering to right 3.41 – 3.91 V
Lever in neutral 2.40 – 2.60 V
Between (3) and
Full steering to left 3.41 – 3.91 V
chassis ground
Full steering to right 1.09 – 1.59 V
40-487 ➁
TROUBLESHOOTING DK5FL8
Related Circuit Diagram

40-488 ➁ WA500-6
TROUBLESHOOTING DK5FL8

MEMORANDUM

WA500-6 40-489 ➁
TROUBLESHOOTING DKA0KA

DKA0KA
Lift Arm Angle Sensor: Disconnection
Action Code Failure Code Lift arm angle sensor: Disconnection
Trouble
E01 DKA0KA (Work equipment controller system)
Contents of • Due to disconnection or grounding fault in lift arm angle sensor system, the signal voltage is lower than
trouble normal range. (Lift arm angle sensor signal: Max. 0.3 V)
• Judges that lift arm is at the lowest position.
• Resets the remote positioner function.
• Resets semi-auto digging function.
Action of • No PC control while the lift arm is rising.
controller • When the remote positioner lower setting is ON, turns OFF the lift arm float detent; when the remote
positioner lower setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm raise detent OFF.
• If cause of failure disappears, system resets itself.
Problem that • Remote positioner malfunction (Not stop)
appears on • Faulty semi-auto digging operation (Not operate)
machine • No PC control while the lift arm is rising
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function (Code:
06002 BOOM ANG).
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
Related
(Code: 06005 BOOM ANG).
information
• If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshooting
for it first.
• Method of reproducing failure code: Turn starting switch ON.

★ Prepare with starting switch OFF, then carry out troubleshooting

without turning starting switch ON.
F13 (male) Resistance
Between (A) and (C) 5 kΩ ±20%
Between (A), (B), (C) and
Min. 1 MΩ
Defective lift arm angle chassis ground
sensor ★ Prepare with starting switch OFF, then start engine and carry out
1
(Internal disconnection or troubleshooting.
short circuit)
F13 Lift arm position Voltage
Possible causes Between (C) and (A) Constant 4.85 – 5.15 V
and standard
value in normal Constant 1.00 – 4.00 V
state Between (B) and (A) Raise stroke end 3.50 – 4.00 V
Lower stroke end 1.00 – 1.88 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between F13 (female) (A) –
Resistance Max. 1Ω
harness chassis ground
2
(Disconnection in wiring Wiring harness between F13 (female) (B) –
harness or defective contact) Resistance Max. 1 Ω
L05 (female) (8)
Wiring harness between F13 (female) (C) –
Resistance Max. 1 Ω
L51 (female) (16)

40-490 ➁ WA500-6
TROUBLESHOOTING DKA0KA

★ Prepare with starting switch OFF, then carry out troubleshooting

without turning starting switch ON.
Wiring harness between F13 (female) (B) –
Grounding fault in wiring
L05 (female) (8), L55 (female) (10) and Resistance Min. 1 MΩ
3 harness
chassis ground
(Contact with ground circuit)
Possible causes Wiring harness between F13 (female) (C) –
and standard L51 (female) (16), – circuit branch end and Resistance Min. 1 MΩ
value in normal chassis ground
state ★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.

Defective work equipment L05 Lift arm position Voltage

4
controller Constant 1.00 – 4.00 V
Between (8) and
Raise stroke end 3.50 – 4.00 V
chassis ground
Lower stroke end 1.00 – 1.88 V

Related Circuit Diagram

WA500-6 40-491 ➁
TROUBLESHOOTING DKA0KX

DKA0KX
Lift Arm Angle Sensor: Out-of-Input Signal Range
Action Code Failure Code Lift arm angle sensor: Out of input signal range
Trouble
E01 DKA0KX (Machine monitor system)

• Due to grounding fault in lift arm angle sensor system, the signal voltage is not input.
(Lift arm angle sensor signal voltage: Max. 1 V)
Contents of
trouble • Due to disconnection or hot short circuit in lift arm angle sensor system, the signal voltage is higher than
normal level.
(Lift arm angle sensor signal voltage: Min. 4 V)
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06001 BOOM ANG).
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
Related
(Code: 06003 BOOM ANG).
information
• If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshooting
for it first.
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F13 (male) Resistance
Between (A) and (C) 5 kΩ ±20%
Between (A), (B), (C) and
Min. 1 MΩ
Defective lift arm angle chassis ground
sensor ★ Prepare with starting switch OFF, then start engine and carry out
1
(Internal disconnection or troubleshooting.
short circuit)
F13 Lift arm position Voltage
Possible causes Between (C) and (A) Constant 4.85 – 5.15 V
and standard
value in normal Constant 1.00 – 4.00 V
state Between (B) and (A) Raise stroke end 3.50 – 4.00 V
Lower stroke end 1.00 – 1.88 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between F13 (female) (A) –
Resistance Max. 1 Ω
harness chassis ground
2
(Disconnection in wiring Wiring harness between F13 (female) (B) –
harness or defective contact) Resistance Max. 1 Ω
L55 (female) (10)
Wiring harness between F13 (female) (C) –
Resistance Max. 1 Ω
L51 (female) (16)

40-492 ➁ WA500-6
TROUBLESHOOTING DKA0KX

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between F13 (female) (B) –
Grounding fault in wiring
L05 (female) (8), L55 (female) (10) and Resistance Min. 1 MΩ
3 harness
chassis ground
(Contact with ground circuit)
Wiring harness between F13 (female) (C) –
L51 (female) (16), – circuit branch end and Resistance Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes carry out troubleshooting. (Lift arm lower position)
and standard Wiring harness between F13 (female) (B) –
value in normal Hot short in wiring harness L05 (female) (8), L55 (female) (10) and Voltage Max. 1 V
state 4
(Contact with 24 V circuit) chassis ground
Wiring harness between F13 (female) (C) –
L51 (female) (16), – circuit branch end and Voltage Max. 1 V
chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
L55 Lift arm position Voltage
5 Defective machine monitor
Constant 1.00 – 4.00 V
Between (10) and
Raise stroke end 3.50 – 4.00 V
chassis ground
Lower stroke end 1.00 – 1.88 V

WA500-6 40-493 ➁
TROUBLESHOOTING DKA0KX
Related Circuit Diagram

40-494 ➁ WA500-6
TROUBLESHOOTING DKA0KX

MEMORANDUM

WA500-6 40-495 ➁
TROUBLESHOOTING DKA0KY

DKA0KY
Lift Arm Angle Sensor: Short Circuit with Power Supply Line
Action Code Failure Code Lift arm angle sensor: Short circuit with power supply line
Trouble
E01 DKA0KY (Work equipment controller system)
Contents of • Due to hot short in lift arm angle sensor system, the signal voltage is higher than normal range.
trouble (Lift arm angle sensor signal: Min. 4.7 V)
• Judges that lift arm is at the highest position.
• Resets the remote positioner function.
• Resets semi-auto digging function.
• No PC control while the lift arm is rising.
Action of
controller • When the remote positioner lower setting is ON, turns OFF the lift arm float detent; when the
remote positioner lower setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm raise detent OFF.
• Even if cause of failure disappears, system does not reset itself until lift arm lever is set to
N (Neutral).
Problem that • Remote positioner malfunction
appears on • Faulty semi-auto digging operation
machine • No PC control while the lift arm is rising
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06002 BOOM ANG).
Related
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
information
(Code: 06005 BOOM ANG).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F13 (male) Resistance
Between (A) and (C) 5 kΩ ±20%
Between (A), (B), (C) and
Min. 1 MΩ
chassis ground
Defective lift arm angle
1 sensor ★ Prepare with starting switch OFF, then start engine and carry out
(Internal short circuit) troubleshooting.
F13 Lift arm position Voltage
Possible causes
Between (C) and (A) Constant 4.85 – 5.15 V
and standard
value in normal Constant 1.00 – 4.00 V
state Between (B) and (A) Raise stroke end 3.50 – 4.00 V
Lower stroke end 1.00 – 1.88 V
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between F13 (female) (B) –
Hot short in wiring harness L05 (female) (8), L55 (female) (10) and Voltage Max. 1 V
2
(Contact with 24 V circuit) chassis ground
Wiring harness between F13 (female) (C) –
L51 (female) (16), – circuit branch end and Voltage Max. 1 V
chassis ground

40-496 ➁ WA500-6
TROUBLESHOOTING DKA0KY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Possible causes
and standard Defective work equipment L05 Lift arm position Voltage
3
value in normal controller Constant 1.00 – 4.00 V
state Between (8) and
Raise stroke end 3.50 – 4.00 V
chassis ground
Lower stroke end 1.00 – 1.88 V

Related Circuit Diagram

WA500-6 40-497 ➁
TROUBLESHOOTING DKA0L0

DKA0L0
Lift Arm Angle Sensor: Double Meshing
Action code Failure code Lift arm angle sensor: Double meshing
Trouble
E01 DKA0L0 (Work equipment controller system)
Contents of • Due to lift arm angle sensor dislocation, lift arm angle is not detectable correctly.
trouble (Lift arm angle upper limit + 5° and above or lift arm angle lower limit + 5° or above)
• Resets the remote positioner function.
• Resets semi-auto digging function.
• No PC control while the lift arm is rising.
Action of
• When the remote positioner lower setting is ON, turns OFF the lift arm float detent; when the remote posi-
controller
tioner lower setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm raise detent OFF.
• If cause of failure disappears, system resets itself.
Problem that • Remote positioner malfunction (Not stop)
appears on • Faulty semi-auto digging operation (Not operate)
machine • No PC control while the lift arm is rising
• This failure code may be displayed when the initial setting of the lift arm angle sensor failed.
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function (Code:
Related 06002 BOOM ANG).
information • The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function (Code:
06005 BOOM ANG).
• Method of reproducing failure code: Start engine and set the lift arm to raise or lower stroke end.

Cause Standard value in normal state/Remarks on troubleshooting

Defective lift arm angle ★ Adjustment of lift arm angle sensor may be defective. Check it
1
sensor adjustment directly (see the Testing and Adjusting section).
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F13 (male) Resistance
Between (A) and (C) 5 kΩ ±20%
Between (A), (B), (C) and
Min. 1 MΩ
chassis ground
Defective lift arm angle ★ Prepare with starting switch OFF, then start engine and carry out
2
sensor (Internal short circuit) troubleshooting.
Possible causes
and standard F13 Lift arm position Voltage
value in normal Between (C) and (A) Constant 4.85 – 5.15 V
state
Constant 1.00 – 4.00 V
Between (B) and (A) Raise stroke end 3.50 – 4.00 V
Lower stroke end 1.00 – 1.88 V
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.

Defective work equipment L05 Lift arm position Voltage

3
controller Constant 1.00 – 4.00 V
Between (8) and
Raise stroke end 3.50 – 4.00 V
chassis ground
Lower stroke end 1.00 – 1.88 V

40-498 ➁ WA500-6
TROUBLESHOOTING DKA0L0
Related Circuit Diagram

WA500-6 40-499 ➁
TROUBLESHOOTING DLF1KA

DLF1KA
Transmission Input Shaft Speed Sensor: Disconnection
Action Code Failure Code Transmission input shaft speed sensor: Disconnection
Trouble
E01 DLF1KA (Transmission controller system)

• Due to disconnection or hot short circuit in the transmission input shaft speed sensor system, the signal
Contents of voltage is higher than normal range.
trouble (Transmission input shaft speed sensor signal: Min. 1.5 V)
• Signal from the transmission input shaft speed sensor: 0 rpm
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on —
machine
• The input state (speed) from the transmission input shaft speed sensor can be checked with the
Related
monitoring function (Code: 31200 T/M SPEED IN).
information
• Method of reproducing failure code: Start engine and drive the machine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective transmission input The transmission input shaft speed sensor adjustment may be defective.
1 shaft speed sensor Check it directly (see Transmission Speed Sensor in the Testing and
adjustment Adjusting section).
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission input
shaft speed sensor REV OUT1 (male) Resistance
2
(Internal disconnection or Between (1) and (2) 500 – 1,000 Ω
short circuit)
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes harness Wiring harness between L03 (female) (39) –
and standard 3 Resistance Max. 1 Ω
(Disconnection in wiring REV OUT1 (female) (2)
value in normal harness or defective contact) Wiring harness between L03 (female) (40) –
state Resistance Max. 1 Ω
REV OUT1 (female) (1)
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short in wiring harness carry out troubleshooting.
4
(Contact with 24 V circuit) Wiring harness between L03 (female) (40) –
Voltage Max. 1 V
REV OUT1 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L03 (female) Resistance
5
controller Between (39) and (40) 500 – 1,000 Ω
Between (39), (40) and
Min. 1 MΩ
chassis ground

40-500 ➁ WA500-6
TROUBLESHOOTING DLF1KA
Related Circuit Diagram

WA500-6 40-501 ➁
TROUBLESHOOTING DLF1LC

DLF1LC
Transmission Input Shaft Speed Sensor: Speed Signals Disagree
Action Code Failure Code Transmission input shaft speed sensor: Speed signals disagree
Trouble
E01 DLF1LC (Transmission controller system)

• Due to grounding fault in the transmission input shaft speed sensor, the transmission input shaft
speed sensor signal voltage is lower than normal range.
• This failure code appears under the following conditions. ([A] or [B])
[A]

• Transmission output shaft speed sensor and transmission input shaft speed obtained from
reduction ratio: Min. 200 rpm
Contents of
• Signal from transmission input shaft speed sensor: 0 rpm
trouble
• Transmission input shaft speed sensor signal line: Disconnection is not detected.
[B]

• Difference between actual transmission output shaft speed and output shaft speed obtained from
input shaft speed sensor and reduction ratio is larger than 200 rpm.
• Output shaft speed is sensed.
• Input shaft speed is sensed.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on —
machine
• The input state (speed) from the transmission input shaft speed sensor can be checked with the
Related monitoring function (Code: 31200, T/M SPEED IN).
information • Method of reproducing failure code: Start engine and drive the machine.
• This error may be detected when engine stalls.

Cause Standard value in normal state/Remarks on troubleshooting

Defective transmission input The transmission input shaft speed sensor adjustment may be defective.
1 shaft speed sensor Check it directly (see Transmission Speed Sensor in the Testing and
adjustment Adjusting section).
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission input REV OUT1 (male) Resistance
2 shaft speed sensor
(Internal short circuit) Between (1) and (2) 500 – 1,000 Ω
Between (1), (2) and
Min. 1 MΩ
Possible causes chassis ground
and standard
★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 3 harness
(Contact with ground circuit) Wiring harness between L03 (female) (40) –
Resistance Min. 1 MΩ
REV OUT1 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L03 (female) Resistance
4
controller Between (39) and (40) 500 – 1,000 Ω
Between (39), (40) and
Min. 1 MΩ
chassis ground

40-502 ➁ WA500-6
TROUBLESHOOTING DLF1LC
Related Circuit Diagram

WA500-6 40-503 ➁
TROUBLESHOOTING DLT4KB

DLT4KB
Transmission Input Shaft Speed Sensor: Short Circuit
Action Code Failure Code Transmission output shaft speed sensor: Short circuit
Trouble
E03 DLT4KB (Transmission controller system)

• Due to grounding fault in the transmission output shaft speed sensor system, transmission output shaft
speed sensor signal voltage is lower than normal range.
• This failure code appears under the following conditions ([A] or [B]).
[A]
• Transmission input shaft speed sensor and transmission output shaft speed obtained from reduction
ratio: Min. 200 rpm
Contents of
• Transmission output shaft speed sensor: 0 rpm
trouble
• Transmission output shaft speed sensor signal line: Disconnection is not detected.
[B]
• Difference between actual transmission output shaft speed and output shaft speed obtained from input
shaft speed sensor and reduction ratio is larger than 200 rpm.
• Output shaft speed is sensed.
• Input shaft speed is sensed.
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the manual
mode.
Action of • In the manual shift mode, performs the normal control.
controller • Obtains the output shaft speed from the input shaft speed and gear speed reduction ratio for control
operation.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Does not change to auto-shift mode (changes to manual shift mode).
Problem that
• No travel speed limit function
appears on
machine • No transmission protection function
• Gear shifting shocks occur.
• The input state (speed) from the transmission output shaft speed sensor can be checked with the
Related monitoring function (Code: 31400, T/M SPEED OUT).
information • Method of reproducing failure code: Start engine and drive the machine.
• This error may be detected when engine stalls.

Cause Standard value in normal state/Remarks on troubleshooting

Defective transmission
1 output shaft speed sensor
adjustment
Possible causes Defective transmission
and standard 2 output shaft speed sensor
(Internal short circuit)
value in normal
state
Grounding fault in wiring
3 harness
(Contact with ground circuit)
The transmission output shaft speed sensor adjustment may be defective.
Check it directly (see Transmission Speed Sensor in the Testing and
Adjusting section).
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
REV OUT2 (male) Resistance
Between (1) and (2) 500 – 1,000 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (20) –
Resistance Min. 1 MΩ
REV OUT2 (female) (1) and chassis ground

40-504 ➁ WA500-6
TROUBLESHOOTING DLT4KB

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes
and standard Defective transmission L03 (female) Resistance
4
value in normal controller Between (20) and (29) 500 – 1,000 Ω
state
Between (20), (29) and
Min. 1 MΩ
chassis ground

Related Circuit Diagram

WA500-6 40-505 ➁
TROUBLESHOOTING DLT4KX

DLT4KX
Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range
Action Code Failure Code Transmission output shaft speed sensor: Out of input signal range
Trouble
E03 DLT4KX (Transmission controller system)

• Due to disconnection or hot short circuit in the transmission output shaft speed sensor system, the signal
Contents of voltage is higher than normal range.
trouble (Transmission output shaft speed sensor signal: Min. 1.5 V)
• Signal from the transmission output shaft speed sensor: 0 rpm
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the manual
mode.
Action of • In the manual shift mode, performs the normal control.
controller • Obtains the output shaft speed from the input shaft speed and gear speed reduction ratio for control
operation.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Does not change to auto-shift mode (changes to manual shift mode).
Problem that
• No travel speed limit function
appears on
machine • No transmission protection function
• Gear shifting shocks occur.
• The input state (speed) from the transmission output shaft speed sensor can be checked with the
Related
monitoring function (Code: 31400, T/M SPEED OUT).
information
• Method of reproducing failure code: Start engine and drive the machine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective transmission
1 output shaft speed sensor
adjustment
Defective transmission
2 output shaft speed sensor
(Internal short circuit)
Disconnection in wiring
Possible causes harness
and standard 3 Resistance
(Disconnection in wiring
value in normal harness or defective contact) Wiring harness between L03 (female) (29) –
state
Hot short in wiring harness
4
(Contact with 24 V circuit)
Defective transmission
5
controller
The transmission input shaft speed sensor adjustment may be defective.
Check it directly (see Transmission Speed Sensor in the Testing and
Adjusting section).
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
REV OUT2 (male) Resistance
Between (1) and (2) 500 – 1,000 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (20) –
Max. 1 Ω
REV OUT2 (female) (1)
Resistance Max. 1 Ω
REV OUT2 (female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L03 (female) (20) –
Voltage Max. 1 V
REV OUT2 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L03 (female) Resistance
Between (20) and (29) 500 – 1,000 Ω
Between (20), (29) and
Min. 1 MΩ
chassis ground

40-506 ➁ WA500-6
TROUBLESHOOTING DLT4KX
Related Circuit Diagram

WA500-6 40-507 ➁
TROUBLESHOOTING DT20KB

DT20KB
Transmission Cutoff Indicator Lamp: Short Circuit
Action Code Failure Code Transmission cutoff indicator lamp: Short circuit
Trouble
E01 DT20KB (Transmission controller system)
Contents of • Due to grounding fault in transmission cutoff indicator lamp system, the signal is not output to the
trouble indicator lamp.
Action of • Turns the transmission cutoff indicator lamp output OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cutoff indicator lamp does not light up.
machine
Related
• Method of reproducing failure code: Start engine and turn the transmission cutoff switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission cutoff
indicator lamp (light-emitting S10 (male) Resistance
1
diode) Between (2) and (1) Min. 1 MΩ (No continuity)
(Internal short circuit)
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L04 (female) (8) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state S10 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective transmission Transmission cutoff
3 L04 Voltage
controller switch
Between (8) and ON Max. 1 V
chassis ground OFF 20 – 30 V

40-508 ➁ WA500-6
TROUBLESHOOTING DT20KB
Related Circuit Diagram

WA500-6 40-509 ➁
TROUBLESHOOTING DUM1KB

DUM1KB
Remote Positioner Raise Set Indicator Lamp: Short Circuit
Action Code Failure Code Remote positioner raise set indicator lamp: Short circuit
Trouble
— DUM1KB (Work equipment controller system)
Contents of • Since the remote positioner raise set indicator lamp system is shorted with the chassis ground, the
trouble signal is not output to the indicator lamp.
Action of • Turns off the remote positioner raise set indicator output.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The remote positioner raise set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner raise set indicator lamp can be checked with the
Related
monitoring function (Code: 40954 D-OUT-18).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective remote positioner
raise set indicator lamp
1 S13 (male)
(light-emitting diode)
(Internal short circuit)
Possible causes
and standard
Grounding fault in wiring
value in normal
2 harness
state
(Contact with ground circuit)
Defective work equipment
3 L07
controller
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (See Electrical System
Troubleshooting: Procedure for Testing Diodes in the Testing and
Adjusting section.)
Resistance
Between (2) and (1) Min. 1 MΩ (No continuity)
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L07 (female) (8) –
Resistance Min. 1 MΩ
S13 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Remote positioner
Voltage
raise
Between (8) and In use 20 – 30 V
chassis ground Not in use Max. 1 V

40-510 ➁ WA500-6
TROUBLESHOOTING DUM1KB
Related Circuit Diagram

WA500-6 40-511 ➁
TROUBLESHOOTING DUM2KB

DUM2KB
Remote Positioner Lower Set Indicator Lamp: Short Circuit
Action Code Failure Code Remote positioner lower set indicator lamp: Short circuit
Trouble
— DUM2KB (Work equipment controller system)
Contents of • Since the remote positioner lower set indicator lamp system is shorted with the chassis ground, the
trouble signal is not output to the indicator lamp.
Action of • Turns off the remote positioner lower set indicator output.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The remote positioner lower set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner lower set indicator lamp can be checked with the
Related
monitoring function (Code: 40954 D-OUT-19).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective remote positioner
lower set indicator lamp
1 S13 (male)
(light-emitting diode)
(Internal short circuit)
Possible causes
and standard
Grounding fault in wiring
value in normal
2 harness
state
(Contact with ground circuit)
Defective work equipment
3 L07
controller
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (See Electrical System
Troubleshooting: Procedure for Testing Diodes in the Testing and
Adjusting section.)
Resistance
Between (2) and (3) Min. 1 MΩ (No continuity)
Between (2), (3) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L07 (female) (18) –
Resistance Min. 1 MΩ
S13 (female) (3) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Remote positioner
Voltage
lower
Between (18) and In use 20 – 30 V
chassis ground Not in use Max. 1 V

40-512 ➁ WA500-6
TROUBLESHOOTING DUM2KB
Related Circuit Diagram

WA500-6 40-513 ➁
TROUBLESHOOTING DV00KB

DV00KB
Alarm Buzzer: Short Circuit
Action code Failure code Alarm buzzer: Short circuit
Trouble
E01 DV00KB (Machine monitor system)
Contents of
• The alarm buzzer output circuit is shorted with the power supply line.
trouble
Action of • Stops alarm buzzer output.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Alarm buzzer does not sound.
machine
• The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function
Related
(Code: 40295, D-OUT-0).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF; disconnect L51 and L20; turn
starting switch ON; and carry out troubleshooting.
1 Hot short in wiring harness
Wiring harness between L51 (female) (14) –
Voltage Min. 5 V
L20 (female) (2) and chassis ground

Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal (Remove buzzer and connect +24 V to L20 (male) (1) and
state connect GND to L20 (male) (2))
2 Defective alarm buzzer
Alarm buzzer sounds. Alarm buzzer is normal.
Alarm buzzer does not sound. Alarm buzzer is abnormal.
★ Check alarm buzzer unit.
3 Defective machine monitor If results of 1 and 2 are normal, machine monitor is defective.

40-514 ➁ WA500-6
TROUBLESHOOTING DV00KB
Related Circuit Diagram

WA500-6 40-515 ➁
TROUBLESHOOTING DW4PKA

DW4PKA
Lift Arm Raise EPC Solenoid: Disconnection
Action Code Failure Code Lift arm raise EPC solenoid: Disconnection
Trouble
E03 DW4PKA (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid output signal system is disconnected, no current flows when the lift
trouble arm raise EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not rise.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
Related
(Code: 41900 RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm raise

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm raise EPC without turning starting switch ON.
1 solenoid
F07 (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L07 (female) (6) –
2 Resistance Max. 1 Ω
value in normal (Disconnection in wiring F07 (female) (1)
state harness or defective contact) Wiring harness between L07 (female) (3) –
Resistance Max. 1 Ω
F07 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (6) and (3) 5 – 15 Ω

40-516 ➁ WA500-6
TROUBLESHOOTING DW4PKA
Related Circuit Diagram

WA500-6 40-517 ➁
TROUBLESHOOTING DW4PKB

DW4PKB
Lift Arm Raise EPC Solenoid: Short Circuit
Action Code Failure Code Lift arm raise EPC solenoid: Short circuit
Trouble
E03 DW4PKB (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the lift arm raise EPC solenoid output was ON.
• Stops outputting the signal to the lift arm raise EPC solenoid.
Action of • Stops outputting the signal to the lift arm raise detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not rise.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
Related
(Code: 41900 RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm raise

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm raise EPC F07 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (6) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state F07 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (6) and (3) 5 – 15 Ω
Between (6), (3) and
Min. 1 MΩ
chassis ground

40-518 ➁ WA500-6
TROUBLESHOOTING DW4PKB
Related Circuit Diagram

WA500-6 40-519 ➁
TROUBLESHOOTING DW4PKY

DW4PKY
Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Lift arm raise EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4PKY (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the lift arm raise EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment does not work.
appears on
machine • The lift arm raise EPC solenoid may be burnt out.

• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
(Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function
(Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function
information
(Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with
the monitoring function (Code: 41906 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with
the monitoring function (Code: 41907 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm raise EPC F07 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L07 (female) (6) –
state Voltage Max. 1 V
F07 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (6) and (3) 5 – 15 Ω
Between (6), (3) and
Min. 1 MΩ
chassis ground

40-520 ➁ WA500-6
TROUBLESHOOTING DW4PKY
Related Circuit Diagram

WA500-6 40-521 ➁
TROUBLESHOOTING DW4QKA

DW4QKA
Lift Arm Lower EPC Solenoid: Disconnection
Action Code Failure Code Lift arm lower EPC solenoid: Disconnection
Trouble
E03 DW4QKA (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid output signal system is disconnected, no current flows when the lift
trouble arm lower EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not lower.
machine
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function
Related
(Code: 41901 LOWER EPC DIR).
information
• Method of reproducing failure code: Start engine and lower the lift arm.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm lower EPC without turning starting switch ON.
1 solenoid
F08 (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L07 (female) (16) –
2 Resistance Max. 1 Ω
value in normal (Disconnection in wiring F08 (female) (1)
state harness or defective contact) Wiring harness between L07 (female) (3) –
Resistance Max. 1 Ω
F08 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (16) and (3) 5 – 15 Ω

40-522 ➁ WA500-6
TROUBLESHOOTING DW4QKA
Related Circuit Diagram

WA500-6 40-523 ➁
TROUBLESHOOTING DW4QKB

DW4QKB
Lift Arm Lower EPC Solenoid: Short Circuit
Action Code Failure Code Lift arm lower EPC solenoid: Short circuit
Trouble
E03 DW4QKB (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the lift arm lower EPC solenoid output was ON.
• Stops outputting the signal to the lift arm lower EPC solenoid.
Action of • Stops outputting the signal to the lift arm float detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not lower.
machine
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
Related
function (Code: 41901 LOWER EPC DIR).
information
• Method of reproducing failure code: Start engine and lower the lift arm.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm lower EPC F08 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (16) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state F08 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (16) and (3) 5 – 15 Ω
Between (16), (3) and
Min. 1 MΩ
chassis ground

40-524 ➁ WA500-6
TROUBLESHOOTING DW4QKB
Related Circuit Diagram

WA500-6 40-525 ➁
TROUBLESHOOTING DW4QKY

DW4QKY
Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Lift arm lower EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4QKY (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the lift arm lower EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment does not work.
appears on
machine • The lift arm lower EPC solenoid may be burnt out.

• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
(Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function
(Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function
information
(Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with
the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with
the monitoring function (Code: 41907 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm lower EPC F08 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L07 (female) (16) –
state Voltage Max. 1 V
F08 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (16) and (3) 5 – 15 Ω
Between (16), (3) and
Min. 1 MΩ
chassis ground

40-526 ➁ WA500-6
TROUBLESHOOTING DW4QKY
Related Circuit Diagram

WA500-6 40-527 ➁
TROUBLESHOOTING DW4RKA

DW4RKA
Bucket Tilt EPC Solenoid: Disconnection
Action Code Failure Code Bucket tilt EPC solenoid: Disconnection
Trouble
E03 DW4RKA (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid output signal system is disconnected, no current flows when the
trouble bucket tilt EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Bucket does not tilt.
machine
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
Related
(Code: 41902 TILT EPC DIR).
information
• Method of reproducing failure code: Start engine and tilt the bucket.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective bucket tilt EPC without turning starting switch ON.
1 solenoid
F09 (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L07 (female) (5) –
2 Resistance Max. 1 Ω
value in normal (Disconnection in wiring F09 (female) (1)
state harness or defective contact) Wiring harness between L07 (female) (13) –
Resistance Max. 1 Ω
F09 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (5) and (13) 5 – 15 Ω

40-528 ➁ WA500-6
TROUBLESHOOTING DW4RKA
Related Circuit Diagram

WA500-6 40-529 ➁
TROUBLESHOOTING DW4RKB

DW4RKB
Bucket Tilt EPC Solenoid: Short Circuit
Action Code Failure Code Bucket tilt EPC solenoid: Short circuit
Trouble
E03 DW4RKB (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system was shorted with the chassis ground, abnormal current
trouble flowed when the bucket tilt EPC solenoid output was ON.
• Stops outputting the signal to the bucket tilt EPC solenoid.
Action of • Stops outputting the signal to the bucket tilt detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Bucket does not tilt.
machine
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
Related
(Code: 41902 TILT EPC DIR).
information
• Method of reproducing failure code: Start engine and tilt the bucket.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket tilt EPC F09 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (5) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state F09 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (5) and (13) 5 – 15 Ω
Between (5), (13) and
Min. 1 MΩ
chassis ground

40-530 ➁ WA500-6
TROUBLESHOOTING DW4RKB
Related Circuit Diagram

WA500-6 40-531 ➁
TROUBLESHOOTING DW4RKY

DW4RKY
Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Bucket tilt EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4RKY (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system was shorted with the power source, abnormal voltage
trouble was applied when the bucket tilt EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment does not work.
appears on
machine • The bucket tilt EPC solenoid may be burnt out.

• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
(Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function
(Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function
information
(Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with
the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with
the monitoring function (Code: 41907 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket tilt EPC F09 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L07 (female) (5) –
state Voltage Max. 1 V
F09 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (5) and (13) 5 – 15 Ω
Between (5), (13) and
Min. 1 MΩ
chassis ground

40-532 ➁ WA500-6
TROUBLESHOOTING DW4RKY
Related Circuit Diagram

WA500-6 40-533 ➁
TROUBLESHOOTING DW4SKA

DW4SKA
Buck Dump EPC Solenoid: Disconnection
Action Code Failure Code Bucket dump EPC solenoid: Disconnection
Trouble
E03 DW4SKA (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid output signal system is disconnected, no current flows when the
trouble bucket dump EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Bucket does not dump.
machine
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
Related
function (Code: 41903 DUMP EPC DIR).
information
• Method of reproducing failure code: Start engine and dump the bucket.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective bucket dump EPC without turning starting switch ON.
1 solenoid
F10 (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L07 (female) (15) –
2 Resistance Max. 1 Ω
value in normal (Disconnection in wiring F10 (female) (1)
state harness or defective contact) Wiring harness between L07 (female) (13) –
Resistance Max. 1 Ω
F10 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (15) and (13) 5 – 15 Ω

40-534 ➁ WA500-6
TROUBLESHOOTING DW4SKA
Related Circuit Diagram

WA500-6 40-535 ➁
TROUBLESHOOTING DW4SKB

DW4SKB
Bucket Dump EPC Solenoid: Short Circuit
Action Code Failure Code Bucket dump EPC solenoid: Short circuit
Trouble
E03 DW4SKB (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the bucket dump EPC solenoid output was ON.
• Stops outputting the signal to the bucket dump EPC solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Bucket does not dump.
appears on
machine • The wiring harness or controller may be burnt out.

• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function
Related
(Code: 41903 DUMP EPC DIR).
information
• Method of reproducing failure code: Start engine and dump the bucket.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket dump EPC F10 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (15) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state F10 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (15) and (13) 5 – 15 Ω
Between (15), (13) and
Min. 1 MΩ
chassis ground

40-536 ➁ WA500-6
TROUBLESHOOTING DW4SKB
Related Circuit Diagram

WA500-6 40-537 ➁
TROUBLESHOOTING DW4SKY

DW4SKY
Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Bucket dump EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4SKY (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the bucket dump EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment does not work.
appears on
machine • The bucket dump EPC solenoid may be burnt out.

• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
(Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function
(Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function
information
(Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with
the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with
the monitoring function (Code: 41907 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket dump EPC F10 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L07 (female) (15) –
state Voltage Max. 1 V
F10 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (15) and (13) 5 – 15 Ω
Between (15), (13) and
Min. 1 MΩ
chassis ground

40-538 ➁ WA500-6
TROUBLESHOOTING DW4SKY
Related Circuit Diagram

WA500-6 40-539 ➁
TROUBLESHOOTING DW7BKA

DW7BKA
Fan Reverse Solenoid: Disconnection
Action Code Failure Code Fan reverse solenoid: Disconnection
Trouble
E01 DW7BKA (Transmission controller system)
Contents of • Since the fan reverse solenoid system is disconnected, no current flows when the fan reverse solenoid
trouble output is ON.
Action of • Disables the automatic fan reverse function (if equipped).
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • The automatic fan reverse function is disabled in the case of automatic fan reverse function (if
appears on equipped) specification.
machine • Fan cannot be reversed.
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-3).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective fan reverse solenoid without turning starting switch ON.
1
(Internal disconnection) G09 (male) Resistance
Between (1) and (2) 35 – 45 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes
harness Wiring harness between L04 (female) (37) –
and standard 2 Resistance Max. 1 Ω
(Disconnection or defective G09 (female) (1)
value in normal
contact in connector) Wiring harness between G09 (female) (2) –
state
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission
3 L04 (female) Resistance
controller
Between (37) and
35 – 45 Ω
chassis ground

40-540 ➁ WA500-6
TROUBLESHOOTING DW7BKA
Related Circuit Diagram

WA500-6 40-541 ➁
TROUBLESHOOTING DW7BKB

DW7BKB
Fan Reverse Solenoid: Short Circuit
Action Code Failure Code Fan reverse solenoid: Short circuit
Trouble
E01 DW7BKB (Transmission controller system)
Contents of • Since the fan reverse solenoid system was shorted with the chassis ground, abnormal current flowed
trouble when the fan reverse solenoid output was ON.
• Turns the output to the fan reverse solenoid OFF.
Action of
• Disables the automatic fan reverse function (if equipped).
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • The fan cannot turn in reverse when the fan reverse switch is operated.
appears on • The automatic fan reverse function is disabled in the case of automatic fan reverse function (if equipped)
machine specification.
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-3).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan reverse solenoid G09 (male) Resistance
1
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Wiring harness between L04 (female) (37) –
Resistance Min. 1 MΩ
G09 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission
3 L04 (female) Resistance
controller
Between (37) and
35 – 45 Ω
chassis ground

40-542 ➁ WA500-6
TROUBLESHOOTING DW7BKB
Related Circuit Diagram

WA500-6 40-543 ➁
TROUBLESHOOTING DW7BKY

DW7BKY
Fan Reverse Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Fan reverse solenoid: Short circuit with power supply line
Trouble
E01 DW7BKY (Transmission controller system)
Contents of • Since the fan reverse solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan reverse switch output was OFF.
Action of • Disables the automatic fan reverse function (if equipped).
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• The automatic fan reverse function is disabled in the case of automatic fan reverse function (if equipped)
Problem that
specification.
appears on
• The fan does not rotate normally.
machine
• The machine may overheat.
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-3).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan reverse solenoid G09 (male) Resistance
1
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes
★ Prepare with starting switch OFF, then turn starting switch ON and
and standard
Hot short in wiring harness carry out troubleshooting.
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (37) –
Voltage Max. 1 V
G09 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission
3 L04 (female) Resistance
controller
Between (37) and
35 – 45 Ω
chassis ground

40-544 ➁ WA500-6
TROUBLESHOOTING DW7BKY
Related Circuit Diagram

WA500-6 40-545 ➁
TROUBLESHOOTING DW7DKA

DW7DKA
Hydraulic Drive Fan Neutral Solenoid: Disconnection
Action Code Failure Code Hydraulic drive fan neutral solenoid: Disconnection
Trouble
E01 DW7DKA (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
• None in particular
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in the WA500-6.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Optional setting may be incorrect.
and standard
value in normal
1 ★ Refer to MACHINE MONITOR SYSTEM: Service Mode: Optional Device Selecting Function in the
Testing and Adjusting section and check that AUTO RE FAN is set to None.
state

40-546 ➁ WA500-6
TROUBLESHOOTING DW7DKB

DW7DKB
Hydraulic Drive Fan Neutral Solenoid: Short Circuit
Action Code Failure Code Hydraulic drive fan neutral solenoid: Short circuit
Trouble
E01 DW7DKB (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
• None in particular
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in the WA500-6.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Optional setting may be improper.
and standard
1 ★ Refer to MACHINE MONITOR SYSTEM: Service Mode: Optional Device Selecting Function
value in normal
in the Testing and Adjusting section and check that AUTO RE FAN is set to None.
state

WA500-6 40-547 ➁
TROUBLESHOOTING DW7DKY

DW7DKY
Hydraulic Drive Fan Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Hydraulic drive fan neutral solenoid: Short circuit with power supply
Trouble line
E01 DW7DKY (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
• None in particular
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in the WA500-6.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Optional setting may be improper.
and standard
value in normal
1 ★ Refer to MACHINE MONITOR SYSTEM: Service Mode: Optional Device Selecting Function in the
state Testing and Adjusting section and check that AUTO RE FAN is set to None.

40-548 ➁ WA500-6
TROUBLESHOOTING DW7DKY

MEMORANDUM

WA500-6 40-549 ➁
TROUBLESHOOTING DWM1KA

DWM1KA
Work Equipment Neutral Lock Solenoid: Disconnection
Action Code Failure Code Work equipment neutral lock solenoid: Disconnection
Trouble
E01 DWM1KA (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is disconnected, no current flows when the work
trouble equipment neutral lock solenoid output is ON.
• Stops outputting the signal to each work equipment solenoid according to an input signal from the work
Action of
equipment lock lever.
controller
• If cause of failure disappears, system resets itself.
Problem that
• Each work equipment solenoid lock normally works according to an input signal from the work
appears on
equipment lock lever.
machine
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock lever
to the LOCK position.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
1 neutral lock solenoid
B02 (male) Resistance
(Internal disconnection)
Between (1) and (2) 35 – 45 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L07 (female) (7) –
2 Resistance Max. 1 Ω
value in normal (Disconnection in wiring B02 (female) (1)
state harness or defective contact) Wiring harness between B02 (female) (2) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (7) and chassis ground 35 – 45 Ω

40-550 ➁ WA500-6
TROUBLESHOOTING DWM1KA
Related Circuit Diagram

WA500-6 40-551 ➁
TROUBLESHOOTING DWM1KB

DWM1KB
Work Equipment Neutral Lock Solenoid: Short Circuit
Action Code Failure Code Work equipment neutral lock solenoid: Short circuit
Trouble
E01 DWM1KB (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is shorted with the chassis ground, no current
trouble flows when the work equipment neutral lock solenoid output is ON.
• Turns the output to the work equipment neutral lock solenoid ON.
Action of • Stops outputting the signal to each work equipment solenoid according to an input signal from the work
controller equipment lock lever.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Each work equipment solenoid lock normally works according to an input signal from the work
appears on equipment lock lever.
machine • The wiring harness or controller may be burnt out.
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment B02 (male) Resistance
1 neutral lock solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
B03 (male) Diode range Continuity
Possible causes Defective diode (B03)
2 Measured from
and standard (Internal short circuit) Between (2) and (1) Continue
side (2)
value in normal
state Measured from
Between (1) and (2) No continuity
side (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
3 harness
(Contact with ground circuit) Wiring harness between L07 (female) (7) –
Resistance Min. 1 MΩ
B02 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
4
controller L07 (female) Resistance
Between (7) and chassis ground 35 – 45 Ω

40-552 ➁ WA500-6
TROUBLESHOOTING DWM1KB
Related Circuit Diagram

WA500-6 40-553 ➁
TROUBLESHOOTING DWM1KY

DWM1KY
Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply
Line
Action Code Failure Code Work equipment neutral lock solenoid: Short circuit with power supply
Trouble line
E01 DWM1KY (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system was shorted with the power source, abnormal
trouble voltage was applied when the work equipment neutral lock solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
Action of • Stops outputting the signal to each work equipment solenoid according to an input signal from the work
controller equipment lock lever.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • All work equipment does not move.
machine
• The work equipment can be operated by disconnecting the connector of the work equipment neutral lock
solenoid.
Related
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
information
monitoring function (Code: 40952, D-OUT-0).
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment B02 (male) Resistance
1 neutral lock solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
B03 (male) Diode range Continuity
Possible causes Defective diode (B03)
2 Measured from
and standard (Internal short circuit) Between (2) and (1) Continue
side (2).
value in normal
state Measured from
Between (1) and (2) No continuity
side (1).
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short in wiring harness carry out troubleshooting.
3
(Contact with 24 V circuit) Wiring harness between L07 (female) (7) –
Voltage Max. 1 V
B02 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
4
controller L07 (female) Resistance
Between (7) and chassis ground 35 – 45 Ω

40-554 ➁ WA500-6
TROUBLESHOOTING DWM1KY
Related Circuit Diagram

WA500-6 40-555 ➁
TROUBLESHOOTING DWN6KA

DWN6KA
Lift Arm Raise Magnet Detent Solenoid: Disconnection
Action Code Failure Code Lift arm raise magnet detent solenoid: Disconnection
Trouble
E01 DWN6KA (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is disconnected, no current flows
trouble when the lift arm raise magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The lift arm remote positioner raise does not function.
appears on
machine • The lift arm is not held at the lift arm raise detent position.

• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the
Related
monitoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Engine started + lift arm raise detent

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm raise without turning starting switch ON.
1 magnet detent solenoid
S05 (male) Resistance
(Internal disconnection)
Between (1) and (2) 35 – 45 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes harness Wiring harness between L07 (female) (17) –
and standard 2 Resistance Max. 1 Ω
(Disconnection or defective S05 (female) (1)
value in normal contact) Wiring harness between S05 (female) (2) –
state Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Lift arm lever Voltage
3
controller Neutral Max. 1 V
Between (17) and
chassis ground Raise detent
20 – 30 V
operation

40-556 ➁ WA500-6
TROUBLESHOOTING DWN6KA
Related Circuit Diagram

WA500-6 40-557 ➁
TROUBLESHOOTING DWN6KB

DWN6KB
Lift Arm Raise Magnet Detent Solenoid: Short Circuit
Action Code Failure Code Lift arm raise magnet detent solenoid: Short circuit
Trouble
E01 DWN6KB (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the lift arm raise magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The lift arm remote positioner raise does not function.
appears on
machine • The lift arm is not held at the lift arm raise detent position.

• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the
Related
monitoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Engine started + lift arm raise detent

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm raise magnet S05 (male) Resistance
1 detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (17) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state S05 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Lift arm lever Voltage
3
controller Neutral Max. 1 V
Between (17) and
chassis ground Raise detent
20 – 30 V
operation

40-558 ➁ WA500-6
TROUBLESHOOTING DWN6KB
Related Circuit Diagram

WA500-6 40-559 ➁
TROUBLESHOOTING DWN6KY

DWN6KY
Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply
Line
Action Code Failure Code Lift arm raise magnet detent solenoid: Short circuit with power supply
Trouble line
E01 DWN6KY (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system was shorted with the power source,
trouble abnormal voltage was applied when the lift arm raise magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• If you perform lift arm raise detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
machine • If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the
Related
monitoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm raise magnet S05 (male) Resistance
1 detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L07 (female) (17) –
state Voltage Max. 1 V
S05 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Lift arm lever Voltage
3
controller Neutral Max. 1 V
Between (17) and
chassis ground Raise detent
20 – 30 V
operation

40-560 ➁ WA500-6
TROUBLESHOOTING DWN6KY
Related Circuit Diagram

WA500-6 40-561 ➁
TROUBLESHOOTING DWN7KA

DWN7KA
Lift Arm Float Magnet Detent Solenoid: Disconnection
Action Code Failure Code Lift arm float magnet detent solenoid: Disconnection
Trouble
E01 DWN7KA (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm float magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The lift arm remote positioner lower does not function.
appears on
machine • The lift arm is not held at the lift arm float detent position.

• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the
Related
monitoring function (Code: 40952, D-OUT-2).
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm float magnet without turning starting switch ON.
1 detent solenoid
S06 (male) Resistance
(Internal disconnection)
Between (1) and (2) 35 – 45 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes harness Wiring harness between L07 (female) (27) –
and standard 2 Resistance Max. 1 Ω
(Disconnection or defective S06 (female) (1)
value in normal contact) Wiring harness between S06 (female) (2) –
state Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Lift arm lever Voltage
3
controller
Between (27) and Neutral Max. 1 V
chassis ground Float detent operation 20 – 30 V

40-562 ➁ WA500-6
TROUBLESHOOTING DWN7KA
Related Circuit Diagram

WA500-6 40-563 ➁
TROUBLESHOOTING DWN7KB

DWN7KB
Lift Arm Float Magnet Detent Solenoid: Short Circuit
Action Code Failure Code Lift arm float magnet detent solenoid: Short circuit
Trouble
E01 DWN7KB (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the lift arm float magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The lift arm remote positioner lower does not function.
appears on
machine • The lift arm is not held at the lift arm float detent position.

• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the
Related
monitoring function (Code: 40952, D-OUT-2).
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm float magnet S06 (male) Resistance
1 detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Wiring harness between L07 (female) (27) –
Resistance Min. 1 MΩ
S06 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Lift arm lever Voltage
3
controller
Between (27) and Neutral Max. 1 V
chassis ground Float detent operation 20 – 30 V

40-564 ➁ WA500-6
TROUBLESHOOTING DWN7KB
Related Circuit Diagram

WA500-6 40-565 ➁
TROUBLESHOOTING DWN7KY

DWN7KY
Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Lift arm float magnet detent solenoid: Short circuit with power supply line
Trouble
E01 DWN7KY (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system was shorted with the power source,
trouble abnormal voltage was applied when the lift arm float magnet detent solenoid output was OFF.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• If you perform lift arm float detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
machine • If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the monitoring
Related
function (Code: 40952, D-OUT-2).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm float magnet S06 (male) Resistance
1 detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
Hot short in wiring harness
value in normal 2
(Contact with 24 V circuit) Wiring harness between L07 (female) (27) –
state Voltage Max. 1 V
S06 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Lift arm lever Voltage
3
controller
Between (27) and Neutral Max. 1 V
chassis ground Float detent operation 20 – 30 V

40-566 ➁ WA500-6
TROUBLESHOOTING DWN7KY
Related Circuit Diagram

WA500-6 40-567 ➁
TROUBLESHOOTING DWN8KA

DWN8KA
Bucket Tilt Magnet Detent Solenoid: Disconnection
Action Code Failure Code Bucket tilt magnet detent solenoid: Disconnection
Trouble
E01 DWN8KA (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system is disconnected, no current flows
trouble when the bucket tilt magnet detent solenoid output is ON.
Action of • Keeps normal output condition to the bucket tilt magnet detent solenoid.
controller • If cause of failure disappears, system resets itself.
Problem that
• Bucket leveler does not work.
appears on
machine • The bucket is not held at the bucket tilt detent position.

• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the monitoring
Related
function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective bucket tilt magnet without turning starting switch ON.
1 detent solenoid
S04 (male) Resistance
(Internal disconnection)
Between (1) and (2) 35 – 45 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes harness Wiring harness between L07 (female) (37) –
2 Resistance Max. 1 Ω
and standard (Disconnection or defective S04 (female) (1)
value in normal contact) Wiring harness between S04 (female) (2) –
state Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Bucket lever Voltage
3
controller Neutral Max. 1 V
Between (37) and
chassis ground Bucket detent
20 – 30 V
operation

40-568 ➁ WA500-6
TROUBLESHOOTING DWN8KA
Related Circuit Diagram

WA500-6 40-569 ➁
TROUBLESHOOTING DWN8KB

DWN8KB
Bucket Tilt Magnet Detent Solenoid: Short Circuit
Action Code Failure Code Bucket tilt magnet detent solenoid: Short circuit
Trouble
E01 DWN8KB (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system was shorted with the chassis ground,
trouble abnormal current flowed when the bucket tilt magnet detent solenoid output was ON.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Bucket leveler does not work.
appears on
machine • The bucket is not held at the bucket tilt detent position.

• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the monitoring
Related
function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket tilt magnet S04 (male) Resistance
1 detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (37) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state S04 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Bucket lever Voltage
3
controller Neutral Max. 1 V
Between (37) and
chassis ground Bucket detent
20 – 30 V
operation

40-570 ➁ WA500-6
TROUBLESHOOTING DWN8KB
Related Circuit Diagram

WA500-6 40-571 ➁
TROUBLESHOOTING DWN8KY

DWN8KY
Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source
Action Code Failure Code Bucket tilt magnet detent solenoid: Short circuit with power supply line
Trouble
E01 DWN8KY (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system was shorted with the power source,
trouble abnormal voltage was applied when the bucket tilt magnet detent solenoid output was OFF.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
controller • If cause of failure disappears, system resets itself.
• If you perform bucket tilt detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
machine • If you do not perform bucket detent operation, return of the bucket lever to neutral is affected by the
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the monitoring
Related
function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket tilt magnet S04 (male) Resistance
1 detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L07 (female) (37) –
state Voltage Max. 1 V
S04 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Bucket lever Voltage
3
controller Neutral Max. 1 V
Between (37) and
chassis ground Bucket detent
20 – 30 V
operation

40-572 ➁ WA500-6
TROUBLESHOOTING DWN8KY
Related Circuit Diagram

WA500-6 40-573 ➁
TROUBLESHOOTING DX16KA

DX16KA
Fan Pump EPC Solenoid: Disconnection
Action Code Failure Code Fan pump EPC solenoid: Disconnection
Trouble
E01 DX16KA (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is disconnected, no current flows when the fan pump EPC
trouble solenoid 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
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400 FAN EPC DIR).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective fan pump EPC without turning starting switch ON.
1 solenoid
T02 (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 10 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L04 (female) (23) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective T02 (female) (2)
state contact in connector) Wiring harness between L04 (female) (27) –
Resistance Max. 1 Ω
T02 (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission without turning starting switch ON.
3
controller L04 (female) Resistance
Between (27) and (23) 5 – 10 Ω

Related Circuit Diagram

40-574 ➁ WA500-6
TROUBLESHOOTING DX16KB

DX16KB
Fan Pump EPC Solenoid: Short Circuit
Action Code Failure Code Fan pump EPC solenoid: Short circuit
Trouble
E01 DX16KB (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the chassis ground, abnormal current flowed
trouble when the fan pump EPC solenoid output was ON.
Action of • Turns the output to the fan pump 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 pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400 FAN EPC DIR).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan pump EPC T02 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 10 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L04 (female) (27) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state T02 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (23) and (27) 5 – 10 Ω
Between (23), (27) and
Min. 1 MΩ
chassis ground

Related Circuit Diagram

WA500-6 40-575 ➁
TROUBLESHOOTING DX16KY

DX16KY
Fan Pump EPC Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Fan pump EPC solenoid: Short circuit with power supply line
Trouble
E01 DX16KY (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan pump EPC solenoid output was OFF.
Action of • Turns the output to the fan pump EPC solenoid OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The fan speed is set to the minimum.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400 FAN EPC DIR).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan pump EPC T02 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 10 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (27) –
state Voltage Max. 1 V
T02 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (23) and (27) 5 – 10 Ω
Between (23), (27) and
Min. 1 MΩ
chassis ground

Related Circuit Diagram

40-576 ➁ WA500-6
TROUBLESHOOTING DXA1KA

DXA1KA
Pump PC-EPC Solenoid: Disconnection
Action Code Failure Code Pump PC-EPC solenoid: Disconnection
Trouble
E01 DXA1KA (Work equipment controller system)
Contents of • Since the loader pump PC-EPC solenoid system is disconnected, no current flows when the loader
trouble pump PC-EPC solenoid output is ON.
Action of • Keeps normal output condition to the loader pump PC-EPC solenoid.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Fuel consumption may become poor when engine speed is low.
Problem that
• The engine may stop.
appears on
machine • Engine acceleration performance is deteriorated.
• The lift arm may increase speed suddenly.
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 94500 PUMP EPC DIR).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective loader pump PC- without turning starting switch ON.
1 EPC solenoid
T01 (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L07 (female) (23) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective T01 (female) (2)
state contact in connector) Wiring harness between L07 (female) (36) –
Resistance Max. 1 Ω
T01 (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (23) and (36) 5 – 15 Ω

Related Circuit Diagram

WA500-6 40-577 ➁
TROUBLESHOOTING DXA1KB

DXA1KB
Pump PC-EPC Solenoid: Short Circuit
Action Code Failure Code Pump PC-EPC solenoid: Short circuit
Trouble
E01 DXA1KB (Work equipment controller system)
Contents of • Since the loader pump PC-EPC solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when the loader pump PC-EPC solenoid output was ON.
Action of • Stops outputting the signal to the loader pump PC-EPC solenoid.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Fuel consumption may become poor when engine speed is low.
Problem that
• Engine acceleration performance is deteriorated.
appears on
machine • The lift arm may increase speed suddenly.
• The wiring harness or controller may be burnt out.
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 94500 PUMP EPC DIR).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective loader pump T01 (male) Resistance
1 PC-EPC solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (36) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state T01 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (23) and (36) 5 – 15 Ω
Between (23), (36) and
Min. 1 MΩ
chassis ground

40-578 ➁ WA500-6
TROUBLESHOOTING DXA1KB
Related Circuit Diagram

WA500-6 40-579 ➁
TROUBLESHOOTING DXH1KA

DXH1KA
Lockup ECMV Solenoid: Disconnection
Action Code Failure Code Lockup ECMV solenoid: Disconnection
Trouble
E01 DXH1KA (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is disconnected, no current flows when the lockup solenoid
trouble output is ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Torque converter lockup is not turned on.
machine
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related (Code: 31609 ECMV LU DIR).
information • Method of reproducing failure code: Start engine; turn the torque convertor lockup switch ON; and drive
the machine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective lockup ECMV without turning starting switch ON.
1 solenoid
LC.PS (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L04 (female) (23) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective LC.PS (female) (2)
state contact of connector) Wiring harness between L04 (female) (35) –
Resistance Max. 1 Ω
LC.PS (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission without turning starting switch ON.
3
controller L04 (female) Resistance
Between (23) and (35) 5 – 15 Ω

40-580 ➁ WA500-6
TROUBLESHOOTING DXH1KA
Related Circuit Diagram

WA500-6 40-581 ➁
TROUBLESHOOTING DXH1KB

DXH1KB
Lockup ECMV Solenoid: Short Circuit
Action Code Failure Code Lockup ECMV solenoid: Short circuit
Trouble
E01 DXH1KB (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is short with the chassis ground, abnormal current flowed
trouble when the lockup solenoid output was ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Torque converter lockup is not turned on.
machine
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related
(Code: 31609 ECMV LU DIR).
information
• Method of reproducing failure code: Engine started + torque convertor lockup switch ON + Travel

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lockup ECMV LC.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L04 (female) (35) –
state
(Contact with ground circuit) Resistance Max. 1 Ω
LC.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (23) and (35) 5 – 15 Ω
Between (23), (35) and
Min. 1 MΩ
chassis ground

40-582 ➁ WA500-6
TROUBLESHOOTING DXH1KB
Related Circuit Diagram

WA500-6 40-583 ➁
TROUBLESHOOTING DXH1KY

DXH1KY
Lockup ECMV Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Lockup ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH1KY (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the lockup ECMV solenoid output was OFF.
• Keeps the transmission in neutral.
• Releases the transmission from neutral if you move the FNR (directional) lever, joystick steering FNR
Action of (directional) switch, or right FNR (directional) switch to N (neutral).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
• Neutral is held until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR
Problem that
(directional) switch is set to N (neutral).
appears on
• The lockup clutch is always in the meshed state.
machine
• When fault occurs, shock and sound may be made by sudden engagement and engine may stall.
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related
(Code: 31609 ECMV LU DIR).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lockup ECMV LC.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (35) –
state Voltage Max. 1 V
LC.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (23) and (35) 5 – 15 Ω
Between (23), (35) and
Min. 1 MΩ
chassis ground

40-584 ➁ WA500-6
TROUBLESHOOTING DXH1KY
Related Circuit Diagram

WA500-6 40-585 ➁
TROUBLESHOOTING DXH4KA

DXH4KA
1st Clutch ECMV Solenoid: Disconnection
Action Code Failure Code 1st clutch ECMV solenoid: Disconnection
Trouble
E03 DXH4KA (Transmission controller system)
Contents of • When the 1st clutch ECMV solenoid system is disconnected, no current flows when 1st clutch ECMV
trouble solenoid output is ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 1st (the machine can travel in any gear speed other than 1st).
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
(Code: 31602, ECMV 1 DIR).
Related
information • Method of reproducing failure code: Turn starting switch to START; set the transmission manual/auto-
shift selector switch in the MANUAL position; and select 1st using the shift down switch or move the gear
shift lever to 1st.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective 1st clutch ECMV without turning starting switch ON.
1 solenoid
1.PS (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L04 (female) (13) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective 1.PS (female) (2)
state contact in connector) Wiring harness between L04 (female) (25) –
Resistance Max. 1 Ω
1.PS (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission without turning starting switch ON.
3
controller L04 (female) Resistance
Between (25) and (13) 5 – 15 Ω

40-586 ➁ WA500-6
TROUBLESHOOTING DXH4KA
Related Circuit Diagram

WA500-6 40-587 ➁
TROUBLESHOOTING DXH4KB

DXH4KB
1st Clutch ECMV Solenoid: Short Circuit
Action Code Failure Code 1st clutch ECMV solenoid: Short circuit
Trouble
E03 DXH4KB (Transmission controller system)
Contents of • When the 1st clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 1st clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 1st (the machine can travel in any gear speed other than 1st).
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
(Code: 31602, ECMV 1 DIR).
Related
information • Method of reproducing failure code: Turn starting switch to START; set the transmission manual/auto-
shift selector switch in the MANUAL position; and select 1st using the shift down switch or move the gear
shift lever to 1st.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 1st clutch ECMV 1.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L04 (female) (25) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state 1.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (25) and (13) 5 – 15 Ω
Between (25), (13) and
Min. 1 MΩ
chassis ground

40-588 ➁ WA500-6
TROUBLESHOOTING DXH4KB
Related Circuit Diagram

WA500-6 40-589 ➁
TROUBLESHOOTING DXH4KY

DXH4KY
1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code 1st clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH4KY (Transmission controller system)
Contents of • When the 1st clutch ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when 1st clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 2nd, 3rd, and 4th clutch ECMV solenoids.
• Stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the speed
Action of clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 2nd, 3rd, nor 4th (the machine can travel at 1st).
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31602 ECMV 1 DIR).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 1st clutch ECMV 1.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (25) –
state Voltage Max. 1 V
1.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (25) and (13) 5 – 15 Ω
Between (25), (13) and
Min. 1 MΩ
chassis ground

40-590 ➁ WA500-6
TROUBLESHOOTING DXH4KY
Related Circuit Diagram

WA500-6 40-591 ➁
TROUBLESHOOTING DXH5KA

DXH5KA
2nd Clutch ECMV Solenoid: Disconnection
Action Code Failure Code 2nd clutch ECMV solenoid: Disconnection
Trouble
E03 DXH5KA (Transmission controller system)
Contents of • When the 2nd clutch ECMV solenoid system is disconnected, no current flows when 2nd clutch ECMV
trouble solenoid output is ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 2nd (the machine can travel in any gear speed other than 2nd).
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31603 ECMV 2 DIR).
Related
information • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift
selector switch in the MANUAL position; and select 2nd using the shift down switch or move the gear
shift lever to 2nd.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective 2nd clutch ECMV without turning starting switch ON.
1 solenoid
2.PS (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L04 (female) (6) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective 2.PS (female) (1)
state contact of connector) Wiring harness between L04 (female) (3) –
Resistance Max. 1 Ω
2.PS (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission without turning starting switch ON.
3
controller L04 (female) Resistance
Between (6) and (3) 5 – 15 Ω

40-592 ➁ WA500-6
TROUBLESHOOTING DXH5KA
Related Circuit Diagram

WA500-6 40-593 ➁
TROUBLESHOOTING DXH5KB

DXH5KB
2nd Clutch ECMV Solenoid: Short Circuit
Action Code Failure Code 2nd clutch ECMV solenoid: Short circuit
Trouble
E03 DXH5KB (Transmission controller system)
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 2nd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 2nd (the machine can travel in any gear speed other than 2nd).
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31603 ECMV 2 DIR).
Related
information • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift
selector switch in the MANUAL position; and select 2nd using the shift down switch or move the gear
shift lever to 2nd.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L04 (female) (6) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state 2.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (6) and (3) 5 – 15 Ω
Between (6), (3) and
Min. 1 MΩ
chassis ground

40-594 ➁ WA500-6
TROUBLESHOOTING DXH5KB
Related Circuit Diagram

WA500-6 40-595 ➁
TROUBLESHOOTING DXH5KY

DXH5KY
2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code 2nd clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH5KY (Transmission controller system)
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when 2nd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 3rd, and 4th clutch ECMV solenoids.
• Stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the speed
Action of clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 3rd, nor 4th (the machine can travel at 2nd).
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31603 ECMV 2 DIR).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (6) –
state Voltage Max. 1 V
2.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (6) and (3) 5 – 15 Ω
Between (6), (3) and
Min. 1 MΩ
chassis ground

40-596 ➁ WA500-6
TROUBLESHOOTING DXH5KY
Related Circuit Diagram

WA500-6 40-597 ➁
TROUBLESHOOTING DXH6KA

DXH6KA
3rd Clutch ECMV Solenoid: Disconnection
Action Code Failure Code 3rd clutch ECMV solenoid: Disconnection
Trouble
E03 DXH6KA (Transmission controller system)
Contents of • When the 3rd clutch ECMV solenoid system is disconnected, no current flows when 3rd clutch ECMV
trouble solenoid output is ON.
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 3rd (the machine can travel in any gear speed other than 3rd).
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31604 ECMV 3 DIR).
Related
information • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift
selector switch in the MANUAL position; and select 3rd using the shift down switch or move the gear
shift lever to 3rd.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective 3rd clutch ECMV without turning starting switch ON.
1 solenoid
3.PS (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L04 (female) (3) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective 3.PS (female) (2)
state contact of connector) Wiring harness between L04 (female) (16) –
Resistance Max. 1 Ω
3.PS (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission without turning starting switch ON.
3
controller L04 (female) Resistance
Between (16) and (3) 5 – 15 Ω

40-598 ➁ WA500-6
TROUBLESHOOTING DXH6KA
Related Circuit Diagram

WA500-6 40-599 ➁
TROUBLESHOOTING DXH6KB

DXH6KB
3rd Clutch ECMV Solenoid: Short Circuit
Action Code Failure Code 3rd clutch ECMV solenoid: Short circuit
Trouble
E03 DXH6KB (Transmission controller system)
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 3rd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 3rd (the machine can travel in any gear speed other than 3rd).
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31604 ECMV 3 DIR).
Related
information • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift
selector switch in the MANUAL position; and select 3rd using the shift down switch or move the gear
shift lever to 3rd.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 3rd clutch ECMV 3.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L04 (female) (16) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state 3.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (16) and (3) 5 – 15 Ω
Between (16), (3) and
Min. 1 MΩ
chassis ground

40-600 ➁ WA500-6
TROUBLESHOOTING DXH6KB
Related Circuit Diagram

WA500-6 40-601 ➁
TROUBLESHOOTING DXH6KY

DXH6KY
3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code 3rd clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH6KY (Transmission controller system)
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when 3rd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 4th clutch ECMV solenoids.
• Stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the speed
Action of clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 4th (the machine can travel at 3rd).
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31604 ECMV 3 DIR).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 3rd clutch ECMV 3.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (16) –
state Voltage Max. 1 V
3.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (16) and (3) 5 – 15 Ω
Between (16), (3) and
Min. 1 MΩ
chassis ground

40-602 ➁ WA500-6
TROUBLESHOOTING DXH6KY
Related Circuit Diagram

WA500-6 40-603 ➁
TROUBLESHOOTING DXH7KA

DXH7KA
R Clutch ECMV Solenoid: Disconnection
Action Code Failure Code R clutch ECMV solenoid: Disconnection
Trouble
E03 DXH7KA (Transmission controller system)
Contents of • When the R (Reverse) clutch ECMV solenoid system is disconnected, no current flows when
trouble R (Reverse) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring
Related function (Code: 31606 ECMV R DIR).
information • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch R (reverse)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective R (Reverse) clutch without turning starting switch ON.
1 ECMV solenoid
R.PS (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L04 (female) (13) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective R.PS (female) (2)
state contact of connector) Wiring harness between L04 (female) (15) –
Resistance Max. 1 Ω
R.PS (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission without turning starting switch ON.
3
controller L04 (female) Resistance
Between (15) and (13) 5 – 15 Ω

40-604 ➁ WA500-6
TROUBLESHOOTING DXH7KA
Related Circuit Diagram

WA500-6 40-605 ➁
TROUBLESHOOTING DXH7KB

DXH7KB
R Clutch ECMV Solenoid: Short Circuit
Action Code Failure Code R clutch ECMV solenoid: Short circuit
Trouble
E03 DXH7KB (Transmission controller system)
Contents of • When the R (Reverse) clutch ECMV solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when R (Reverse) clutch ECMV solenoid output was ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring
Related function (Code: 31606 ECMV R DIR).
information • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch R (reverse)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L04 (female) (15) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state R.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (15) and (13) 5 – 15 Ω
Between (15), (13) and
Min. 1 MΩ
chassis ground

40-606 ➁ WA500-6
TROUBLESHOOTING DXH7KB
Related Circuit Diagram

WA500-6 40-607 ➁
TROUBLESHOOTING DXH7KY

DXH7KY
R Clutch ECMV Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code R clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH7KY (Transmission controller system)
Contents of • Since the R (Reverse) ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when the R (Reverse) ECMV solenoid output was OFF.
• Outputs the signal to the R (Reverse) clutch ECMV solenoid when the directional lever or directional
switch is in R (Reverse).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or F (Forward).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine can travel only at R (reverse).
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring
Related
function (Code: 31606 ECMV R DIR).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Hot short in wiring harness without turning starting switch ON.
2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (15) –
state Voltage Max. 1 V
R.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (15) and (13) 5 – 15 Ω
Between (15), (13) and
Min. 1 MΩ
chassis ground

40-608 ➁ WA500-6
TROUBLESHOOTING DXH7KY
Related Circuit Diagram

WA500-6 40-609 ➁
TROUBLESHOOTING DXH8KA

DXH8KA
F Clutch ECMV Solenoid: Disconnection
Action Code Failure Code F clutch ECMV solenoid: Disconnection
Trouble
E03 DXH8KA (Transmission controller system)
Contents of • When the F (Forward) clutch ECMV solenoid system is disconnected, no current flows when
trouble F (Forward) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
Related (Code: 31608 ECMV F DIR).
information • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch F (forward)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective F (Forward) clutch without turning starting switch ON.
1 ECMV solenoid
F.PS (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L04 (female) (3) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective F.PS (female) (2)
state contact of connector) Wiring harness between L04 (female) (5) –
Resistance Max. 1 Ω
F.PS (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission without turning starting switch ON.
3
controller L04 (female) Resistance
Between (5) and (3) 5 – 15 Ω

40-610 ➁ WA500-6
TROUBLESHOOTING DXH8KA
Related Circuit Diagram

WA500-6 40-611 ➁
TROUBLESHOOTING DXH8KB

DXH8KB
F Clutch ECMV Solenoid: Short Circuit
Action Code Failure Code F clutch ECMV solenoid: Short circuit
Trouble
E03 DXH8KB (Transmission controller system)
Contents of • When the F (Forward) clutch ECMV solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when F (Forward) clutch ECMV solenoid output was ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
Related (Code: 31608 ECMV F DIR).
information • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch F (forward)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L04 (female) (5) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state F.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (5) and (3) 5 – 15 Ω
Between (5), (3) and
Min. 1 MΩ
chassis ground

40-612 ➁ WA500-6
TROUBLESHOOTING DXH8KB
Related Circuit Diagram

WA500-6 40-613 ➁
TROUBLESHOOTING DXH8KY

DXH8KY
F Clutch ECMV Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code F clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH8KY (Transmission controller system)
Contents of • Since the F (Forward) ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the F (Forward) ECMV solenoid output was OFF.
• Outputs the signal to the F (Forward) clutch ECMV solenoid when the directional lever or directional
switch is in F (Forward).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or R (Reverse).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine can travel only at F (forward).
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31608 ECMV F DIR).
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Hot short in wiring harness without turning starting switch ON.
2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (5) –
state Voltage Max. 1 V
F.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (5) and (3) 5 – 15 Ω
Between (5), (3) and
Min. 1 MΩ
chassis ground

40-614 ➁ WA500-6
TROUBLESHOOTING DXH8KY
Related Circuit Diagram

WA500-6 40-615 ➁
TROUBLESHOOTING DXHHKA

DXHHKA
4th Clutch ECMV Solenoid: Disconnection
Action Code Failure Code 4th clutch ECMV solenoid: Disconnection
Trouble
E03 DXHHKA (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system is disconnected, no current flows when 4th clutch ECMV
trouble solenoid output is ON.
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 4th (the machine can travel in any gear speed other than 4th).
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
(Code: 31605 ECMV 4 DIR).
Related
information • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift
selector switch in the MANUAL position; and select 4th using the shift down switch or move the gear shift
lever to 4th.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective 4th clutch ECMV without turning starting switch ON.
1 solenoid
4.PS (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L04 (female) (13) –
2 Resistance Max. 1 Ω
value in normal (Disconnection or defective 4.PS (female) (2)
state contact of connector) Wiring harness between L04 (female) (26) –
Resistance Max. 1 Ω
4.PS (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission without turning starting switch ON.
3
controller L04 (female) Resistance
Between (26) and (13) 5 – 15 Ω

40-616 ➁ WA500-6
TROUBLESHOOTING DXHHKA
Related Circuit Diagram

WA500-6 40-617 ➁
TROUBLESHOOTING DXHHKB

DXHHKB
4th Clutch ECMV Solenoid: Short Circuit
Action Code Failure Code 4th clutch ECMV solenoid: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when 4th clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 4th (the machine can travel in any gear speed other than 4th).
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring
function (Code: 31605 ECMV 4 DIR).
Related
information • Method of reproducing failure code: Turn starting switch START; set the transmission manual/
auto-shift selector switch in the MANUAL position; and select 4th using the shift down switch or
move the gear shift lever to 4th.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 4th clutch ECMV 4.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L04 (female) (26) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state 4.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (26) and (13) 5 – 15 Ω
Between (26), (13) and
Min. 1 MΩ
chassis ground

40-618 ➁ WA500-6
TROUBLESHOOTING DXHHKB
Related Circuit Diagram

WA500-6 40-619 ➁
TROUBLESHOOTING DXHHKY

DXHHKY
4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code 4th clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when 4th clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 3rd clutch ECMV solenoids.
• Stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the speed
Action of clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick
steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 3rd (the machine can travel at 4th).
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31605 ECMV 4 DIR).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 4th clutch ECMV 4.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (26) –
state Voltage Max. 1 V
4.PS (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission L04 (female) Resistance
3
controller Between (26) and (13) 5 – 15 Ω
Between (26), (13) and
Min. 1 MΩ
chassis ground

40-620 ➁ WA500-6
TROUBLESHOOTING DXHHKY
Related Circuit Diagram

WA500-6 40-621 ➁
TROUBLESHOOTING DXHJKA

DXHJKA
3-Spool Valve Extract EPC Solenoid: Disconnection
Action Code Failure Code 3-spool valve extract EPC solenoid: Disconnection
Trouble
E03 DXHJKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) extract EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) extract EPC solenoid output is ON.
• Continues outputting.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The 3-spool valve (attachment) cylinder is not extracted.
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine
monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with
information
the monitoring function (Code: 41906 3RD EPC1 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve ★ Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F21 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes
harness
and standard Wiring harness between L07 (female) (3) –
2 (Disconnection in wiring Resistance Max. 1 Ω
value in normal F21 (female) (2)
harness and defective
state Wiring harness between L07 (female) (25) –
contact) Resistance Max. 1 Ω
F21 (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (25) and (3) 5 – 15 Ω

Related Circuit Diagram

40-622 ➁ WA500-6
TROUBLESHOOTING DXHJKB

DXHJKB
3-Spool Valve Extract EPC Solenoid: Short Circuit
Action Code Failure Code 3-spool valve extract EPC solenoid: Short circuit
Trouble
E03 DXHJKB (Work equipment controller system)

• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the
Contents of
chassis ground, abnormal current flowed when the 3-spool valve (attachment) extract EPC solenoid
trouble
output was ON.
• The output to the 3-spool valve (attachment) extract EPC solenoid is stopped.
Action of • Stops outputting the signal to all work equipment detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not extracted.
appears on
machine • The wiring harness or controller may be burnt out.

• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine
monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with
information
the monitoring function (Code: 41906 3RD EPC1 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve ★ Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F21 (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 Ω
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (25) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state F21 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (25) and (3) 5 – 15 Ω

Related Circuit Diagram

WA500-6 40-623 ➁
TROUBLESHOOTING DXHJKY

DXHJKY
3-Spool Valve Extract EPC Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code 3-spool valve extract EPC solenoid: Short circuit with power supply line
Trouble
E03 DXHJKY (Work equipment controller system)

• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the
Contents of
power source, abnormal voltage was applied when the 3-spool valve (attachment) extract EPC solenoid
trouble
output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not extracted.
appears on
machine • The 3-spool valve (attachment) extract EPC solenoid may be burnt out.

• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine
monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with
information
the monitoring function (Code: 41906 3RD EPC1 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve ★ Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F21 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 Ω
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short in wiring harness carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L07 (female) (25) –
state Voltage Max. 1 V
F21 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (25) and (3) 5 – 15 Ω

40-624 ➁ WA500-6
TROUBLESHOOTING DXHJKY
Related Circuit Diagram

WA500-6 40-625 ➁
TROUBLESHOOTING DXHKKA

DXHKKA
3-Spool Valve Retract EPC Solenoid: Disconnection
Action Code Failure Code 3-spool valve retract EPC solenoid: Disconnection
Trouble
E03 DXHKKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) retract EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) retract EPC solenoid output is ON.
• Continues outputting.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The 3-spool valve (attachment) cylinder is not retracted.
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine
monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with
information
the monitoring function (Code: 41907 3RD EPC2 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve ★ Prepare with starting switch OFF, then carry out troubleshooting
(attachment) retract EPC without turning starting switch ON.
1
solenoid F22 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes
harness
and standard Wiring harness between L07 (female) (3) –
2 (Disconnection in wiring Resistance Max. 1 Ω
value in normal F22 (female) (2)
harness and defective
state Wiring harness between L07 (female) (35) –
contact) Resistance Max. 1 Ω
F22 (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (35) and (3) 5 – 15 Ω

Related Circuit Diagram

40-626 ➁ WA500-6
TROUBLESHOOTING DXHKKB

DXHKKB
3-Spool Valve Retract EPC Solenoid: Short Circuit
Action Code Failure Code 3-spool valve retract EPC solenoid: Short circuit
Trouble
E03 DXHKKB (Work equipment controller system)

• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with the
Contents of
chassis ground, abnormal current flowed when the 3-spool valve (attachment) retract EPC solenoid
trouble
output was ON.
• The output to the 3-spool valve (attachment) retract EPC solenoid is stopped.
Action of • Stops outputting the signal to all work equipment detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
machine • The wiring harness or controller may be burnt out.

• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine
monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with
information
the monitoring function (Code: 41907 3RD EPC2 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve ★ Prepare with starting switch OFF, then carry out troubleshooting
(attachment) retract EPC without turning starting switch ON.
1
solenoid F22 (male) Resistance
(Internal short circuit)
Between (1) and (2) 5 – 15 Ω
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard
2 harness
value in normal Wiring harness between L07 (female) (35) –
(Contact with ground circuit) Resistance Min. 1 MΩ
state F22 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (35) and (3) 5 – 15 Ω

Related Circuit Diagram

WA500-6 40-627 ➁
TROUBLESHOOTING DXHKKY

DXHKKY
3-Spool Valve Retract EPC Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code 3-spool valve retract EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHKKY (Work equipment controller system)
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with
Contents of
the power source, abnormal voltage was applied when the 3-spool valve (attachment) retract EPC
trouble
solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
machine • The 3-spool valve (attachment) retract EPC solenoid may be burnt out.

• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this
failure code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the
machine monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
information
with the monitoring function (Code: 41907 3RD EPC2 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve ★ Prepare with starting switch OFF, then carry out troubleshooting
(attachment) retract EPC without turning starting switch ON.
1
solenoid F22 (male) Resistance
(Internal short circuit)
Between (1) and (2) 5 – 15 Ω
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON
and standard Hot short in wiring harness and carry out troubleshooting.
2
value in normal (Contact with 24 V circuit) Wiring harness between L07 (female) (35) –
state Voltage Max. 1 V
F22 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (35) and (3) 5 – 15 Ω

40-628 ➁ WA500-6
TROUBLESHOOTING DXHKKY
Related Circuit Diagram

WA500-6 40-629 ➁
TROUBLESHOOTING DXHLKA

DXHLKA
Joystick Steering Right EPC Solenoid: Disconnection
Action Code Failure Code Joystick steering right EPC solenoid: Disconnection
Trouble
E03 DXHLKA (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is disconnected, no current flows when the joystick
trouble steering right EPC solenoid output is ON.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable (operable in handle mode).
machine
• The output state (current) to the joystick steering right EPC solenoid can be checked with the monitoring
function (Code: 41904 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to right.
Related
information • Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring function
(Code: 40953, D-OUT-8).
• If failure code of joystick steering solenoid cut relay system (D193KA, D193KB, or D193KY) is displayed,
carry out troubleshooting for joystick steering solenoid cut relay system first.

Cause Standard value in normal state/Remarks on troubleshooting

Defective joystick steering
1 right EPC solenoid
(Internal disconnection)
Defective joystick cutoff relay
2 (L118)
Possible causes (Internal disconnection)
and standard
value in normal
state
Disconnection in wiring
harness
3
(Disconnection or defective
contact of connector)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS5 (male) Resistance
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L118 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type
and the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L07 (female) (28) –
Resistance Max. 1 Ω
JS5 (female) (1)
Wiring harness between JS5 (female) (2) –
Resistance Max. 1 Ω
L118 (female) (5)
Wiring harness between L118 (female) (3) –
Resistance Max. 1 Ω
L07 (female) (23)

40-630 ➁ WA500-6
TROUBLESHOOTING DXHLKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Possible causes Joystick lever
L07 (female) Voltage
and standard Defective work equipment operation
4
value in normal controller Joystick lever in
state Max. 1 V
neutral
Between (28) and (23)
Joystick lever at
5 – 10 V
right stroke end

Related Circuit Diagram

WA500-6 40-631 ➁
TROUBLESHOOTING DXHLKB

DXHLKB
Joystick Steering Right EPC Solenoid: Short Circuit
Action Code Failure Code Joystick steering right EPC solenoid: Short circuit
Trouble
E03 DXHLKB (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is short with the chassis ground, no current flows
trouble when the joystick steering right EPC solenoid output is ON.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable (operable in handle mode).
machine
• The output state (current) to the joystick steering right EPC solenoid can be checked with the monitoring
function (Code: 41904 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to right.
Related
information • Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring function
(Code: 40953, D-OUT-8).
• If failure code of joystick steering solenoid cut relay system (D193KA, D193KB, or D193KY) is displayed,
carry out troubleshooting for joystick steering solenoid cut relay system first.

Cause Standard value in normal state/Remarks on troubleshooting

Defective joystick steering
1 right EPC solenoid
(Internal short circuit)
Possible causes
and standard
value in normal Defective joystick cutoff relay
state 2 (L118)
(Internal short circuit)
Grounding fault in wiring
3 harness
(Contact with ground circuit)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS5 (male) Resistance
Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L118 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type and
the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L07 (female) (28) –
Resistance Min. 1 MΩ
JS5 (female) (1) and chassis ground

40-632 ➁ WA500-6
TROUBLESHOOTING DXHLKB

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L07 (female) Resistance
Between (23), (28) and
Min. 1 MΩ
chassis ground
Possible causes
and standard Defective work equipment
★ Prepare with starting switch OFF, then turn starting switch ON and
4 carry out troubleshooting.
value in normal controller
state Joystick lever
Voltage
operation
Joystick lever in
Between L07 (28) – (23) Max. 1 V
neutral
Joystick lever at
5 – 10 V
right stroke end

WA500-6 40-633 ➁
TROUBLESHOOTING DXHLKB
Related Circuit Diagram

40-634 ➁ WA500-6
TROUBLESHOOTING DXHLKY

DXHLKY
Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Joystick steering right EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHLKY (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system was shorted with the power source, abnormal
trouble voltage was applied when the joystick steering right EPC solenoid output was OFF.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable (operable in handle mode).
machine
• The output state (current) to the joystick steering right EPC solenoid can be checked with the
Related
monitoring function (Code: 41904 J/S EPC DIR RH).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective joystick steering
1 right EPC solenoid
(Internal short circuit)
Possible causes
and standard
value in normal Defective joystick cutoff relay
state 2 (L118)
(Internal short circuit)
Hot short in wiring harness
3
(Contact with 24 V circuit)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS5 (male) Resistance
Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L118 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type
and the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L07 (female) (28) –
Voltage Max. 1 V
JS5 (female) (1) and chassis ground

WA500-6 40-635 ➁
TROUBLESHOOTING DXHLKY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L07 (female) Resistance
Between (23), (28) and
Min. 1 MΩ
chassis ground
Possible causes
and standard Defective work equipment
★ Prepare with starting switch OFF, then turn starting switch ON and
4 carry out troubleshooting.
value in normal controller
state Joystick lever
Voltage
operation
Joystick lever in
Between L07 (28) – (23) Max. 1 V
neutral
Joystick lever at
5 – 10 V
right stroke end

40-636 ➁ WA500-6
TROUBLESHOOTING DXHLKY
Related Circuit Diagram

WA500-6 40-637 ➁
TROUBLESHOOTING DXHMKA

DXHMKA
Joystick Steering Left EPC Solenoid: Disconnection
Action Code Failure Code Joystick steering left EPC solenoid: Disconnection
Trouble
E03 DXHMKA (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is disconnected, no current flows when the joystick
trouble steering left EPC solenoid output is ON.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable (operable in handle mode).
machine
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitoring
function (Code: 41905 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to left.
Related
information • Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring function
(Code: 40953, D-OUT-8).
• If failure code of joystick steering solenoid cut relay system (D193KA, D193KB, or D193KY) is displayed,
carry out troubleshooting for joystick steering solenoid cut relay system first.

Cause Standard value in normal state/Remarks on troubleshooting

Defective joystick steering
1 left EPC solenoid
(Internal disconnection)
Defective joystick cutoff relay
2 (L118)
Possible causes (Internal disconnection)
and standard
value in normal
state
Disconnection in wiring
harness
3
(Disconnection or defective
contact of connector)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS6 (male) Resistance
Between (1) and (2) 5 – 15 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L118 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type and
the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L07 (female) (38) –
Resistance Max. 1 Ω
JS6 (female) (1)
Wiring harness between JS6 (female) (2) –
Resistance Max. 1 Ω
L118 (female) (5)
Wiring harness between L118 (female) (3) –
Resistance Max. 1 Ω
L07 (female) (23)

40-638 ➁ WA500-6
TROUBLESHOOTING DXHMKA

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Possible causes Joystick lever
L07 (female) Voltage
and standard Defective work equipment operation
4
value in normal controller Joystick lever in
state Max. 1 V
neutral
Between L07 (38) – (23)
Joystick lever at
5 – 10 V
left stroke end

Related Circuit Diagram

WA500-6 40-639 ➁
TROUBLESHOOTING DXHMKB

DXHMKB
Joystick Steering Left EPC Solenoid: Short Circuit
Action Code Failure Code Joystick steering left EPC solenoid: Short circuit
Trouble
E03 DXHMKB (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is short with the chassis ground, no current flows
trouble when the joystick steering left EPC solenoid output is ON.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable (operable in handle mode).
machine
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitoring
function (Code: 41905 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to left.
Related
information • Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring function
(Code: 40953, D-OUT-8).
• If failure code of joystick steering solenoid cut relay system (D193KA, D193KB, or D193KY) is displayed,
carry out troubleshooting for joystick steering solenoid cut relay system first.

Cause Standard value in normal state/Remarks on troubleshooting

Defective joystick steering
1 left EPC solenoid
(Internal short circuit)
Possible causes
and standard
value in normal Defective joystick cutoff relay
state 2 (L118)
(Internal short circuit)
Grounding fault in wiring
3 harness
(Contact with ground circuit)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS6 (male) Resistance
Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L118 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type and
the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L07 (female) (38) –
Resistance Min. 1 MΩ
JS6 (female) (1) and chassis ground

40-640 ➁ WA500-6
TROUBLESHOOTING DXHMKB

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L07 (female) Resistance
Between (23), (38) and
Min. 1 MΩ
chassis ground
Possible causes
and standard Defective work equipment
★ Prepare with starting switch OFF, then turn starting switch ON and
4 carry out troubleshooting.
value in normal controller
state Joystick lever
Voltage
operation
Joystick lever in
Between L07 (38) – (23) Max. 1 V
neutral
Joystick lever at
5 – 10 V
left stroke end

WA500-6 40-641 ➁
TROUBLESHOOTING DXHMKB
Related Circuit Diagram

40-642 ➁ WA500-6
TROUBLESHOOTING DXHMKY

DXHMKY
Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line
Action Code Failure Code Joystick steering left EPC solenoid: Short circuit with power supply line
Trouble
E03 DXHMKY (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system was shorted with the power source, abnormal
trouble voltage was applied when the joystick steering left EPC solenoid output was OFF.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable (operable in handle mode).
machine
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitoring
Related
function (Code: 41905 J/S EPC DIR RH).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective joystick steering
1 left EPC solenoid
(Internal short circuit)
Possible causes
and standard
value in normal Defective joystick cutoff relay
state 2 (L118)
(Internal short circuit)
Hot short in wiring harness
3
(Contact with 24 V circuit)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
JS6 (male) Resistance
Between (1) and (2) 5 – 15 Ω
Between (1), (2) and
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L118 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type and
the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L07 (female) (38) –
Voltage Max. 1 V
JS6 (female) (1) and chassis ground

WA500-6 40-643 ➁
TROUBLESHOOTING DXHMKY

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L07 (female) Resistance
Between (23), (38) and
Min. 1 MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard Defective work equipment carry out troubleshooting.
4
value in normal controller
Joystick lever
state Voltage
operation
Joystick lever in
Max. 1 V
Between L07 (38) – (23) neutral
Joystick lever at
right stroke end 5 – 10 V

40-644 ➁ WA500-6
TROUBLESHOOTING DXHMKY
Related Circuit Diagram

WA500-6 40-645 ➁
TROUBLESHOOTING TROUBLESHOOTING: E-MODE

TROUBLESHOOTING: E-MODE
Troubleshooting Electrical System
Information in Troubleshooting Table
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before
carrying out troubleshooting, understand that information fully.

Trouble Problem that appears on 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 required to judge the assumed
cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes into
contact with the power (24 V) circuit.
• Short circuit
Possible causes Causes by which a problem is A harness of an independent circuit abnormally comes into contact
and standard assumed to be detected with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority
sequence.)
<Notes on troubleshooting>
(1) Method of indicating connector numbers and handling of T-adapter
3 For troubleshooting, insert or connect T-adapter shown below
unless especially specified.
• When male or female is not indicated for a connector number,
disconnect the connector and insert the T-adapters in both the
male and female.
• When male or female is indicated for a connector number, unplug
the connector and insert the T-adapter in 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 indicated in the front.
• Connect the minus (–) lead to a pin or harness indicated in the
rear.

40-646 ➁ WA500-6
TROUBLESHOOTING TROUBLESHOOTING: E-MODE
Related Circuit Diagram

This is the excerpted circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – No. of pins) (Color).

• “Connector No. and pin No.” from each branching/merging point: indicate the ends of branch or source of
merging within the parts of the same wiring harness.

WA500-6 40-647 ➁
TROUBLESHOOTING E-1

E-1
Engine Does Not Start
Contents of
• The engine does not start.
trouble
• The engine does not start because the starting motor does not run due to problems in the starting motor
system and starting switch terminal C signal system.
• Check that No. 2 fuse of fuse box A is normal.
(If it is broken, check the related wiring harness for a grounding fault.)
• The input state (ON/OFF) from starting switch terminal C to the machine monitor can be checked with the
Related monitoring function (Code: 40900, D-IN-7).
information • The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked with
the monitoring function (Code: 40905, D-IN-7).
• The input state (ON/OFF) from starting switch terminal C to work equipment controller can be checked
with the monitoring function (Code: 40912, D-IN-17).
• If failure code [D5ZHKA], [D5ZHKB], [D5ZHKZ], [DDK4KA], [DDK4KB], [DDK6KA], or [DDK6KB] is
displayed, carry out troubleshooting for it first.

Cause Standard value in normal state/Remarks on troubleshooting

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective battery relay (BTR1) • The battery is normal if any operating sound is heard at the battery
2 (Internal disconnection or relay contact when operating the starting switch.
short circuit) • Operate the starting switch OFF→ON→OFF.
Defective fuse No.5 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
3
box B (See cause 15.)
★ Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch to START and carry out troubleshooting.
Starting motor Voltage
Between terminals
Power supply input 20 – 30 V
B and E
Possible Defective starting motor
4 Between terminals
causes and (Internal defect) Battery input Max. 1 V
R and E
standard value
in normal state Between terminals
Starting input 20 – 30 V
C and E
If the starting motor does not run even if power supply input, battery input,
and starting input is normal, the starting motor is defective.
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective alternator carry out troubleshooting.
5
(Internal short circuit) Wiring harness between alternator terminal R
Voltage Max. 1 V
(E03) and chassis ground
★ Prepare with starting switch OFF, then keep starting switch OFF and
turn it to START and carry out troubleshooting in each case.
Defective starting switch LS4 Position of switch Resistance
6
(Internal disconnection)
OFF Min. 1 MΩ
Between (1) and (3)
START Max. 1 Ω

40-648 ➁ WA500-6
TROUBLESHOOTING E-1

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective FNR (directional)
lever switch L63 FNR (directional) lever Voltage
7
(Internal disconnection or Between (1) and (10) Constant 20 – 30 V
short circuit) N (Neutral) 20 – 30 V
Between (3) and (10)
Other than above Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective joystick steering Joystick steering FNR

JL2 (male) Resistance
FNR (directional) switch (directional) switch
8
(Internal disconnection or N (Neutral) Max. 1 Ω
short circuit) Between (1) and (3)
Other than above Min. 1 MΩ
Between (1), (3) –
Constant Min. 1 MΩ
chassis ground
Right FNR (directional)
S09 (male) Resistance
switch
Defective right FNR
(directional) switch N (Neutral) Max. 1 Ω
9 Between (1) and (3)
(Internal disconnection or Other than above Min. 1 MΩ
short circuit)
Between (1), (3) and
Constant Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible
without turning starting switch ON.
causes and
standard value D02 (male) Diode range Continuity
in normal state Measure at (1) in diode
Between (1) and (2)
range
Continue
Measure at (3) in diode
Between (3) and (2)
range
Defective diode (D02, D03, ★ Prepare with starting switch OFF, then carry out troubleshooting
10 D04) without turning starting switch ON.
(Internal disconnection) D03 (male) Diode range Continuity
Measure at (2) in diode
Between (2) and (1) Continue
range
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
D04 (male) Diode range Continuity
Measure at (2) in diode
Between (2) and (1) Continue
range
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L103 (male) Resistance
Defective neutral safety relay
Between (1) and (2) 200 – 400 Ω
11 (L103)
(Internal defect) ★ Prepare with starting switch OFF, then turn starting switch to START
and carry out troubleshooting.
If neutral safety relay (L103) is replaced with a relay of the same type and
the condition becomes normal, the neutral safety relay is defective.

WA500-6 40-649 ➁
TROUBLESHOOTING E-1

Cause Standard value in normal state/Remarks on troubleshooting

Defective lever neutral cutoff
12 relay (L104)
(Internal defect)
Defective KOMTRAX engine
13 cut relay (L120)
(Internal defect)
Possible
causes and
standard value
in normal state
Disconnection in wiring
harness
14
(Disconnection or defective
contact in connector)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L104 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then turn starting switch to START
and carry out troubleshooting.
If lever neutral cutoff relay (L104) is replaced with a relay of the same type
and the condition becomes normal, the lever neutral cutoff relay is
defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L120 (male) Resistance
Between (1) and (2) 200 – 400 Ω
★ Prepare with starting switch OFF, then turn starting switch to START
and carry out troubleshooting.
If KOMTRAX engine cut relay (L120) is replaced with a relay of the same
type and the condition becomes normal, the KOMTRAX engine cut relay
is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between battery relay BTR1 D04
Resistance Max. 1 Ω
– starting motor terminal B (E08)
Wiring harness between starting motor terminal
Resistance Max. 1 Ω
E – chassis ground
Wiring harness between LS4 (female) (3) – L120
Resistance Max. 1 Ω
(female) (3)
Wiring harness between L120 (female) (6) –
Resistance Max. 1 Ω
L103 (female) (5)
Wiring harness between L104 (female) (6) –
Resistance Max. 1 Ω
L103 (female) (3), – L06 (female) (25)
Wiring harness between L63 (female) (3) – L03
Resistance Max. 1 Ω
(female) (26), – L103 (female) (1)
Wiring harness between JL2 (female) (3) – S09
Resistance Max. 1 Ω
(female) (3), – L03 (female) (28)
Wiring harness between L104 (female) (3) – D04
Resistance Max. 1 Ω
(female) (2)
Wiring harness between D04 (female) (2) –D03
Resistance Max. 1 Ω
(female) (2)
Wiring harness between D04 (female) (1) -D03
Resistance Max. 1 Ω
(female) (1)
Wiring harness between D03 (female) (1) – E01
Resistance Max. 1 Ω
(female) (1)
Wiring harness between L07 (female) (4) – L104
Resistance Max. 1 Ω
(female) (1)
Wiring harness between L103 (female) (2), L104
Resistance Max. 1 Ω
(female) (2) – chassis ground

40-650 ➁ WA500-6
TROUBLESHOOTING E-1

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between battery relay BTR1 D04
– starting motor terminal B (E08) and chassis Resistance Min. 1 MΩ
ground
Wiring harness between LS4 (female) (3) – L120
(female) (3), – circuit branch end and chassis Resistance Min. 1 MΩ
ground
Wiring harness between L120 (female) (6) -L103
Resistance Min. 1 MΩ
(female) (5) and chassis ground
Wiring harness between L104 (female) (6) –
L103 (female) (3), – L06 (female) (25), – circuit Resistance Min. 1 MΩ
branch end and chassis ground
Wiring harness between L63 (female) (3) – L03
Ground fault in wiring harness (female) (26), – L103 (female) (1), – circuit Resistance Min. 1 MΩ
15
(Short circuit with ground circuit) branch end
Wiring harness between JL2 (female) (3), S09
Resistance Min. 1 MΩ
(female) (3) – L03 (female) (28)
Possible Wiring harness between L104 (female) (3) – D04
causes and (female) (2), – circuit branch end and chassis Resistance Min. 1 MΩ
standard value ground
in normal state Wiring harness between D04 (female) (2) – D03
Resistance Min. 1 MΩ
(female) (2) and chassis ground
Wiring harness between D04 (female) (1) – D03
Resistance Min. 1 MΩ
(female) (1) and chassis ground
Wiring harness between D03 (female) (1) – E01
Resistance Min. 1 MΩ
(female) (1) and chassis ground
Wiring harness between L07 (female) (4) – L104
Resistance Min. 1 MΩ
(female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness
16 Wiring harness between alternator terminal R –
(Contact with 24 V circuit)
E01 (female) (2), – L80 (female) (28), – L52 Voltage Max. 1 V
(female) (18), – circuit branch end
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective work equipment L07 Joystick lever Voltage
17
controller
Between (4) and Neutral Max. 1 V
chassis ground Other than above 20 – 30 V

WA500-6 40-651 ➁
TROUBLESHOOTING E-1
Related Circuit Diagrams

40-652 ➁ WA500-6
TROUBLESHOOTING E-2

E-2
Wiper Does Not Operate
Contents of
(1) Front wiper does not operate.
trouble
Related
• Since the front wiper switch, timer, or wiring harness is defective, the front wiper does not operate.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 9 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
box B (See cause 6.)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
C12 Front wiper switch Voltage
Defective front wiper motor Between (6) and (3) Constant 20 – 30 V
2
(Internal defect) Between (2) and (3) Lo 20 – 30 V
Between (1) and (3) Hi 20 – 30 V
If wiper switch is turned OFF while wiper is operating, voltage is applied
between C12 (5) and chassis ground until wiper motor stops.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L21 Front wiper switch Voltage
Between (3) and (1) Constant 20 – 30 V
Defective wiper timer (relay)
Possible 3 Between (4) and (1) INT 20 – 30 V
(Internal defect)
causes and
Between (2) and (1) Washer side 20 – 30 V
standard value
in normal state INT (If wiper switch is
Repeat
Between (5) and (1) set in INT, voltage is
20 to 30 V → 0 V
output intermittently.)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L22 Voltage
Between (7) and chassis ground 20 – 30 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective front wiper switch
4 L22 Front wiper switch Resistance
(Internal defect)
Between (7) and (5) Lo Max. 1 Ω
Between (7) and (4) Hi Max. 1 Ω
Between (7) and (2) INT Max. 1 Ω
Between (3) and (5) INT Max. 1 Ω
Other than above Min. 1 MΩ

WA500-6 40-653 ➁
TROUBLESHOOTING E-2

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L22 (female) (3) –
Resistance Max. 1 Ω
L21 (female) (5)
Wiring harness between L22 (female) (5) –
Resistance Max. 1 Ω
Disconnection in wiring C12 (female) (2)
harness Wiring harness between L22 (female) (7) –
5 Resistance Max. 1 Ω
(Disconnection or defective fuse No. 9 of fuse box B, – circuit branch end
contact in connector)
Wiring harness between L22 (female) (4) –
Resistance Max. 1 Ω
C12 (female) (1)
Wiring harness between C12 (female) (3)
Possible Resistance Max. 1 Ω
and chassis ground
causes and
Wiring harness between L21 (female) (1)
standard value Resistance Max. 1 Ω
in normal state and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L22 (female) (3) -
Resistance Min. 1 MΩ
L21 (female) (5) and chassis ground
Wiring harness between L22 (female) (5) –
Ground fault in wiring harness Resistance Min. 1 MΩ
6 C12 (female) (2) and chassis ground
(Short circuit with ground circuit)
Wiring harness between L22 (female) (7) –
fuse No. 9 of fuse box B, – circuit branch end Resistance Min. 1 MΩ
and chassis ground
Wiring harness between L22 (female) (4) –
Resistance Min. 1 MΩ
C12 (female) (1) and chassis ground

40-654 ➁ WA500-6
TROUBLESHOOTING E-2

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

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
C15 Rear wiper switch Voltage
Defective rear wiper motor
1 Between (1) and (4) Constant 20 – 30 V
(Internal defect)
Between (2) and (4) ON 20 – 30 V
If wiper switch is turned OFF while wiper is operating, voltage is applied
between C15 (1) and chassis ground until wiper motor stops.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L22 Voltage
Between (7) and chassis ground 20 – 30 V
Defective rear wiper switch ★ Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal defect)
L22 Rear wiper switch Resistance
Between (7) and (9) ON Max. 1 Ω
Possible Between (8) and (9) OFF Max. 1 Ω
causes and Other than above Min. 1 MΩ
standard value
★ Prepare with starting switch OFF, then carry out troubleshooting
in normal state
without turning starting switch ON.
Wiring harness between L22 (female) (7) –
Resistance Max. 1 Ω
Disconnection in wiring C15 (female) (1)
harness Wiring harness between L22 (female) (8) –
3 Resistance Max. 1 Ω
(Disconnection or defective C15 (female) (3)
contact in connector) Wiring harness between L22 (female) (9) –
Resistance Max. 1 Ω
C15 (female) (2)
Wiring harness between C15 (female) (4) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L22 (female) (7) –
Resistance Min. 1 MΩ
Ground fault in wiring harness C15 (female)(1), – circuit branch end
4
(Short circuit with ground circuit) Wiring harness between L22 (female) (8) –
Resistance Min. 1 MΩ
C15 (female) (3) and chassis ground
Wiring harness between L22 (female) (9) –
Resistance Min. 1 MΩ
C15 (female) (2) and chassis ground

WA500-6 40-655 ➁
TROUBLESHOOTING E-2
Related Circuit Diagram

40-656 ➁ WA500-6
TROUBLESHOOTING E-3

E-3
Windshield Washer Does Not Operate
Contents of
Windshield washer does not operate.
trouble
• Since the windshield washer motor, switch, timer (for front only), 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 operate
normally, carry out troubleshooting for E-2: Wiper Does Not Operate first.)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
Defective front washer motor carry out troubleshooting.
1
(Internal defect) B09 Voltage
Between (1) and (2) 20 – 30 V
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective rear washer motor carry out troubleshooting.
2
(Internal defect) B11 Voltage
Between (1) and (2) 20 – 30 V
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L22 Voltage
Between (7) and chassis ground 20 – 30 V
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective front wiper switch without turning starting switch ON.
3
(Internal defect) Front wiper washer
L22 (male) Resistance
switch
Possible ON Max. 1 Ω
Between (7) and (6)
causes and OFF Min. 1 MΩ
standard value
in normal state Between (7), (6) and
Constant Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L22 Voltage
Between (7) and chassis ground 20 – 30 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Rear wiper washer
L22 (male) Resistance
Defective rear wiper switch switch
4
(Internal defect) ON Max. 1 Ω
Between (7) and (10)
OFF Min. 1 MΩ
Between (7), (10) and
Constant Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Rear wiper washer
L22 (male) Resistance
switch

WA500-6 40-657 ➁
TROUBLESHOOTING E-3

Cause Standard value in normal state/Remarks on troubleshooting

Between
ON Max. 1 Ω
Defective rear wiper switch (7) and (9), (10)
4
(Internal defect) Between (7), (9), (10)
Constant Min. 1 MΩ
and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Front wiper washer
Defective wiper timer (relay) L21 (male) Voltage
5 switch
(for front wiper only)
Between (3) and (1) Constant 20 – 30 V
Between (2) and (1) ON 20 – 30 V
Between (5) and (1) 0.2 – 0.8 sec after ON 20 – 30 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L22 (female) (6) –
Resistance Max. 1 Ω
Possible B09 (female) (1), L21 (female) (2)
causes and
Disconnection in wiring Wiring harness between L22 (female) (7) –
standard value Resistance Max. 1 Ω
harness fuse No. 9 of fuse box B
in normal state 6
(Disconnection or defective Wiring harness between L22 (female) (10) –
contact in connector) Resistance Max. 1 Ω
B11 (female) (1)
Wiring harness between B09 (female) (2), –
Resistance Max. 1 Ω
B11 (female) (2) – chassis ground
Wiring harness between L21 (female) (1)
Resistance Max. 1 Ω
and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L22 (female) (6) –
B09 (female) (1), L21 (female) (2) and Resistance Min. 1 MΩ
Ground fault in wiring harness chassis ground
7
(Short circuit with ground circuit)
Wiring harness between L22 (female) (7) –
Resistance Min. 1 MΩ
fuse No. 9 of fuse box B and chassis ground
Wiring harness between L22 (female) (10) –
Resistance Min. 1 MΩ
B11 (female) (1) and chassis ground

40-658 ➁ WA500-6
TROUBLESHOOTING E-3
Related Circuit Diagram

WA500-6 40-659 ➁
TROUBLESHOOTING E-4

E-4
Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up
or Go Off
Contents of
(1) None of headlamp, clearance lamp, tail lamp, and license lamp lights up.
trouble
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
lamps lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp light
up.
• Headlamp at HEAD position: Above lamps and headlamp light up.
Related
information • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked with
the monitoring function (Code: 40200, SMALL LAMP).
• The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked with
the monitoring function (Code: 40900 D-IN-0).
• The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be checked
with the monitoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 11 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
box B (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L61 (male) Lamp switch Resistance
OFF Min. 1 MΩ
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 Ω
2 (Internal disconnection or
short circuit) OFF Min. 1 MΩ
Between (1) and (2) SMALL Min. 1 MΩ
Possible
causes and HEAD Max. 1 Ω
standard value Between (1), (2), (5)
in normal state Constant Min. 1 MΩ
and chassis ground
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between fuse No. 11 of fuse
contact in connector) Resistance Max. 1 Ω
box B – L61 (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring harness
4
(Short circuit with ground circuit) Wiring harness between fuse No. 11 of fuse
box B – L61 (female) (1), – circuit branch Resistance Min. 1 MΩ
end and chassis ground

40-660 ➁ WA500-6
TROUBLESHOOTING E-4

Contents of
(2) Either of headlamp low or 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.
• When the clearance lamp, tail lamp, and license lamp light up and go off normally.
Related • The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked with
information the monitoring function (Code: 40900 D-IN-0).
• The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be checked
with the monitoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 14 or If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
No. 15 of fuse box B (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L115 (male) Resistance
Defective head lamp relay Between (1) and (2) 200 – 400 Ω
2
(L115)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
If head lamp relay (L115) is replaced with a relay of the same type and the
condition becomes normal, the head lamp relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible L61 (male) Headlamp switch Resistance
causes and Defective lamp switch OFF Min. 1 MΩ
standard value 3 (Internal disconnection or
short circuit) Between (1) and (2) SMALL Min. 1 MΩ
in normal state
HEAD Max. 1 Ω
Between (1), (2) and
Constant Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L61 (male) Dimmer switch Resistance

Defective dimmer switch Low Min. 1 MΩ

Between (6) and (3)
4 (Internal disconnection or High Max. 1 Ω
short circuit)
Low Max. 1 Ω
Between (6) and (4)
High Min. 1 MΩ
Between (3), (4) and
Constant Min. 1 MΩ
chassis ground

WA500-6 40-661 ➁
TROUBLESHOOTING E-4

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L61 (female) (2) –
Resistance Max. 1 Ω
L115 (female) (1)
Wiring harness between L115 (female) (2) –
Resistance Max. 1 Ω
chassis ground
Disconnection in wiring Wiring harness between fuse No. 11 of fuse
Resistance Max. 1 Ω
harness box B – L115 (female) (3)
5
(Disconnection or defective Wiring harness between L115 (female) (5) –
contact in connector) Resistance Max. 1 Ω
fuse No. 14 or No. 15 of fuse box B
Wiring harness between fuse No. 14 of fuse
Resistance Max. 1 Ω
box B – right HEAD (female) (B)
Wiring harness between fuse No. 15 of fuse
Resistance Max. 1 Ω
box B – left HEAD (female) (B)
Wiring harness between L61 (female) (6)
Resistance Max. 1 Ω
and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L61 (female) (2) –
L115 (female) (1), – circuit branch end and Resistance Min. 1 MΩ
Possible chassis ground
causes and Wiring harness between L115 (female) (5) –
standard value Ground fault in wiring harness fuse No. 14 or No. 15 of fuse box B and Resistance Min. 1 MΩ
6
in normal state (Short circuit with ground circuit) chassis ground
Wiring harness between fuse No. 14 of fuse
box B – right HEAD (female) (B) and chassis Resistance Min. 1 MΩ
ground
Wiring harness between fuse No. 15 of fuse
box B – left HEAD (female) (B) and chassis Resistance Min. 1 MΩ
ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Headlamp switch is OFF.
Wiring harness between L61 (female) (2) –
L115 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground

Hot short in wiring harness Wiring harness between L115 (female) (5) –
7 fuse No. 14 or No. 15 of fuse box B and Voltage Max. 1 V
(Contact with 24 V circuit)
chassis ground
Wiring harness between fuse No. 14 of fuse
box B – right HEAD (female) (B) and chassis Voltage Max. 1 V
ground
Wiring harness between fuse No. 15 of fuse
box B – left HEAD (female) (B) and chassis Voltage Max. 1 V
ground

40-662 ➁ WA500-6
TROUBLESHOOTING E-4

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
chassis ground.
• When the high beam lights up (goes off) normally.
Related
information • The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked with
the monitoring function (Code: 40900 D-IN-0).
• The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be checked
with the monitoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific headlamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L61 (male) Dimmer switch Resistance

Defective dimmer switch Low Min. 1 MΩ

Between (6) and (3)
2 (Internal disconnection or High Max. 1 Ω
short circuit) Low Max. 1 Ω
Possible Between (6) and (4)
causes and High Min. 1 MΩ
standard value Between (3), (4) and
Constant Min. 1 MΩ
in normal state chassis ground
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between HEAD (female) (A)
contact in connector) Resistance Max. 1 Ω
– L61 (female) (4)
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring harness without turning starting switch ON.
4
(Short circuit with ground circuit) Wiring harness between HEAD (female) (A)
Resistance Min. 1 MΩ
– L61 (female) (4) and chassis ground

WA500-6 40-663 ➁
TROUBLESHOOTING E-4

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
chassis ground.
• When the low beam lights up (goes off) normally.
Related
information • The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked with
the monitoring function (Code: 40900 D-IN-0).
• The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be checked
with the monitoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific headlamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L61 (male) Dimmer switch Resistance

Defective dimmer switch Low Min. 1 MΩ

Between (6) and (3)
2 (Internal disconnection or High Max. 1 Ω
short circuit)
Low Max. 1 Ω
Between (6) and (4)
Possible High Min. 1 MΩ
causes and
Between (3), (4) and
standard value Constant Min. 1 MΩ
chassis ground
in normal state
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between HEAD (female) (C)
contact in connector) Resistance Max. 1 Ω
– L61 (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring harness
4
(Short circuit with ground circuit) Wiring harness between HEAD (female) (C)
– L61 (female) (3), – circuit branch end and Resistance Min. 1 MΩ
chassis ground

40-664 ➁ WA500-6
TROUBLESHOOTING E-4

Contents of (5) Clearance lamp does not light up or go off.

trouble (6) Tail lamp does not light up or go off.
• The switch, lamp, or wiring harness of the clearance lamp or tail lamp system is defective.
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: 40200, SMALL LAMP).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific lamp does not light up, its bulb may be broken or may have a
1 Broken bulb
defective contact. Check the bulb directly.
Defective fuse No. 12 or If the fuse is burnt out, the circuit probably has a grounding fault, etc.
2
No. 13 of fuse box B (See cause 5.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L61 (male) Headlamp switch Resistance
OFF Min. 1 MΩ
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 Ω
3 (Internal disconnection or
short circuit) OFF Min. 1 MΩ
Between (1) and (2) SMALL Min. 1 MΩ
HEAD Max. 1 Ω
Between (1), (2), (5)
Constant Min. 1 MΩ
and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L61 (female) (5) –
Possible Resistance Max. 1 Ω
fuse No. 12 or No. 13 of fuse box B
causes and
standard value Disconnection in wiring Wiring harness between fuse No. 12 of fuse
Resistance Max. 1 Ω
in normal state harness box B – right COMBI (female) (A)
4
(Disconnection or defective Wiring harness between fuse No. 12 of fuse
contact in connector) Resistance Max. 1 Ω
box B – G01 (female) (6)
Wiring harness between fuse No. 13 of fuse
Resistance Max. 1 Ω
box B – left COMBI (female) (A)
Wiring harness between fuse No. 13 of fuse
Resistance Max. 1 Ω
box B – G02 (female) (6)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 12 of fuse
box B – right COMBI (female) (A) and Resistance Min. 1 MΩ
chassis ground
Ground fault in wiring harness Wiring harness between fuse No. 12 of fuse
5 Resistance Min. 1 MΩ
(Short circuit with ground circuit) box B – G01 (female) (6) and chassis ground
Wiring harness between fuse No. 13 of fuse
box B – left COMBI (female) (A) and chassis Resistance Min. 1 MΩ
ground
Wiring harness between fuse No. 13 of fuse
Resistance Min. 1 MΩ
box B – G02 (female) (6) and chassis ground

WA500-6 40-665 ➁
TROUBLESHOOTING E-4

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Headlamp switch is OFF.
Wiring harness between L61 (female) (5) –
fuse No. 12 or No. 13 of fuse box B and Voltage Max. 1 V
chassis ground
Possible Wiring harness between fuse No. 12 of fuse
causes and Hot short in wiring harness box B – right COMBI (female) (A) and Voltage Max. 1 V
6
standard value (Contact with 24 V circuit) chassis ground
in normal state Wiring harness between fuse No. 12 of fuse
Voltage Max. 1 V
box B – G01 (female) (6) and chassis ground
Wiring harness between fuse No. 13 of fuse
box B – left COMBI (female) (A) and chassis Voltage Max. 1 V
ground
Wiring harness between fuse No. 13 of fuse
Voltage Max. 1 V
box B – G02 (female) (6) and chassis ground

40-666 ➁ WA500-6
TROUBLESHOOTING E-4
Related Circuit Diagram

WA500-6 40-667 ➁
TROUBLESHOOTING E-5

E-5
Working Lamp Does Not Light Up or Go Off
Contents of
(1) Either of front working lamp or rear working lamp does not light up
trouble
• The working lamp system power supply wiring harness is disconnected or shorted with the chassis
Related
ground.
information
• If the clearance lamp does not light up or go off, carry out troubleshooting for the clearance lamp first.

Cause Standard value in normal state/Remarks on troubleshooting

Possible Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
causes and harness without turning starting switch ON.
1
standard value (Disconnection or defective Wiring harness between L61 (female) (5) –
in normal state contact in connector) Resistance Max. 1 Ω
S67 (female) (5), S68 (female) (5)

Contents of
(2) 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 lights up (goes off).
information
• If the clearance lamp does not light up or go off, carry out troubleshooting for the clearance lamp first.

Cause Standard value in normal state/Remarks on troubleshooting

If a specific working lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuse No. 3 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
2
box B (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L109 (male) Resistance
Between (5) and (6) 200 – 400 Ω
Defective front working lamp
3
relay (L109) ★ Prepare with starting switch OFF, then turn starting switch ON and
Possible carry out troubleshooting.
causes and
standard value If front working lamp relay (L109) is replaced with a relay of the same type
in normal state and the condition becomes normal, the front working lamp relay is
defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective front working lamp Front working lamp

S67 (male) Resistance
switch switch
4
(Internal disconnection or ON Max. 1 Ω
short circuit) Between (5) and (6)
OFF Min. 1 MΩ
Between (5), (6) and
Constant Min. 1 MΩ
chassis ground

40-668 ➁ WA500-6
TROUBLESHOOTING E-5

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L61 (female) (5)
Resistance Max. 1 Ω
and S67 (female) (5)
Wiring harness between S67 (female) (6)
Resistance Max. 1 Ω
and L109 (female) (5)
Wiring harness between L109 (female) (6) –
Resistance Max. 1 Ω
Disconnection in wiring chassis ground
harness Wiring harness between fuse No. 3 of fuse
5 Resistance Max. 1 Ω
(Disconnection or defective box B – L109 (female) (2), (4)
contact in connector)
Wiring harness between L109 (female) (1) –
Resistance Max. 1 Ω
C04 (female) (1), C05 (female) (1)
Wiring harness between C04 (female) (2),
Resistance Max. 1 Ω
C05 (female) (2) – chassis ground
Wiring harness between L109 (female) (3) –
Resistance Max. 1 Ω
RS1 (female) (1), RS2 (female) (1)
Wiring harness between RS1 (female) (1),
Resistance Max. 1 Ω
RS2 (female) (1) – chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible without turning starting switch ON.
causes and
Wiring harness between S67 (female) (6) –
standard value Resistance Min. 1 MΩ
L109 (female) (5) and chassis ground
in normal state
Wiring harness between fuse No. 3 of fuse
box B – L109 (female) (2), (4) and chassis Resistance Min. 1 MΩ
Ground fault in wiring harness
6 ground
(Short circuit with ground circuit)
Wiring harness between L109 (female) (1) –
C04 (female) (1), C05 (female) (1), – circuit Resistance Min. 1 MΩ
branch end and chassis ground
Wiring harness between L109 (female) (3) –
RS1 (female) (1), RS2 (female) (1) and Resistance Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Front working lamp switch OFF.
Wiring harness between S67 (female) (6) –
Voltage Max. 1 V
L109 (female) (5) and chassis ground
Hot short in wiring harness
7 Wiring harness between L109 (female) (1) –
(Contact with 24 V circuit)
C04 (female) (1), C05 (female) (1), – circuit Voltage Max. 1 V
branch end and chassis ground
Wiring harness between L109 (female) (3) –
RS1 (female) (1), – RS1 (female) (1) and Voltage Max. 1 V
chassis ground

WA500-6 40-669 ➁
TROUBLESHOOTING E-5

Contents of
(3) 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 and side working lamp (OPT) light up (goes off).
information
• If the clearance lamp does not light up or go off, carry out troubleshooting for the clearance lamp first.

Cause Standard value in normal state/Remarks on troubleshooting

If a specific working lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuse No. 4 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
2
box B (Se cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L110 (male) Resistance
Between (5) and (6) 200 – 400 Ω
Defective rear working lamp
3
relay (L110) ★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
If rear working lamp relay (L110) is replaced with a relay of the same type
and the condition becomes normal, the rear working lamp relay is
defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective rear working lamp Front working lamp

Possible S68 (male) Resistance
switch switch
causes and 4
(Internal disconnection or ON Max. 1 Ω
standard value Between (5) and (6)
short circuit)
in normal state OFF Min. 1 MΩ
Between (5), (6) and
Constant Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L61 (female) (5)
Resistance Max. 1 Ω
and S68 (female) (5)
Wiring harness between S68 (female) (6)
Resistance Max. 1 Ω
Disconnection in wiring and L110 (female) (5)
harness Wiring harness between L110 (female) (6) –
5 Resistance Max. 1 Ω
(Disconnection or defective chassis ground
contact in connector) Wiring harness between fuse No. 4 of fuse
Resistance Max. 1 Ω
box B – L110 (female) (2)
Wiring harness between L110 (female) (1) –
Resistance Max. 1 Ω
G03 (female) (1), G04 (female) (1)
Wiring harness between G03 (female) (2) or
Resistance Max. 1 Ω
G04 (female) (2) – chassis ground

40-670 ➁ WA500-6
TROUBLESHOOTING E-5

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S68 (female) (6) –
Resistance Min. 1 MΩ
L110 (female) (5) and chassis ground
Ground fault in wiring harness Wiring harness between fuse No. 4 of fuse
6
(Short circuit with ground circuit) box B – L110 (female) (2), – circuit branch Resistance Min. 1 MΩ
end and chassis ground
Possible Wiring harness between L110 (female) (1) –
causes and G03 (female) (1), G04 (female) (1) and Resistance Min. 1 MΩ
standard value chassis ground
in normal state ★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• Front working lamp switch OFF.
Hot short in wiring harness Wiring harness between S68 (female) (6) –
7 Voltage Max. 1 V
(Contact with 24 V circuit) L110 (female) (5) and chassis ground
Wiring harness between L110 (female) (1) –
G03 (female) (1), G04 (female) (1) and Voltage Max. 1 V
chassis ground

WA500-6 40-671 ➁
TROUBLESHOOTING E-5
Related Circuit Diagram

40-672 ➁ WA500-6
TROUBLESHOOTING E-6

E-6
Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off
Contents of
(1) Either of turn signal lamp or 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) from turn signal lamp and hazard lamp switch (right turn signal lamp) to
Related
machine monitor can be checked with the monitoring function (Code: 40901, D-IN-12).
information
• The input state (ON/OFF) from turn signal lamp and hazard lamp switch (left turn signal lamp) to machine
monitor can be checked with the monitoring function (Code: 40901, D-IN-13).

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 4 of fuse
If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1 box A and fuse No. 1 of fuse
(See cause 6.)
box B
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L113 (male) Resistance
Between (1) and (2) 200 – 400 Ω
2 Defective hazard relay (L113)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Possible If hazard relay (L113) is replaced with a relay of the same type and the
causes and condition becomes normal, the hazard relay is defective.
standard value
in normal state
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L19 (male) Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit
Between (4) and (1) Repeat 20 to 30 V → 0 V
3 (Internal disconnection or
short circuit) ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L19 (male) Resistance
Between (3), (4) and
Min. 1 MΩ
chassis ground

WA500-6 40-673 ➁
TROUBLESHOOTING E-6

Cause Standard value in normal state/Remarks on troubleshooting

Turn signal lamp and
L62 (male) Resistance
hazard lamp switches
Turn signal lever: Left Min. 1 MΩ
Turn signal lever:
Min. 1 MΩ
Neutral
Between (2) and (3) Turn signal lever:
Max. 1 Ω
Right
Hazard lamp switch:
Max. 1 Ω
ON
Turn signal lever: Left Max. 1 Ω
Defective turn signal lamp and
hazard lamp switches Turn signal lever:
4 Min. 1 MΩ
(Internal disconnection or Neutral
short circuit) Between (2) and (4) Turn signal lever:
Min. 1 MΩ
Right
Hazard lamp switch:
Max. 1 Ω
ON
Hazard lamp switch:
Max. 1 Ω
ON
Between (1) and (5)
Hazard lamp switch:
Min. 1 MΩ
OFF
Between (1), (2), (4),
Possible (5) and chassis Constant Min. 1 MΩ
causes and ground
standard value
in normal state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L113 (female) (3) –
Resistance Max. 1 Ω
Disconnection in wiring L19 (female) (3)
harness Wiring harness between L19 (female) (4) –
5 Resistance Max. 1 Ω
(Disconnection or defective L62 (female) (2)
contact in connector) Wiring harness between L19 (female) (1) –
Resistance Max. 1 Ω
chassis ground
Wiring harness between L62 (female) (5)
Resistance Max. 1 Ω
and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring harness Wiring harness between L113 (female) (3) –
6 Resistance Min. 1 MΩ
(Short circuit with ground circuit) L19 (female) (3) and chassis ground
Wiring harness between L19 (female) (4) –
Resistance Min. 1 MΩ
L62 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness Wiring harness between L113 (female) (3) –
7 Voltage Max. 1 V
(Contact with 24 V circuit) L19 (female) (3) and chassis ground
Wiring harness between L19 (female) (4) –
Voltage Max. 1 V
L62 (female) (2) and chassis ground

40-674 ➁ WA500-6
TROUBLESHOOTING E-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 blinks.
Related • The input state (ON/OFF) from turn signal lamp and hazard lamp switch (right turn signal lamp) to machine
information monitor can be checked with the monitoring function (Code: 40901, D-IN-12).
• The input state (ON/OFF) from turn signal lamp and hazard lamp switch (left turn signal lamp) to machine
monitor can be checked with the monitoring function (Code: 40901, D-IN-13).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific turn signal lamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.
Turn signal lamp and
L62 (male) Resistance
hazard lamp switches
Turn signal lever: Left Min. 1 MΩ
Turn signal lever:
Min. 1 MΩ
Neutral
Between (2) and (3) Turn signal lever:
Max. 1 Ω
Right
Defective turn signal lamp and Hazard lamp switch:
Max. 1 Ω
hazard lamp switches ON
2
(Internal disconnection or Turn signal lever: Left Max. 1 Ω
short circuit)
Turn signal lever:
Min. 1 MΩ
Neutral
Between (2) and (4) Turn signal lever:
Min. 1 MΩ
Possible Right
causes and Hazard lamp switch:
standard value Max. 1 Ω
ON
in normal state
Between (2), (3), (4)
Constant Min. 1 MΩ
and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L62 (female) (3) –
Resistance Max. 1 Ω
G01 (female) (1), – right COMBI (female) (C)
Wiring harness between L62 (female) (4) –
Resistance Max. 1 Ω
Disconnection in wiring G02 (female) (1), – left COMBI (female) (C)
harness Wiring harness between G01 (female) (4) –
3 Resistance Max. 1 Ω
(Disconnection or defective chassis ground
contact in connector) Wiring harness between G02 (female) (4) –
Resistance Max. 1 Ω
chassis ground
Wiring harness between right COMBI
Resistance Max. 1 Ω
(female) (B) – chassis ground
Wiring harness between left COMBI (female)
Resistance Max. 1 Ω
(B) – chassis ground

WA500-6 40-675 ➁
TROUBLESHOOTING E-6

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L62 (female) (3) –
Ground fault in wiring harness G01 (female) (1), – right COMBI (female) (C) Resistance Min. 1 MΩ
4
(Short circuit with ground circuit) and chassis ground
Wiring harness between L62 (female) (4) –
Possible G02 (female) (1), – left COMBI (female) (C) Resistance Min. 1 MΩ
causes and and chassis ground
standard value ★ Prepare with starting switch OFF, then turn starting switch ON and
in normal state carry out troubleshooting.
Wiring harness between L62 (female) (3) –
Hot short in wiring harness G01 (female) (1), – right COMBI (female) (C) Voltage Max. 1 V
5
(Contact with 24 V circuit) and chassis ground
Wiring harness between L62 (female) (4) –
G02 (female) (1), – left COMBI (female) (C) Voltage Max. 1 V
and chassis ground

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 • When the turn signal lamp flashes normally.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No.4 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
box A (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L113 (male) Resistance
Between (1) and (2) 200 – 400 Ω
2 Defective hazard relay (L113)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.

Possible If hazard relay (L113) is replaced with a relay of the same type and the
causes and condition becomes normal, the hazard relay is defective.
standard value ★ Prepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch ON.
L62 (male) Hazard lamp switch Resistance
Between ON Max. 1 Ω
Defective hazard lamp switch (2) and (3), (4) OFF Min. 1 MΩ
3 (Internal disconnection or
short circuit) ON Max. 1 Ω
Between (1) and (5)
OFF Min. 1 MΩ
Between (1), (2), (3),
(4), (5) and Constant Min. 1 MΩ
chassis ground

40-676 ➁ WA500-6
TROUBLESHOOTING E-6

Cause Standard value in normal state/Remarks on troubleshooting

Disconnection in wiring
harness
4
(Disconnection or defective
contact in connector)
Ground fault in wiring harness
5 box A – L113 (female) (1), (5) and chassis
(Short circuit with ground circuit)
Hot short in wiring harness
6
(Contact with 24 V circuit)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 4 of fuse
Resistance Max. 1 Ω
box A – L113 (female) (1), (5)
Wiring harness between L113 (female) (2) –
Resistance Max. 1 Ω
L62 (female) (1)
Wiring harness between L62 (female) (5) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 4 of fuse
Resistance Min. 1 MΩ
ground
Wiring harness between L113 (female) (2) –
Resistance Min. 1 MΩ
L62 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
• The harnesses in the following two systems are shorted with the
power source simultaneously.
Wiring harness between L62 (female) (3) –
G01 (female) (1), – right COMBI (female) (C) Voltage Max. 1 V
and chassis ground
Wiring harness between L62 (female) (4) –
G02 (female) (1), – left COMBI (female) (C) Voltage Max. 1 V
and chassis ground

WA500-6 40-677 ➁
TROUBLESHOOTING E-6
Related Circuit Diagram

40-678 ➁ WA500-6
TROUBLESHOOTING E-7

E-7
Brake Lamp Does Not Light or It Keeps Lighting Up
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

Cause Standard value in normal state/Remarks on troubleshooting

If a specific brake lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuse No. 2 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
2
box B (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective brake lamp relay L102 (male) Resistance

(L102) Between (1) and (2) 200 – 400 Ω
3
(Internal disconnection or
★ Prepare with starting switch OFF, then turn starting switch ON and
short circuit)
carry out troubleshooting.
If brake lamp relay (L102) is replaced with a relay of the same type and
the condition becomes normal, the brake lamp relay is defective.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Possible L16 (male) Brake pedal Resistance
causes and Defective brake lamp switch
standard value 4 (Internal disconnection or Pressed Max. 1 Ω
short circuit) Between (1) and (2)
in normal state Released Min. 1 MΩ
Between (1), (2) and
Constant Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
Resistance Max. 1 Ω
box B – L102 (female) (2), – L16 (female) (1)
Disconnection in wiring Wiring harness between L16 (female) (2) –
Resistance Max. 1 Ω
harness L102 (female) (5)
5
(Disconnection or defective Wiring harness between L102 (female) (6) –
contact in connector) Resistance Max. 1 Ω
chassis ground
Wiring harness between L102 (female) (1) –
Resistance Max. 1 Ω
G01 (female) (5), – G02 (female) (5)
Wiring harness between G01 (female) (4),
Resistance Max. 1 Ω
G02 (female) (4) – chassis ground

WA500-6 40-679 ➁
TROUBLESHOOTING E-7

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
box B – L102 (female) (2), – L16 (female) Resistance Min. 1 MΩ
Ground fault in wiring harness (1), – circuit branch end and chassis ground
6 (Short circuit with ground
circuit) Wiring harness between L16 (female) (2) –
Resistance Min. 1 MΩ
L102 (female) (5) and chassis ground
Possible
Wiring harness between L102 (female) (1) –
causes and
G01 (female) (5), – G02 (female) (5) and Resistance Min. 1 MΩ
standard value
chassis ground
in normal state
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between L16 (female) (2) –
Hot short in wiring harness Voltage Max. 1 V
7 L102 (female) (5) and chassis ground
(Contact with 24 V circuit)
Wiring harness between L102 (female) (1) –
G01 (female) (5), – G02 (female) (5) and Voltage Max. 1 V
chassis ground

40-680 ➁ WA500-6
TROUBLESHOOTING E-7
Related Circuit Diagram

WA500-6 40-681 ➁
TROUBLESHOOTING E-8

E-8
Backup Lamp Does Not Light or It Keeps Lighting Up
Contents of
Backup lamp does not light or it keeps lighting up.
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for problems.
Related
• (If a disconnection or short circuit occurs in the primary side of the backup lamp relay, failure code
information
[D160KA] or [D160KZ] is displayed. Carry out troubleshooting for it first.)

Cause Standard value in normal state/Remarks on troubleshooting

If a specific backup lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuse No. 2 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
2
box B (See cause 5.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective backup lamp relay L101 (male) Resistance

(L101) Between (1) and (2) 200 – 400 Ω
3
(Internal disconnection or
★ Prepare with starting switch OFF, then turn starting switch ON and
short circuit)
carry out troubleshooting.
If backup lamp relay (L101) is replaced with a relay of the same type and
the condition becomes normal, the backup lamp relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible without turning starting switch ON.
causes and
Wiring harness between fuse No. 2 of fuse
standard value Resistance Max. 1 Ω
box B – L101 (female) (5)
in normal state
Wiring harness between L101 (female) (3) –
Resistance Max. 1 Ω
G01 (female) (2), – G02 (female) (2)
Wiring harness between L04 (female) (18) –
Disconnection in wiring L101 (female) (1)
Resistance Max. 1 Ω
harness • If any abnormality is detected, failure
4
(Disconnection or defective code [D160KA] is displayed.
contact in connector)
Wiring harness between L101 (female) (2) –
chassis ground
Resistance Max. 1 Ω
• If any abnormality is detected, failure
code [D160KA] is displayed.
Wiring harness between G01 (female) (4) –
Resistance Max. 1 Ω
chassis ground
Wiring harness between G02 (female) (4) –
Resistance Max. 1 Ω
chassis ground

40-682 ➁ WA500-6
TROUBLESHOOTING E-8

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
box B – L101 (female) (5) and chassis Resistance Min. 1 MΩ
Ground fault in wiring harness ground
(Short circuit with ground circuit) Wiring harness between L101 (female) (3) –
5
Ground fault in wiring harness G01 (female) (2), – G02 (female) (2) and Resistance Min. 1 MΩ
Possible (Short circuit with ground circuit) chassis ground
causes and
standard value Wiring harness between L04 (female) (18) –
in normal state L101 (female) (1) and chassis ground
Resistance Min. 1 MΩ
• If any abnormality is detected, failure
code [D160KZ] is displayed.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness
6 Wiring harness between L101 (female) (3) –
(Contact with 24 V circuit)
G01 (female) (2), – G02 (female) (2), – Voltage Max. 1 V
circuit branch end and chassis ground

Related Circuit Diagram

WA500-6 40-683 ➁
TROUBLESHOOTING E-9

E-9
Backup Buzzer Does Not Sound or It Keeps Sounding
Contents of
Backup buzzer does not sound or it keeps sounding.
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for problems.
Related
information • (If disconnection or short circuit occurs in the primary side of the backup lamp relay, failure code
[D160KA] or [D160KZ] is displayed. Carry out troubleshooting for it first.)

Cause Standard value in normal state/Remarks on troubleshooting

Defective backup buzzer
1 (Internal disconnection or
short circuit)
Defective fuse No. 2 of fuse
2
box B
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
G06 Gearshift lever Voltage
R 20 – 30 V
Between (1) and (2)
Other than R Max. 1 V
If the fuse is burnt out, the circuit probably has a grounding fault, etc.
(See cause 5.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective backup lamp relay L101 (male) Resistance

(L101) Between (1) and (2) 200 – 400 Ω
3
(Internal disconnection or
★ Prepare with starting switch OFF, then turn starting switch ON and
short circuit)
carry out troubleshooting.
Possible If backup lamp relay (L101) is replaced with a relay of the same type and
causes and the condition becomes normal, the backup lamp relay is defective.
standard value
★ Prepare with starting switch OFF, then carry out troubleshooting
in normal state
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
Resistance Max. 1 Ω
box B – L101 (female) (5)
Wiring harness between L101 (female) (3) –
Resistance Max. 1 Ω
G06 (female) (1)
Disconnection in wiring Wiring harness between L04 (female) (18) –
harness L101 (female) (1)
4
(Disconnection or defective Resistance Max. 1 Ω
• If any abnormality is detected, failure
contact in connector) code [D160KA] is displayed.
Wiring harness between L101 (female) (2) –
chassis ground
Resistance Max. 1 Ω
• If any abnormality is detected, failure
code [D160KA] is displayed.
Wiring harness between G06 (female) (2) –
Resistance Max. 1 Ω
chassis ground

40-684 ➁ WA500-6
TROUBLESHOOTING E-9

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
box B – L101 (female) (5) and chassis Resistance Min. 1 MΩ
ground
Ground fault in wiring harness
5
(Short circuit with ground circuit) Wiring harness between L101 (female) (3) – Resistance Min. 1 MΩ
Possible G06 (female) (1) and chassis ground
causes and Wiring harness between L04 (female) (18) –
standard value L101 (female) (1) and chassis ground
in normal state Resistance Min. 1 MΩ
• If any abnormality is detected, failure
code [D160KZ] is displayed.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short in wiring harness
6 Wiring harness between L101 (female) (3) –
(Contact with 24 V circuit)
G06 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground

Related Circuit Diagram

WA500-6 40-685 ➁
TROUBLESHOOTING E-10

E-10
Horn Does Not Sound or It Keeps Sounding
Contents of
Horn does not sound or it keeps sounding (steering wheel specification).
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 9 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
box A (See cause 7.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L108 (male) Resistance
Defective horn relay (L108)
Between (1) and (2) 200 – 400 Ω
2 (Internal disconnection or
short circuit) ★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
If horn relay (L108) is replaced with a relay of the same type and the
condition becomes normal, the horn relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering wheel horn
switch Steering wheel horn
3 L64 (male) Resistance
(Internal disconnection or switch
Possible short circuit) Between (1) and ON Max. 1 Ω
causes and
standard value chassis ground OFF Min. 1 MΩ
in normal state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective joystick lever horn
switch Joystick lever horn
4 JL2 (male) Resistance
(Internal disconnection or switch
short circuit) ON Max. 1 Ω
Between (9) and (10)
OFF Min. 1 MΩ
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting. (Disconnect connector and measure on
female side.)
Defective horn F03, F05 Horn switch Voltage
5 (Internal disconnection or OFF Max. 1 V
Between
short circuit)
F03 (2) and (1) ON 20 – 30 V
Between OFF Max. 1 V
F05 (2) and (1) ON 20 – 30 V

40-686 ➁ WA500-6
TROUBLESHOOTING E-10

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 9 of fuse
box A – L108 (female) (1), – F03 (female) Resistance Max. 1 Ω
(2), – F05 (female) (2)
Wiring harness between L108 (female) (2) –
Resistance Max. 1 Ω
L64 (female) (1)
Disconnection in wiring Wiring harness between L108 (female) (2) –
harness Resistance Max. 1 Ω
6 JL2 (female) (9)
(Disconnection or defective
Wiring harness between L108 (female) (3) –
contact in connector) Resistance Max. 1 Ω
chassis ground
Wiring harness between L108 (female) (5) –
Resistance Max. 1 Ω
F03 (female) (1), – F05 (female) (1)
Possible
Wiring harness between steering wheel horn
causes and Resistance Max. 1 Ω
switch – chassis ground
standard value
in normal state Wiring harness between JL2 (female) (10) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 9 of fuse
box A – L108 (female) (1), – F03 (female) Resistance Min. 1 MΩ
(2), – F05 (female) (2) and chassis ground
Ground fault in wiring harness Wiring harness between L108 (female) (2) –
7 Resistance Min. 1 MΩ
(Short circuit with ground circuit) L64 (female) (1) and chassis ground
Wiring harness between L108 (female) (2) –
Resistance Min. 1 MΩ
JL2 (female) (9) and chassis ground
Wiring harness between L108 (female) (5) –
F03 (female) (1), F05 (female) (1) and Resistance Min. 1 MΩ
chassis ground

WA500-6 40-687 ➁
TROUBLESHOOTING E-10
Related Circuit Diagram

40-688 ➁ WA500-6
TROUBLESHOOTING E-10

MEMORANDUM

WA500-6 40-689 ➁
TROUBLESHOOTING E-11

E-11
Alarm Buzzer Does Not Sound or It Keeps Sounding
Contents of
Alarm buzzer does not sound or it keeps sounding.
trouble
• The alarm buzzer output circuit is disconnected or shorted with the chassis ground.
Related • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
information monitoring function (Code: 40952, D-OUT-0).
• If failure code [DV00KB] (Alarm buzzer: Short circuit) is displayed, carry out troubleshooting for it first.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 8 of fuse If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
box B (See cause 4.)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective alarm buzzer • Check two seconds after starting switch is turned ON.
2
(Internal short circuit) L20 (female) Alarm buzzer Normal/Defective
Sounds Buzzer is normal
Ground (2)
Does not sound. Buzzer is defective
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between fuse No. 8 of fuse
3 Resistance Max. 1 Ω
(Disconnection or defective box B – L20 (female) (1)
contact in connector) Wiring harness between L20 (female) (2) –
Possible Resistance Max. 1 Ω
L51 (female) (14)
causes and
★ Prepare with starting switch OFF, then carry out troubleshooting
standard value
without turning starting switch ON.
in normal state
Wiring harness between fuse No. 8 of fuse
Ground fault in wiring harness
4 box B – L20 (female) (1), – circuit branch end Resistance Min. 1 MΩ
(Short circuit with ground circuit)
and chassis ground
Wiring harness between L20 (female) (2) –
Resistance Min. 1 MΩ
L51 (female) (14) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
L51 Starting switch Voltage
For two sec after ON
5 Defective machine monitor 20 – 30 V
(Alarm buzzer sounds)
Between (14) and For three sec
chassis ground from two sec after ON
Max. 1 V
(Alarm buzzer does
not sound)

40-690 ➁ WA500-6
TROUBLESHOOTING E-11
Related Circuit Diagram

WA500-6 40-691 ➁
TROUBLESHOOTING E-12

E-12
Air Conditioner Does Not Operate or Stop
Contents of
Air conditioner does not operate or stop.
trouble
• The following is troubleshooting for only the power supply or ground circuit between the air conditioner
Related
and operator's cab. For troubleshooting the air conditioner unit, see the Shop Manual for the air
information
conditioner.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 10 or No.11
of fuse box A and fuse 5A or If the fuse is burnt out, the circuit probably has a grounding fault, etc.
1
15A in main circuit in air
conditioner unit
Grounding fault in power
2 supply wiring harness
(Contact with ground circuit)
Possible
causes and
standard value
in normal state
Disconnection in air
conditioner control panel
power supply or ground wire
3
harness
(Disconnection or defective
contact in connector)
(See cause 2.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
• When fuse No. 10 of fuse box A is broken.
Wiring harness between fuse No. 10 of fuse
box A – fuse 5A of main circuit in air
Resistance Min. 1 MΩ
conditioner unit, – fuse 15 A in air conditioner
unit and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
• When fuse No. 11 of fuse box A is broken.
Wiring harness between fuse No. 11 of fuse
box A – compressor clutch relay and chassis Resistance Min. 1 MΩ
ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
• When fuse 5 A of main circuit in air conditioner unit is broken.
Wiring harness between fuse 5 A of main
circuit in air conditioner unit – C48 (female)
Resistance Min. 1 MΩ
(7), – pressure switch, – primary side of
blower OFF relay and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
• When fuse 15 A in air conditioner unit is broken
Wiring harness between fuse 15A in air
conditioner unit – blower OFF relay and Resistance Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
C48 Starting switch Voltage
ON 20 – 30 V
Between (7) and (1)
OFF Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 10 of fuse
Resistance Max. 1 Ω
box A – C48 (female) (7)
Wiring harness between C48 (female) (1) –
Resistance Max. 1 Ω
chassis ground

40-692 ➁ WA500-6
TROUBLESHOOTING E-12

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Blower OFF relay,
Starting switch Voltage
pressure switch
Between blower OFF ON 20 – 30 V
relay (15 A fuse line)
– chassis ground OFF Max. 1 V

Between blower OFF ON 20 – 30 V

relay (5 A fuse line of
main circuit) – OFF Max. 1 V
chassis ground
Between pressure ON 20 – 30 V
Possible Disconnection in relay wiring switch (5 A fuse line
causes and harness of main circuit) – OFF Max. 1 V
4 chassis ground
standard value (Disconnection or defective
in normal state contact in connector) ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 10 of fuse
box A – blower OFF relay Resistance Max. 1 Ω
(15 A fuse line side)
Wiring harness between fuse No. 10 of fuse
box A – blower OFF relay Resistance Max. 1 Ω
(5 A fuse line side of main circuit)
Wiring harness between fuse No. 10 of fuse
box A – pressure switch Resistance Max. 1 Ω
(5 A fuse line side of main circuit)
Wiring harness between pressure switch –
Resistance Max. 1 Ω
compressor clutch relay

WA500-6 40-693 ➁
TROUBLESHOOTING E-12
Related Circuit Diagram

40-694 ➁ WA500-6
TROUBLESHOOTING E-13

E-13
KOMTRAX System Does Not Work Properly
Trouble KOMTRAX system does not work properly.
• If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
Related
system, carry out the following troubleshooting.
information
• A defect in the KOMTRAX system, if any, does not appear as a defective phenomenon.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
1 Defective power supply L80 Signal Voltage
Between (39), (40) and Constant
20 – 30V
(37), (38) power supply
Turn the starting switch ON, then start engine and carry out
troubleshooting.
LED(6) Normal state
LED-C1 ON
Defective starting switch ★ Prepare with starting switch OFF, then start engine and carry out
2 ACC signal and alternator troubleshooting.
R signal L80 Signal Voltage
Between
Starting switch ACC 20 – 30V
(36) and (37), (38)
Between
Alternator R 20 – 30V
(28) and (37), (38)
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes carry out troubleshooting.
and standard
value in normal L80 Signal Voltage
state Between
Starting switch C Max. 1 V
Defective starting switch (27) and (37), (38)
3
C signal ★ Prepare with starting switch OFF, then turn starting switch START
and carry out troubleshooting.
L80 Signal Voltage
Between
Starting switch C 20 – 30V
(27) and (37), (38)
Turn the starting switch ON, and carry out troubleshooting.
LED(4) Normal state
LED-C4 ON
Defective CAN connection
4
state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L80 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 Ω
Turn the starting switch ON, and carry out troubleshooting.
5 Number of unsent mails LED(7) Normal state
7 segments 0–9

WA500-6 40-695 ➁
TROUBLESHOOTING E-13

Cause Standard value in normal state/Remarks on troubleshooting

Turn the starting switch ON, and carry out troubleshooting.
Possible causes LED(8) Normal state
and standard Defective GPS positioning
6 Dot ON
value in normal status
state One or more minutes may pass before GPS positioning is completed after
the starting switch has been turned ON even in an outdoor service area.

40-696 ➁ WA500-6
TROUBLESHOOTING E-13

Lamp Display Section of KOMTRAX Terminal

CPU LEDs

See graphic to the right.

1. LED-C1 (R signal and ACC signal status)

2. LED-C2 (engine control signal status)

3. LED-C3 (S-NET, C signal status)

4. LED-C4 (CAN status)

5. LED-C5 (download writing condition)

6. LED-C6 (download writing condition)

7-Segment and Dot Displays for CPU

7. 7 segments (number of unsent mail messages)

8. Dot (GPS positioning state)

L80 Connector

See graphic to the right.

WA500-6 40-697 ➁
TROUBLESHOOTING TROUBLESHOOTING: H-MODE

TROUBLESHOOTING: H-MODE
Troubleshooting Hydraulic and Mechanical Systems
Using Troubleshooting Chart
This troubleshooting chart, like the other troubleshooting charts (YES/NO type), determines the location of the problem
occurring on the machine and categorizes the problem under one of the main components, such as the steering system or work
equipment hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.

Step 1. Ask operator questions

The questions to ask the operator are given under the problem.

If the answer to the question matches the content given, the cause given after the arrow is the probable cause. Keeping the
content of the questions in mind, read the matrix and proceed with Steps 2 and 3 to pinpoint the correct cause.

Example: Steering wheel does not turn

★ Ask the operator and check the following points.

• Did the problem suddenly start?
• → Related equipment broken
• Was the steering wheel heavy before the problem started?
• → Wear of related parts, defective seal

Step 2. Checks before troubleshooting

Before measuring the oil pressure or starting the troubleshooting, confirm the checks before starting items, check for leakage
of oil, or for loose bolts. This will prevent wasting time when troubleshooting.

Before starting the actual troubleshooting, it is very important to determine the condition of the machine by checking the items
given in Checks Before Troubleshooting.

Example: Checks before starting troubleshooting

• Is oil level and type of oil in hydraulic tank correct?

• Is there any oil leakage from steering valve or demand valve?
• Is steering linkage adjusted properly?

Step 3. Method of reading matrix

Remedy
1. Operate the machine when carrying out troubleshooting of the items No.
Diagnosis
in the Diagnosis column. If any problems occur as the result of the
troubleshooting, put a check against the items. Steering does not turn in both
1
directions (left and right)
★ When carrying out the troubleshooting, check the easier items
first. Steering turns only in one direction
2
(left or right)
★ It is not necessary to follow the numerical order.
Steering is heavy when turned in both
★ Marks and Remedies in Remedy line 3
directions (left and right)
• X: Replace
Steering wheel is heavy in one
• Δ: Repair 4
direction (left or right)
• A: Adjust
5 Work equipment moves
• C: Clean

40-698 ➁ WA500-6
TROUBLESHOOTING TROUBLESHOOTING: H-MODE
2. Find the matching cause in the Cause column. If a problem is
found, the ❍ marks on the same line as the troubleshooting are the
causes.
★ In Diagnosis item 2 in the diagram on the right, the cause is
(c) or (e).
★ When there is one ❍ mark:
• Carry out troubleshooting for the other items marked with
❍ in the same Cause column to check if the problem
occurs, then make repairs.
★ When there are two ❍ marks:
• Go to Step (3) to narrow down the cause.

3. Operate the machine and carry out troubleshooting of the items not
checked in Step 1.
• Operate the machine in the same way as in Step 1 and if any
problem occurs, put a check against the item.
★ In Troubleshooting item 5 in the diagram to the right, the
problem was repeated.

4. Find the matching cause in the Cause column.

• In the same way as in Step 2, if a problem is found, the
❍ marks on the same line for the troubleshooting item are the
causes.
★ In Diagnosis item 5 in the diagram to the right the cause is
(b) or (e).

5. Narrow down the causes.

Of the causes found in Steps 2 and 4, there are common items
(❍ marks on the line for each Diagnosis item and in the same
Cause column) that have causes common with the problem items
found when troubleshooting in Steps 1 and 3.
★ The items that are not common (items that do not have
❍ marks in the same cause common to each other) are
probably not the cause, so they can be eliminated.
★ The causes for Diagnosis item 2 in the diagram to the
right are (c) or (e), and the causes in Diagnosis item 5 are
(b) or (e). Cause (e) is the common cause.

6. Repeat the operation in Steps 3, 4, and 5 until the cause is

narrowed down to one item (one common item).
★ If cause items are two or more, continue until you get a
minimum number of items.

7. Remedy
• After narrowing down the common causes, take the action
given in the remedy line.

WA500-6 40-699 ➁
TROUBLESHOOTING TROUBLESHOOTING: H-MODE

Failure Codes and Causes Table

Clogging of torque converter charging pump strainer

Part that can cause failure

Clogging or air intake on torque converter charging

Drop of transmission main relief valve set pressure

Defective operation of torque converter relief valve
Clogged or broken torque converter oil cooler
Defective torque converter charging pump
Internal breakage of torque converter
Defective regulator valve
pump suction side
Defective engine
PTO is defective
Failure mode

Machine does not start. ❍ ❍ ❍ ❍ ❍ ❍ ❍

Torque converter lockup is not switched off (engine stalls). [Machine with lockup clutch (if equipped)]
Power train

Torque converter lockup is not switched on. [Machine with lockup clutch (if equipped)] ❍
Travel speed is slow; thrusting force is weak; uphill traveling power is weak; gear is not shifted. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
Shocks are large when starting and shifting gear. ❍ ❍ ❍ ❍
Time lag is large when starting and shifting gear. ❍ ❍ ❍ ❍
Torque converter oil temperature is high. ❍ ❍ ❍ ❍ ❍ ❍ ❍
Steering does not turn. ❍
Steering does not turn. [Machine with joystick steering (if equipped)] ❍
Steering response is poor. ❍
Steering

Turning response of steering is poor. [Machine with joystick steering (if equipped)] ❍
Steering is heavy.
When machine turns, it shakes or makes large shocks.
When machine turns, it shakes or makes large shocks. [Machine with joystick steering (if equipped)]
Wheel brake does not work or does not work well. ❍
Wheel brake is not released or it drags.
Brake

Parking brake does not work or does not work well.

Parking brake is not released or it drags (including emergency release system).
Lift arm does not rise. ❍
Lift arm speed is low or rising force of lift arm is insufficient.
When rising, lift arm starts to move slowly at specific height.
Lift arm cylinder cannot hold bucket down (bucket floats).
Hydraulic drifts of lift arm occur often.
Lift arm wobbles during operation.
Work equipment

Bucket does not tilt back. ❍

Bucket speed is low or tilting back force is insufficient.
Bucket starts to operate slowly in midst of tilting back.
Bucket cylinder cannot hold bucket down.
Hydraulic drifts of the bucket occur often.
The bucket wobbles during travel with cargo. (The work equipment valve is set to HOLD.)
Engine speed lowers remarkably or engine stalls during work equipment control. ❍
Large shocks are made when work equipment starts and stops.
When work equipment circuit is relieved singly, other work equipment moves.
ECSS does not operate and pitching and bouncing occur.

40-700 ➁ WA500-6
 Clogging of last chance filter

❍ ❍
❍ ❍
❍ ❍
❍
❍ ❍
Defective operation of relevant ECMV

❍ ❍ ❍
Defect of transmission controller system

❍
❍
Internal breakage of transmission

WA500-6
❍ ❍
❍
❍ ❍
Wear or seizure of relevant clutch disc
Defective clutch piston
Relevant clutch piston seal is defective

❍ ❍
❍ ❍ ❍
❍ ❍
❍ ❍
Defective seal of relevant clutch shaft

❍
❍ ❍ ❍
Clogging of transmission breather
TROUBLESHOOTING

❍
❍
Defective transmission oil temperature sensor

❍
Defective transmission output shaft speed sensor
Defective seal of work equipment and steering

❍
❍
system hydraulic pump shaft
Clogging or air intake on steering pump suction side

❍ ❍
❍ ❍
Defective steering pump

❍ ❍
Defective steering pump servo
Defective Orbitrol

❍ ❍
Defective steering stop valve
Defective steering main relief valve
Defective demand spool

❍
Defective steering spool of steering valve
Defective safety-suction valve

❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍
Defective seal of steering cylinder piston
Clogging of joystick steering solenoid valve line filter
Defective joystick steering solenoid valve

❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍
Defective actuation of rotary valve

❍
Defective steering wheel or steering shaft
Defective seal of brake piston

❍
Defective operation of brake piston
Internal breakage of wheel brake

❍ ❍ ❍ ❍
Wear of wheel brake disc

❍
Seized wheel brake disc plate
❍
❍
❍

Defective brake pump

❍ ❍
❍ ❍
❍ ❍
❍ ❍

Clogging or air intake on brake pump suction side

Air in wheel brake circuit
Defective brake valve

Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1

H-11

H-34
H-33
H-32
H-31
H-30
H-29
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

40-701 ➁
TROUBLESHOOTING: H-MODE
TROUBLESHOOTING TROUBLESHOOTING: H-MODE

Defective operation of check valve (between last chance

Part that can cause failure

Gas leakage from accumulator, defective seal of piston

Defective operation of wheel brake emergency switch

Defective operation of parking brake solenoid valve

Defective parking brake emergency release valve

Defective operation of parking brake piston

Defective accumulator charge valve

filter and parking brake solenoid)

Defective parking brake spring

Defective slack adjuster
Defective axle oil
Failure mode

Machine does not start. ❍ ❍ ❍

Torque converter lockup is not switched off (engine stalls). [Machine with lockup clutch (if equipped)]
Power train

Torque converter lockup is not switched on. [Machine with lockup clutch (if equipped)]
Travel speed is slow; thrusting force is weak; uphill traveling power is weak; gear is not shifted.
Shocks are large when starting and shifting gear.
Time lag is large when starting and shifting gear.
Torque converter oil temperature is high.
Steering does not turn. ❍
Steering does not turn. [Machine with joystick steering (if equipped)] ❍
Steering response is poor. ❍
Steering

Turning response of steering is poor. [Machine with joystick steering (if equipped)] ❍
Steering is heavy. ❍
When machine turns, it shakes or makes large shocks. ❍
When machine turns, it shakes or makes large shocks. [Machine with joystick steering (if equipped)] ❍
Wheel brake does not work or does not work well. ❍ ❍ ❍ ❍
Wheel brake is not released or it drags. ❍
Brake

Parking brake does not work or does not work well. ❍ ❍ ❍ ❍

Parking brake is not released or it drags (including emergency release system). ❍ ❍ ❍
Lift arm does not rise.
Lift arm speed is low or rising force of lift arm is insufficient.
When rising, lift arm starts to move slowly at a specific height.
Lift arm cylinder cannot hold bucket down (bucket floats).
Hydraulic drifts of lift arm occur often.
Lift arm wobbles during operation.
Work equipment

Bucket does not tilt back.

Bucket speed is low or tilting-back force is insufficient.
Bucket starts to operate slowly in midst of tilting back.
Bucket cylinder cannot hold bucket down.
Hydraulic drifts of bucket occur often.
Bucket wobbles during travel with cargo. (Work equipment valve is set to HOLD.)
Engine speed lowers remarkably or engine stalls during work equipment control.
Large shocks are made when work equipment starts and stops.
When work equipment circuit is relieved singly, other work equipment moves.
ECSS does not operate and pitching and bouncing occur. ❍

40-702 ➁ WA500-6
 ❍
❍
❍
❍
The parking brake piston seal is defective

❍
Wear of parking brake disc

❍
Seizure of parking brake disc and plate
Defective harness of parking brake switch line

WA500-6
Clogging or air intake on work equipment pump

❍
❍
❍
❍
❍
❍
❍
❍
❍
suction side

❍
Defective work equipment controller
Defective work equipment pump

❍ ❍
Defective work equipment pump servo
TROUBLESHOOTING

❍
❍
Defective work equipment valve body
Defective work equipment main relief valve

❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍
Defective work equipment unload valve

❍ ❍ ❍ ❍ ❍ ❍
❍
❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍
Defective lift arm spool of work equipment valve

❍ ❍
❍ ❍
❍
❍
❍
❍
❍
Defective bucket spool of work equipment valve

Defective lift arm load check valve of work

❍
❍
❍
❍
❍
❍
equipment valve

Defective safety-suction valve on bucket head side

❍
❍
of work equipment valve

Defective safety-suction valve on bucket bottom side

❍
❍
❍
❍
❍
of work equipment valve

❍
❍
❍
Defective lift arm cylinder

❍
Defective bucket cylinder

❍
❍
❍
❍
❍
Defective seal of lift arm cylinder piston

❍
❍
❍
❍
❍
❍
Defective seal of bucket cylinder piston

❍
Defective stroke of lift arm EPC lever

❍
Defective stroke of bucket EPC lever

Defect in electrical system of lift arm or bucket EPC

❍
lever

Clearance error of pin or bush of working equipment

❍
linkage

❍
Defective ECSS solenoid valve

❍
❍
❍
❍
❍
❍
❍
Defective ECSS charge valve

Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1

H-11

H-34
H-33
H-32
H-31
H-30
H-29
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

40-703 ➁
TROUBLESHOOTING: H-MODE
TROUBLESHOOTING H-1

H-1
Machine Does Not Start
Ask the operator about the following: Cause
• DId the machine suddenly not start?

Parking brake emergency

→ Seizure of clutch, breakage of parts

Torque converter

Torque converter

Main relief valve

charging pump

Parking brake
• Did the machine cause any abnormal noise at the

Transmission

release valve
Check valve
time and where?

ECMV
Checks before troubleshooting
• Does the machine monitor function normally?
• Has the machine monitor displayed any failure
code of the electrical system?
a b c d e f g h i j k l m n o p q
• Are the transmission oil level and the oil type

(between last chance filter and parking brake solenoid)

appropriate?

Defective operation of parking brake solenoid valve

Defective operation of torque converter relief valve
• Did you smell deteriorated or burnt transmission
oil?

Defective operation of spool of parking brake

• Have the transmission filter and strainer been

The relevant clutch shaft seal is defective

clogged?

Relevant clutch piston seal is defective

Defective operation of relevant ECMV
Set pressure drop of main relief valve

Parking brake piston seal is defective

Internal breakage of torque converter
Clogging or air intake on suction side
• Can you find any damage or oil leak from

Defective operation of check valve

appearances?

Wear or seizure of relevant clutch

Internal breakage of transmission
• Has the drive shaft been broken?

Clogging of last chance filter

Charging pump is defective
• Have the wheel brake and the parking brake been

emergency release valve

locked?
Clogging of strainer

* Proceed to Defective Clutch and ECMV Specifying

PTO is defective

Method (Check by Failure Code) on next page.

Remedy Δ Δ Δ Δ Δ Δ Δ Δ Δ
No.
Diagnosis x C x
x
x x x
x * x
* * x
x x
x x

1 The machine does not start at all gear speeds. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍

2 The machine does not start at specific gear speeds. ❍ ❍ ❍ ❍ ❍

When the transmission oil temperature is low, the

3 charging pump or the transmission filter causes an ❍ ❍
abnormal noise(s).
When the transmission oil temperature rises, the
4 ❍ ❍ ❍ ❍
machine does not start.
Metal (aluminum, copper, iron, etc.) powders are
5 ❍ ❍ ❍
stuck to the transmission filter or the strainer.
The speed is higher at all
6 When the stall speed gear speeds. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
of the torque converter
is measured The speed is higher at
7 ❍ ❍ ❍ ❍ ❍
specific gear speeds.
The oil pressure is low at all
8 ❍ ❍ ❍ ❍ ❍ ❍ ❍
gear speeds.
When the ECMV The oil pressure is low at
9 ❍ ❍ ❍ ❍
output (Clutch) oil specific gear speeds.
pressure is measured The oil pressure does not
10 become stable as the ❍ ❍
gauge fluctuates.
When the torque converter relief (Inlet) oil pressure
11 ❍ ❍ ❍ ❍ ❍ ❍
is measured, the oil pressure is low.

40-704 ➁ WA500-6
TROUBLESHOOTING H-1

Defective Clutch and ECMV Specifying Method (Check by Failure Code)

★ To check the failure code display, see Normal and Special Functions of Machine
Monitor in the Testing and Adjusting section. Cause
• When replacing the ECMV for diagnosis, remove mud and dust around the ECMV Transmission ECMV
completely and clean it. Then tighten the mounting bolt with the specified torque.
• For the following diagnoses, start the engine and select the manual mode. a b c d e f g h i j k l
Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th

Wear or seizure of 2nd clutch disc or wear of piston seal

Wear or seizure of 3rd clutch disc or wear of piston seal
Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
●

Wear or seizure of R clutch disc or wear of piston seal

In the automatic mode

Wear or seizure of F clutch disc or wear of piston seal

Defective operation of 2nd clutch ECMV (Fill switch)

N

Defective operation of 3rd clutch ECMV (Fill switch)

Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
In the manual mode ❍ ❍ ❍ ❍

Defective operation of R clutch ECMV (Fill switch)

Defective operation of F clutch ECMV (Fill switch)
F1 ● ●
F2 ● ●
Gear Speed

F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●

• When the gear speed is N in the manual mode, the clutch of the gear speed
(marked with ❍), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position
cannot be changed.

Remedy Failure
No. x x x x x x x x x x x x
Diagnosis Code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 ❍ ❍
When the failure code is 15SAL1 after the diagnosis in (1), the failure code is
1 not displayed when the F fill switch connector (CN-F.SW) is disconnected.
(2) 15SALH ❍
When the failure code is 15SALH, the failure code is not displayed when the
ECMV is replaced with any one other than F clutch ECMV.
(1) The code is not displayed at F1-F4 but is displayed at R1-R4. 15SBL1 ❍ ❍
When the failure code is 15SBL1 after the diagnosis in (1), the failure code is
2 not displayed when the R fill switch connector (CN-R.SW) is disconnected.
(2) 15SBLH ❍
When the failure code is 15SBLH, the failure code is not displayed when the
ECMV is replaced with any one other than R clutch ECMV.
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1. 15SEL1 ❍ ❍
When the failure code is 15SEL1 after the diagnosis in (1), the failure code is
3 not displayed when the 1st fill switch connector (CN-1.SW) is disconnected.
(2) 15SELH ❍
When the failure code is 15SELH, the failure code is not displayed when the
ECMV is replaced with any one other than the 1st clutch ECMV.
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2. 15SFL1 ❍ ❍
When the failure code is 15SFL1 after the diagnosis in (1), the failure code is
4 not displayed when the 2nd fill switch connector (CN-2.SW) is disconnected.
(2) 15SFLH ❍
When the failure code is 15SFLH, the failure code is not displayed when the
ECMV is replaced with any one other than the 2nd clutch ECMV.
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3. 15SGL1 ❍ ❍
When the failure code is 15SGL1 after the diagnosis in (1), the failure code is
5 not displayed when the 3rd fill switch connector (CN-3.SW) is disconnected.
(2) 15SGLH ❍
When the failure code is 15SGLH, the failure code is not displayed when the
ECMV is replaced with any one other than the 3rd clutch ECMV.
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4. 15SHL1 ❍ ❍
When the failure code is 15SHL1 after the diagnosis in (1), the failure code is
6 not displayed when the 4th fill switch connector (CN-4.SW) is disconnected.
(2) 15SHLH ❍
When the failure code is 15SHLH, the failure code is not displayed when the
ECMV is replaced with any one other than the 4th clutch ECMV.

WA500-6 40-705 ➁
TROUBLESHOOTING H-2

H-2
Torque Converter Lockup is Not Switched OFF (Engine Stalls)
Machine with lockup clutch (if equipped)

Checks before troubleshooting Cause

• Is the oil level in the transmission case appropriate? a b

Defective operation of lockup clutch ECMV

Wear or seizure of lockup clutch disc

Remedy
No. x x
Diagnosis
1 Lockup oil pressure does not drop to 0. ❍

2 Lockup cannot be turned off even when the lockup oil pressure is 0. ❍

40-706 ➁ WA500-6
TROUBLESHOOTING H-3

H-3
Torque Converter Lockup is Not Switched ON
Machine with lockup clutch (if equipped)

Ask the operator about the following:

• Has the lockup suddenly started not to turn on? Cause
→ Seizure or breakage inside torque converter
a b c d e f g
• Did any abnormal noise occur at the time?

Drop of transmission main relief valve set pressure

→ Breakage of parts

Checks before troubleshooting

Defective operation of lockup clutch ECMV

• Is the oil level in the transmission case appropriate?
• Is there any external oil leakage?

Defective seal of lockup clutch piston

Wear or seizure of lockup clutch disc

Defective seal of lockup clutch shaft

Check for abnormality
• Main relief oil pressure

Clogging of last chance filter

Crack on lockup clutch case
• Lockup oil pressure
• Travel speed

Remedy
Δ
No. Diagnosis Transmission x x x x C x
x
controller self-diagnosis code
1 Main relief oil pressure is low. ❍

2 Main relief oil pressure is normal but lockup oil pressure is low or 0. ❍ ❍ ❍ ❍ ❍

3 Main relief oil pressure and oil pressure is normal but lockup oil pressure is low or 0. ❍

4 Time to lockup actuation takes long. 15SJLH ❍

WA500-6 40-707 ➁
TROUBLESHOOTING H-4

H-4
Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is
Weak, Gear is Not Shifted
Ask the operator about the following: Cause
• Has the abnormality occurred suddenly?

Torque converter
Torque converter

Torque converter

Main relief valve

Regulator valve
charging pump

Parking brake
→ Breakage of related equipment

Transmission
oil cooler

Others
ECMV
• Did any abnormal noise occur at the time and where?
• Have any abnormal signs occurred gradually?
→ Wear of related equipment, defective seal
Check for abnormality
a b c d e f g h i j k l m n o p q r s
• Execute digging and measure traveling speeds on level

Defective seal of work equipment and steering system hydraulic pump

ground and on a slope to check whether the abnormality
actually occurs or is simply the operator's opinion.

Breakage of oil cooler and piping (after torque converter outlet)

Checks before troubleshooting

Clogging of oil cooler and piping (after torque converter outlet)

• Is any failure code of the electrical system displayed on
the machine monitor?
• Are the transmission oil level and the oil type

Defective operation of torque converter relief valve

shaft (Mixing of hydraulic oil in transmission case)

appropriate?
• Are the transmission filter and strainer clogged?
Clogging or air intake on pump suction side
• Is any external oil leak found on the mating faces of

Defective seal of relevant clutch piston

Defective operation of relevant ECMV

Defective seal of parking brake piston

pipings and valves around the torque converter and the

Defective operation of regulator valve

Drop of main relief valve set pressure

Defective seal of relevant clutch shaft

Internal breakage of torque converter
transmission?

Internal breakage of transmission

Oil leak inside torque converter
• Is the wheel brake or the parking brake being dragged?

Clogging of last chance filter

Charging pump is defective

• Are the tire air pressure and the tread shape

appropriate?

Clogging of breather
• Is the operating method correct?

Note Engine degradation

Clogging of strainer

★ When the inspection result is Engine Degradation,

proceed to Troubleshooting of Engine (S-mode).
* Proceed to Defective Clutch and ECMV Specifying Method
(Check by Failure Code) on page 40-710.

Remedy ❍ Δ Δ Δ Δ Δ Δ Δ Δ ❍ Δ
No.
Diagnosis x x
x
x x
x
x x x x
x * x
* x
x
x
x
1 An abnormality occurs at all gear speeds. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍

2 An abnormality occurs at specific gear speeds. ❍ ❍ ❍ ❍

When the transmission oil temperature is low, the

3 charging pump or the transmission filter causes an ❍ ❍
abnormal noise.
4 The torque converter oil temperature is abnormally high. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍

5 The transmission oil level rises and falls. ❍ ❍ ❍ ❍ ❍ ❍

Metal (aluminum, copper, iron, etc.) powders are stuck to

6 ❍ ❍ ❍
the transmission filter or the strainer.
The engine low idle and high idle speeds are measured
7 ❍ ❍ ❍
and are abnormal.
8 When the stall speed of the The speed is high. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
torque converter is
9 measured The speed is low. ❍

40-708 ➁ WA500-6
 11

15
13
12
10
No.

WA500-6
normal.)
Diagnosis

measured
TROUBLESHOOTING

(clutch) oil pressure is

When the ECMV output gear speeds.

gauge fluctuates.

14 measured, the oil pressure is low. (No. 11 - 13 are

specific gear speeds.

become stable as the

measured, the oil pressure is low. (No. 14 is normal.)

When the torque converter relief (inlet) oil pressure is
the oil temperature rises.

When the oil pressure at the torque converter outlet is

The oil pressure is low at
The oil pressure drops as

The oil pressure does not

The oil pressure is low at all
a

Clogging of strainer
Torque converter
b

x x
Remedy ❍ Δ

❍ ❍
Clogging or air intake on pump suction side
charging pump
c

❍ ❍ ❍
❍
Charging pump is defective
d

Defective operation of regulator valve Regulator valve

e

x x
Δ Δ
Clogging of oil cooler and piping (after torque converter outlet) Torque converter
f

oil cooler

❍
Breakage of oil cooler and piping (after torque converter outlet)
g

Oil leak inside torque converter

Torque converter
h

Internal breakage of torque converter

i

❍ ❍ ❍
Defective operation of torque converter relief valve
j

x x x x
Δ Δ Δ Δ
Drop of main relief valve set pressure Main relief valve
k

❍ ❍
Clogging of last chance filter
Cause

Defective operation of relevant ECMV ECMV

x
Δ

❍
Internal breakage of transmission
m n

Defective seal of relevant clutch piston

Transmission
o

❍ ❍ ❍ ❍
❍ ❍

Defective seal of relevant clutch shaft

p

x
❍

Clogging of breather
q

❍ ❍
❍

Defective seal of parking brake piston Parking brake

Defective seal of work equipment and steering system hydraulic pump
r

x
Δ

shaft (Mixing of hydraulic oil in transmission case) Others

s

Note Engine degradation

40-709 ➁
H-4
TROUBLESHOOTING H-4
Defective Clutch and ECMV Specifying Method (Check by Failure Code)

★ To check the failure code display, see Normal and Special Functions of
Machine Monitor in the Testing and Adjusting section. Cause
• When replacing the ECMV for diagnosis, remove mud and dust around Transmission ECMV
the ECMV completely and clean it. Then tighten the mounting bolt with a b c d e f g h i j k l
the specified torque.
• For the following diagnoses, start the engine and select the manual
mode.
Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th
In the automatic mode ●

Wear or seizure of 2nd clutch disc or wear of piston seal

N

Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
❍ ❍ ❍ ❍

Wear or seizure of R clutch disc or wear of piston seal

In the manual mode

Wear or seizure of F clutch disc or wear of piston seal

Defective operation of 2nd clutch ECMV (Fill switch)

Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
F1 ● ●

Defective operation of R clutch ECMV (Fill switch)

Defective operation of F clutch ECMV (Fill switch)
F2 ● ●
Gear Speed

F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●

• When the gear speed is N in the manual mode, the clutch of the gear
speed (marked with ❍), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch
position cannot be changed.

Remedy Failure
No. x x x x x x x x x x x x
Diagnosis Code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4. 15SAL1 ❍ ❍
When the failure code is 15SAL1 after the diagnosis in (1), the
1 failure code is not displayed when the F fill switch connector
(2) (CN-F.SW) is disconnected. When the failure code is 15SALH, the 15SALH ❍
failure code is not displayed when the ECMV is replaced with any
one other than F clutch ECMV.
(1) The code is not displayed at F1-F4 but is displayed at R1-R4. 15SBL1 ❍ ❍
When the failure code is 15SBL1 after the diagnosis in (1), the
2 failure code is not displayed when the R fill switch connector
(2) (CN-R.SW) is disconnected. When the failure code is 15SBLH, the 15SBLH ❍
failure code is not displayed when the ECMV is replaced with any
one other than R clutch ECMV.
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1. 15SEL1 ❍ ❍
When the failure code is 15SEL1 after the diagnosis in (1), the
3 failure code is not displayed when the 1st fill switch connector (CN-
(2) 1.SW) is disconnected. When the failure code is 15SELH, the 15SELH ❍
failure code is not displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV.
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2. 15SFL1 ❍ ❍
When the failure code is 15SFL1 after the diagnosis in (1), the
4 failure code is not displayed when the 2nd fill switch connector
(2) (CN-2.SW) is disconnected. When the failure code is 15SFLH, the 15SFLH ❍
failure code is not displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV.

40-710 ➁ WA500-6
TROUBLESHOOTING H-4

Cause
Transmission ECMV
a b c d e f g h i j k l

Wear or seizure of 2nd clutch disc or wear of piston seal

Wear or seizure of 3rd clutch disc or wear of piston seal
Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
Wear or seizure of R clutch disc or wear of piston seal
Wear or seizure of F clutch disc or wear of piston seal

Defective operation of 2nd clutch ECMV (Fill switch)

Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis Code
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3. 15SGL1 ❍ ❍
When the failure code is 15SGL1 after the diagnosis in (1), the
5 failure code is not displayed when the 3rd fill switch connector
(2) (CN-3.SW) is disconnected. When the failure code is 15SGLH, the 15SGLH ❍
failure code is not displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV.
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4. 15SHL1 ❍ ❍
When the failure code is 15SHL1 after the diagnosis in (1), the
6 failure code is not displayed when the 4th fill switch connector
(2) (CN-4.SW) is disconnected. When the failure code is 15SHLH, the 15SHLH ❍
failure code is not displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV.

WA500-6 40-711 ➁
TROUBLESHOOTING H-5

H-5
Large Shocks When Starting and Shifting Gears
Ask the operator about the following: Cause
• Did shocks suddenly become large?

Torque converter

Main relief valve

charging pump
→ Breakage of related equipment

Parking brake
Transmission

Sensor
• Did any abnormal noise occur at the time and where?

ECMV
• Did shocks gradually become large?
→ Wear of related equipment, defective seal

Checks before troubleshooting

• Did any of the following abnormal phenomena occur at the same time: a b c d e f g h i j k l

Defective return (release) of relevant clutch piston

• Traveling speed is slow.
• Braking is weak.

Defective transmission oil temperature sensor

Clogging or air intake on pump suction side
• Uphill travelling power is weak.

Defective operation of relevant ECMV ★

• Gear is not shifted.

Defect of transmission controller system

Defective operation of main relief valve

Relevant clutch piston seal is defective

→ Execute H-4

Defective seal of relevant clutch shaft

Parking brake piston seal is defective
Checks before troubleshooting
• Is any failure code of the electrical system displayed on the machine

Clogging of last chance filter

Charging pump is defective
monitor?
• Are the transmission oil level and the oil type appropriate?
• Are the transmission filter and strainer clogged?

Clogging of strainer
• Is any external oil leak found on the mating faces of pipings and valves
around the torque converter and the transmission?
• Is the engine speed high at the time of low idle?
• Is play of each drive shaft large?

Remedy C Δ Δ
No.
Diagnosis x x
x
x
x * ** * * x x **
1 Shocks are large at all gear speeds. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
2 Shocks are large at specific gear speeds. ❍ ❍ ❍ ❍ ❍ ❍
3 When the ECMV output The oil pressure is low at all gear speeds. ❍ ❍ ❍ ❍ ❍ ❍
4 (clutch) oil pressure is The oil pressure is low at specific gear speeds. ❍ ❍ ❍
5 measured The oil pressure is high at all gear speeds. ❍

★: Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting wastes of pressure
control valve spool

*: Proceed to Defective Clutch and ECMV Specifying Method (Check by Failure Code) on page 40-714.

**: See Troubleshooting by Failure Code in this section.

40-712 ➁ WA500-6
TROUBLESHOOTING H-5

MEMORANDUM

WA500-6 40-713 ➁
TROUBLESHOOTING H-5

Defective Clutch and ECMV specifying method (Check by Failure Code)

★ To check the failure code display, see Normal and Special Functions of
Machine Monitor in the Testing and Adjusting section.
Cause
• When replacing the ECMV for diagnosis, remove mud and dust around
the ECMV completely and clean it. Then tighten the mounting bolt with Transmission ECMV
the specified torque. a b c d e f g h i j k l
• For the following diagnoses, start the engine and select the manual
mode.
Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th
In the automatic mode ●

Wear or seizure of 2nd clutch disc or wear of piston seal

N

Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
❍ ❍ ❍ ❍

Wear or seizure of R clutch disc or wear of piston seal

In the manual mode

Wear or seizure of F clutch disc or wear of piston seal

Defective operation of 2nd clutch ECMV (Fill switch)

Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
F1 ● ●

Defective operation of R clutch ECMV (Fill switch)

Defective operation of F clutch ECMV (Fill switch)
F2 ● ●
Gear Speed

F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●

• When the gear speed is N in the manual mode, the clutch of the gear
speed (marked with ❍), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch
position cannot be changed.

Remedy Failure
No. x x x x x x x x x x x x
Diagnosis Code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4. 15SAL1 ❍ ❍
When the failure code is 15SAL1 after the diagnosis in (1), the failure
1 code is not displayed when the F fill switch connector (CN-F.SW) is
(2) disconnected. When the failure code is 15SALH, the failure code is not 15SALH ❍
displayed when the ECMV is replaced with any one other than F clutch
ECMV.
(1) The code is not displayed at F1-F4 but is displayed at R1-R4. 15SBL1 ❍ ❍
When the failure code is 15SBL1 after the diagnosis in (1), the failure
2 code is not displayed when the R fill switch connector (CN-R.SW) is
(2) disconnected. When the failure code is 15SBLH, the failure code is not 15SBLH ❍
displayed when the ECMV is replaced with any one other than R clutch
ECMV.
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1. 15SEL1 ❍ ❍
When the failure code is 15SEL1 after the diagnosis in (1), the failure
3 code is not displayed when the 1st fill switch connector (CN-1.SW) is
(2) disconnected. When the failure code is 15SELH, the failure code is not 15SELH ❍
displayed when the ECMV is replaced with any one other than the 1st
clutch ECMV.
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2. 15SFL1 ❍ ❍
When the failure code is 15SFL1 after the diagnosis in (1), the failure
4 code is not displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code is not 15SFLH ❍
displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV.

40-714 ➁ WA500-6
TROUBLESHOOTING H-5

Cause
Transmission ECMV
a b c d e f g h i j k l

Wear or seizure of 2nd clutch disc or wear of piston seal

Wear or seizure of 3rd clutch disc or wear of piston seal
Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
Wear or seizure of R clutch disc or wear of piston seal
Wear or seizure of F clutch disc or wear of piston seal

Defective operation of 2nd clutch ECMV (Fill switch)

Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis Code
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3. 15SGL1 ❍ ❍
When the failure code is 15SGL1 after the diagnosis in (1), the failure
5 code is not displayed when the 3rd fill switch connector (CN-3.SW) is
(2) disconnected. When the failure code is 15SGLH, the failure code is not 15SGLH ❍
displayed when the ECMV is replaced with any one other than the 3rd
clutch ECMV.
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4. 15SHL1 ❍ ❍
When the failure code is 15SHL1 after the diagnosis in (1), the failure
6 code is not displayed when the 4th fill switch connector (CN-4.SW) is
(2) disconnected. When the failure code is 15SHLH, the failure code is not 15SHLH ❍
displayed when the ECMV is replaced with any one other than the 4th
clutch ECMV.

WA500-6 40-715 ➁
TROUBLESHOOTING H-6

H-6
Large Time Lag When Starting and Shifting Gear
Ask the operator about the following: Cause
• Did the time lag suddenly become large?

Torque converter

Main relief valve

charging pump
→ Breakage of related equipment

Parking brake
Transmission

Sensor
• Did any abnormal noise occur at the time and where?

ECMV
• Has the time lag gradually become large?
→ Wear of related equipment, defective seal

Check for abnormality

a b c d e f g h i j
• Did any of the following abnormal phenomena occur at the same time:

Defective transmission oil temperature sensor

• Traveling speed is slow.

Clogging or air intake on pump suction side

• Braking is weak.

Defective operation of relevant ECMV ★

Relevant clutch piston seal is defective
• Uphill travelling power is weak.

Drop of main relief valve set pressure

Defective seal of relevant clutch shaft

Parking brake piston seal is defective
• Gear is not shifted.
→ Execute H-4

Clogging of last chance filter

Charging pump is defective
Checks before troubleshooting
• Is any failure code of the electrical system displayed on the machine monitor?
• Are the transmission oil level and the oil type appropriate?

Clogging of strainer
• Are the transmission filter and strainer clogged?
• Is any external oil leak found on the mating faces of pipings and valves around the
torque converter and the transmission?

Remedy C Δ Δ
No. x x * * x x **
Diagnosis x x x
1 Time lag is large at all gear speeds. ❍ ❍ ❍ ❍ ❍ ❍ ❍
2 Time lag is large at specific gear speeds. ❍ ❍ ❍ ❍
When the transmission oil temperature is low, any abnormal noise occurs from the
3 ❍ ❍
charging pump or the transmission filter.
4 The torque converter oil temperature is heated abnormally high. ❍ ❍ ❍ ❍
5 When the ECMV output (Clutch) The oil pressure is low at all gear speeds. ❍ ❍ ❍ ❍ ❍
6 oil pressure is measured The oil pressure is low at specific gear speeds. ❍ ❍ ❍

★ Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting wastes of pressure
control valve spool.

*: Proceed to Defective Clutch and ECMV Specifying Method (Check by Failure Code) on page 40-718.

**: See Troubleshooting by Failure Code in this section.

40-716 ➁ WA500-6
TROUBLESHOOTING H-6

MEMORANDUM

WA500-6 40-717 ➁
TROUBLESHOOTING H-6

Defective Clutch and ECMV specifying method (Check by Failure Code)

★ To check the failure code display, see Normal and Special Functions of
Machine Monitor in the Testing and Adjusting section.
• When replacing the ECMV for diagnosis, remove mud and dust around
the ECMV completely and clean it. Then tighten the mounting bolt with
the specified torque. Cause
• For the following diagnoses, start the engine and select the manual Transmission ECMV
mode. a b c d e f g h i j k l

Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th
In the automatic mode ●

Wear or seizure of 2nd clutch disc or wear of piston seal

N

Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
❍ ❍ ❍ ❍

Wear or seizure of R clutch disc or wear of piston seal

In the manual mode

Wear or seizure of F clutch disc or wear of piston seal

Defective operation of 2nd clutch ECMV (Fill switch)

Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
F1 ● ●

Defective operation of R clutch ECMV (Fill switch)

Defective operation of F clutch ECMV (Fill switch)
F2 ● ●
Gear Speed

F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●

• When the gear speed is N in the manual mode, the clutch of the gear
speed (marked with ❍), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch
position cannot be changed.

Remedy Failure
No. x x x x x x x x x x x x
Diagnosis Code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4. 15SAL1 ❍ ❍
When the failure code is 15SAL1 after the diagnosis in (1), the
1 failure code is not displayed when the F fill switch connector
(2) (CN-F.SW) is disconnected. When the failure code is 15SALH, the 15SALH ❍
failure code is not displayed when the ECMV is replaced with any
one other than F clutch ECMV.
(1) The code is not displayed at F1-F4 but is displayed at R1-R4. 15SBL1 ❍ ❍
When the failure code is 15SBL1 after the diagnosis in (1), the
2 failure code is not displayed when the R fill switch connector
(2) (CN-R.SW) is disconnected. When the failure code is 15SBLH, the 15SBLH ❍
failure code is not displayed when the ECMV is replaced with any
one other than R clutch ECMV.
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1. 15SEL1 ❍ ❍
When the failure code is 15SEL1 after the diagnosis in (1), the
3 failure code is not displayed when the 1st fill switch connector
(2) (CN-1.SW) is disconnected. When the failure code is 15SELH, the 15SELH ❍
failure code is not displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV.
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2. 15SFL1 ❍ ❍
When the failure code is 15SFL1 after the diagnosis in (1), the
4 failure code is not displayed when the 2nd fill switch connector
(2) (CN-2.SW) is disconnected. When the failure code is 15SFLH, the 15SFLH ❍
failure code is not displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV.

40-718 ➁ WA500-6
TROUBLESHOOTING H-6

Cause
Transmission ECMV
a b c d e f g h i j k l

Wear or seizure of 2nd clutch disc or wear of piston seal

Wear or seizure of 3rd clutch disc or wear of piston seal
Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
Wear or seizure of R clutch disc or wear of piston seal
Wear or seizure of F clutch disc or wear of piston seal

Defective operation of 2nd clutch ECMV (Fill switch)

Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis Code
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3. 15SGL1 ❍ ❍
When the failure code is 15SGL1 after the diagnosis in (1), the
5 failure code is not displayed when the 3rd fill switch connector
(2) (CN-3.SW) is disconnected. When the failure code is 15SGLH, the 15SGLH ❍
failure code is not displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV.
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4. 15SHL1 ❍ ❍
When the failure code is 15SHL1 after the diagnosis in (1), the
6 failure code is not displayed when the 4th fill switch connector
(2) (CN-4.SW) is disconnected. When the failure code is 15SHLH, the 15SHLH ❍
failure code is not displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV.

WA500-6 40-719 ➁
TROUBLESHOOTING H-7

H-7
Torque Converter Oil Temperature is High
Ask the operator about the following: Cause
• Does the oil temperature rise when the torque converter stalls and

Torque converter
Torque converter

Torque converter

Main relief valve

charging pump

Transmission
does the temperature fall at the time of no load?

oil cooler
→ Selection of improper gear speed

Others
• Did any abnormal noise occur at the time and where?
• Does the oil temperature rise only at the time of lifting?
→ Improvement of operating method

Check for abnormality a b c d e f g h i j k l

Defective seal of work equipment and steering

• Measure the torque converter oil temperature to find if the oil

(Mixing of hydraulic oil in transmission case)

Clogging or air intake on pump suction side
temperature is really high.
→ The torque converter oil temperature gauge is defective.

Drop of main relief valve set pressure

Internal breakage of torque converter
Checks before troubleshooting

Internal breakage of transmission

Breakage of oil cooler and piping
Clogging of oil cooler and piping
• Are the coolant level in the radiator and the belt tension appropriate?

Oil leak inside torque converter

(After torque converter outlet)

(After torque converter outlet)

• Are the oil level in the transmission and the oil type appropriate?

system hydraulic pump shaft

Charging pump is defective
• Are the transmission filter and strainer clogged?

★ When the inspection result is Engine Degradation, proceed to

Clogging of breather
Clogging of strainer

Note Engine degradation

Troubleshooting of Engine (S-mode).

Remedy C Δ Δ Δ Δ Δ Δ C Δ
No. x x
Diagnosis x x x x x x x x x
When the transmission oil temperature is low, the charging pump or the
1 ❍ ❍
transmission filter causes an abnormal noise.
Traveling speed, braking force, and uphill traveling power do not occur
2 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
at all gear speeds.
Traveling speed, braking force, and uphill traveling power do not occur
3 ❍
at specific gear speeds.
4 The transmission oil level rises and falls. ❍ ❍ ❍
Metal powders (aluminum, copper, iron, etc.) are stuck to the
5 ❍ ❍ ❍
transmission filter and the strainer.
The engine low idle and high idle speeds are measured and are
6 ❍ ❍ ❍
abnormal.
When the stall speed of the torque converter is measured, the speed is
7 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
high.
The oil pressure drops as the oil temperature
8 ❍
rises.
9 When the ECMV output The oil pressure is low at all gear speeds. ❍ ❍ ❍ ❍ ❍
(Clutch) oil pressure is The oil pressure is low at specific gear
10 measured ❍
speeds.
The oil pressure does not become stable as
11 ❍ ❍
the gauge vibrates.
When the torque converter relief (Inlet) oil pressure is measured, the oil
12 ❍ ❍ ❍
pressure is low. (No. 9 - 11 are normal.)
When the oil pressure at the torque converter outlet is measured, the
13 ❍
oil pressure is low. (No. 12 is normal.)

40-720 ➁ WA500-6
TROUBLESHOOTING H-8

H-8
Steering Does Not Turn
Ask the operator about the following: Cause
• Did the problem suddenly start?

Hydraulic cylinder
Hydraulic pump
→ Breakage of related equipment

Steering valve
Charge valve

Stop valve
Orbitrol
• Did the machine cause any abnormal noise at the time and where?

Checks before troubleshooting

• Is oil level in hydraulic tank correct? Is the type of oil correct?
• Is the steering shaft broken?
• Is the steering stop valve properly adjusted? a b c d e f g h i j k

Defect in steering cylinder (defective piston seal)

• Has the lock bar been removed from the frame?

Clogging or air intake on pump suction side

Defective actuation of demand spool

Defective actuation of steering spool
Defective accumulator charge valve

Defective safety-suction valve

Defective steering pump
Defective brake pump

Defective stop valve

Defective Orbitrol
Defective PTO
Remedy Δ Δ Δ Δ Δ Δ Δ Δ
No. Δ x x
Diagnosis x x x x x x x x
1 Steering does not turn in both directions (left and right). ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
2 Steering turns only in one direction (left or right). ❍ ❍
3 Steering is heavy when turned in both directions (left and right). ❍ ❍ ❍ ❍
4 Steering wheel is heavy in one direction (left or right). ❍
5 Work equipment moves. ❍ ❍ ❍ ❍ ❍ ❍ ❍
6 Work equipment does not move. ❍ ❍ ❍ ❍
7 Abnormal noise comes from around PTO. ❍
8 Abnormal noise comes from around hydraulic tank. ❍ ❍
Oil pressure is low or there is no pressure in both
9 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
When steering relief directions (left and right).
pressure is measured Oil pressure is low or there is no pressure in one
10 ❍ ❍
direction (left or right).
When Orbitrol output pressure is measured, oil pressure is found to be low or
11 ❍ ❍ ❍ ❍ ❍
there is no oil pressure.
12 When Orbitrol basic Oil pressure is low. ❍ ❍ ❍ ❍
13 pressure is measured There is no oil pressure. ❍ ❍ ❍

WA500-6 40-721 ➁
TROUBLESHOOTING H-9

H-9
Steering Does Not Turn (Joystick Steering, if equipped)
Ask the operator about the following: Cause
• Did the problem suddenly start?

Hydraulic cylinder
Joystick steering
Hydraulic pump

solenoid valve
→ Breakage of related equipment

Steering valve
Charge valve

Rotary valve
• Did the machine cause any abnormal noise at the time and where?

Checks before troubleshooting

• Is oil level in hydraulic tank correct? Is the type of oil correct?
• Is the steering shaft broken?
• Has the lock bar been removed from the frame? a b c d e f g h i j k l

Defect in steering cylinder (defective piston seal)

• Are the steering mode switch and steering operations correct?

Clogging or air intake on pump suction side

Defective joystick steering solenoid valve

Defective actuation of demand spool

Defective actuation of steering spool
Defective accumulator charge valve

Defective actuation of rotary valve

Defective safety-suction valve

Defective steering pump
Defective brake pump

Clogged line filter

PTO is defective

Remedy Δ Δ Δ Δ C Δ Δ Δ
No. Δ x x x
Diagnosis x x x x x x x x
1 Steering does not turn in both directions (left and right). ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
2 Steering turns only in one direction (left or right). ❍
3 Joystick steering is heavy when turned in both directions (left and right). ❍ ❍ ❍
4 Joystick steering is heavy in one direction (left or right).
5 Work equipment moves. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
6 Work equipment does not move. ❍ ❍ ❍ ❍
7 Abnormal noise comes from around PTO. ❍
8 Abnormal noise comes from around hydraulic tank. ❍ ❍
Oil pressure is low or there is no pressure in both
9 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
When steering relief directions (left and right).
pressure is measured Oil pressure is low or there is no pressure in one
10 ❍
direction (left or right).
When joystick steering solenoid valve output pressure is measured, oil
11 ❍ ❍ ❍ ❍ ❍ ❍ ❍
pressure is found to be low.
12 When Orbitrol basic Oil pressure is low. ❍ ❍ ❍ ❍
13 pressure is measured There is no oil pressure. ❍ ❍ ❍

40-722 ➁ WA500-6
TROUBLESHOOTING H-10

H-10
Steering Response is Poor
Ask the operator about the following: Cause
• Did the problem suddenly start?

Hydraulic cylinder
Hydraulic pump
→ Breakage of related equipment

Steering valve
Charge valve

Stop valve
Orbitrol
• Did the machine cause any abnormal noise at the time and where?
• Did the problem gradually appear?
→ Wear of related parts, defective seal

Checks before troubleshooting

• Is oil level in hydraulic tank correct? Is the type of oil correct? a b c d e f g h i j k l m

Defect in steering cylinder (defective piston seal)

Clogging or air intake on pump suction side

Defective actuation of demand spool

Defective accumulator charge valve
Defective steering pump servo

Defective safety-suction valve

Defective main relief valve
Defective steering pump

Defective steering spool

Defective brake pump

Defective stop valve

Defective Orbitrol
PTO is defective

Remedy Δ Δ Δ Δ Δ Δ Δ Δ Δ Δ Δ
No. Δ x
Diagnosis x x x x x x x x x x x
Turning response of steering wheel is poor in both directions (left and
1 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
right).
2 Turning response of steering wheel is poor in one direction (left or right). ❍ ❍
3 Steering wheel is heavy in both directions (left and right). ❍ ❍ ❍ ❍
4 Steering wheel is heavy in one direction (left or right). ❍
5 Work equipment moves. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
6 Work equipment does not move. ❍ ❍ ❍ ❍
7 Abnormal noise comes from around PTO. ❍
8 Abnormal noise comes from around hydraulic tank. ❍ ❍
Oil pressure is low or there is no pressure in
9 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
When steering relief both directions (left and right).
pressure is measured Oil pressure is low or there is no pressure in one
10 ❍ ❍
direction (left or right).
11 When Orbitrol output pressure is measured, oil pressure is low. ❍ ❍ ❍ ❍ ❍
When Orbitrol basic pressure is measured, oil pressure is low or there is
12 ❍ ❍ ❍ ❍
no pressure.
13 When steering pump servo assembly is replaced, oil pressure is normal. ❍

★ There is a close connection between the steering circuit and the work equipment circuit. If any abnormality is present in
the steering, check the operation of the work equipment also.

WA500-6 40-723 ➁
TROUBLESHOOTING H-11

H-11
Steering Turning Response is Poor (Joystick Steering, if Equipped)
Ask the operator about the following: Cause
• Did the problem suddenly start?

Hydraulic cylinder
Joystick steering
Steering pump

solenoid valve
→ Breakage of related equipment

Steering valve
Charge valve

Rotary valve
• Did the machine cause any abnormal noise at the time and where?
• Did the problem gradually appear?
→ Wear of related parts, defective seal

Checks before troubleshooting

• Is oil level in hydraulic tank correct? Is the type of oil correct? a b c d e f g h i j k l m n

Defect in steering cylinder (defective piston seal)

Clogging or air intake on pump suction side

Defective joystick steering solenoid valve

Defective actuation of demand spool

Defective actuation of steering spool

Defective accumulator charge valve
Defective steering pump servo

Defective safety-suction valve

Defective main relief valve
Defective steering pump
Defective brake pump

Defective rotary valve

Clogged line filter
PTO is defective

Remedy Δ Δ Δ Δ Δ C Δ Δ Δ Δ Δ
No. Δ x x
Diagnosis x x x x x x x x x x x
Turning response of steering wheel is poor in both directions (left and
1 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
right).
2 Turning response of steering wheel is poor in one direction (left or right). ❍
3 Steering wheel is heavy in both directions (left and right). ❍ ❍ ❍
4 Work equipment moves. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
5 Work equipment does not move. ❍ ❍ ❍ ❍
6 Abnormal noise comes from around PTO. ❍
7 Abnormal noise comes from around hydraulic tank. ❍ ❍
Oil pressure is low or there is no pressure in
8 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
When steering relief both directions (left and right).
pressure is measured Oil pressure is low or there is no pressure in
9 ❍
one direction (left or right).
When joystick steering solenoid valve output pressure is measured, oil
10 ❍ ❍ ❍ ❍ ❍ ❍ ❍
pressure is low.
11 When steering pump servo assembly is replaced, oil pressure is normal. ❍

★ There is a close connection between the steering circuit and the work equipment circuit. If any abnormality is present in
the steering, check the operation of the work equipment also.

40-724 ➁ WA500-6
TROUBLESHOOTING H-12

H-12
Steering is Heavy
Check for abnormality Cause
• Is the steering difficult to turn?

Hydraulic pump

Steering valve
Charge valve
→ See H-8 or H-9.

Stop valve
Orbitrol

Others
• Measure the operating effort and turning speed. Check the Standard Value table in Section 20 to
see if the values are abnormal.

Ask the operator about the following: a b c d e f

• Did the problem suddenly start?

Defective actuation of steering wheel or steering shaft

→ Breakage of related equipment
• Was there previously any symptom that could lead to heavy steering?
→ Wear of related equipment, defective seal

Checks before troubleshooting

• Is oil level in hydraulic tank correct? Is the type of oil correct?

Defective actuation of steering spool

Defective accumulator charge valve
• Is the tire inflation pressure correct?

Defective brake pump

Defective stop valve

Defective Orbitrol
Remedy Δ Δ Δ Δ Δ Δ
No.
Diagnosis x x x x x x
1 Steering is heavy when turned in both directions (left and right). ❍ ❍ ❍ ❍ ❍
2 Steering wheel is heavy in one direction (left or right). ❍
3 Steering is heavy even when joint between steering shaft and Orbitrol is disconnected. ❍
Oil pressure is low or there is no pressure in both directions (left and
4 When steering relief right). ❍ ❍ ❍ ❍
pressure is measured
5 Oil pressure is low or there is no pressure in one direction (left or right). ❍
6 When Orbitrol output pressure is measured, oil pressure is low. ❍ ❍ ❍ ❍
7 When Orbitrol basic Oil pressure is low. ❍ ❍
8 pressure is measured There is no oil pressure. ❍

WA500-6 40-725 ➁
TROUBLESHOOTING H-13

H-13
When Machine Turns, It Shakes or Jerks
Check for abnormality Cause
• Is the steering difficult to turn?

Hydraulic pump

Steering valve
Charge valve
→ See H-8.

Stop valve

Cylinder
Orbitrol
• Is there any abnormal noise from around the steering equipment?

Checks before troubleshooting

• Is the steering wheel play correct?
• Is there any abnormality in the connection between the steering shaft and the a b c d e f g h i
Orbitrol?

Defect in steering cylinder (defective piston seal)

• Is the tire inflation pressure correct?

Defective actuation of demand spool

Defective actuation of steering spool

Defective accumulator charge valve

Defective safety-suction valve

Defective main relief valve
Defective brake pump

Defective stop valve

Defective Orbitrol
Remedy Δ Δ Δ Δ Δ Δ Δ Δ
No. E
Diagnosis x x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right). ❍ ❍ ❍ ❍ ❍ ❍ ❍
2 When machine turns, it shakes or jerks in one direction (left or right). ❍ ❍
3 During operations or when traveling (steering is neutral), the machine shakes or jerks. ❍ ❍ ❍
Machine jerks or there is excessive shock when steering is operated to end of its
4 ❍
stroke.
5 Work equipment also jerks. ❍ ❍
6 When steering relief Oil pressure is unstable in both directions (left and right). ❍ ❍ Q ❍ ❍ ❍ ❍
7 pressure is measured Oil pressure is unstable in one direction (left or right). ❍ ❍
8 When Orbitrol output Oil pressure is unstable in both directions (left and right). ❍ ❍ ❍
9 pressure is measured Oil pressure is unstable in one direction (left or right). ❍
10 When Orbitrol basic pressure is measured, oil pressure is unstable. ❍ ❍

40-726 ➁ WA500-6
TROUBLESHOOTING H-14

H-14
When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped)
Check for abnormality Cause
• Is the steering difficult to turn?

Joystick steering solenoid valve

→ See H-9.
• Is there any abnormal noise from around the steering equipment?

Hydraulic pump

Steering valve
Charge valve

Rotary valve
Checks before troubleshooting

Cylinder
• Has the machine monitor displayed any failure code?
→ See Troubleshooting by Failure Code in this section.
• Is the steering play proper?
• Is there any abnormality in the connection between the steering shaft and the
Orbitrol?
• Is the tire inflation pressure correct?
a b c d e f g h i

Defective operation in joystick steering solenoid valve

Defect in steering cylinder (defective piston seal)

Defective actuation of demand spool

Defective actuation of steering spool

Defective accumulator charge valve

Defective actuation of rotary valve

Defective safety-suction valve

Defective main relief valve
Defective brake pump

Remedy Δ Δ Δ Δ Δ Δ Δ
No. x Δ
Diagnosis x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right). ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
2 When machine turns, it shakes or jerks in one direction (left or right). ❍
3 During operations or when traveling (steering is neutral), the machine shakes or jerks. ❍ ❍ ❍
4 Work equipment also jerks. ❍ ❍
5 When steering relief Oil pressure is unstable in both directions (left and right). ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
6 pressure is measured Oil pressure is unstable in one direction (left or right). ❍
7 When Orbitrol output Oil pressure is unstable in both directions (left and right). ❍ ❍ ❍ ❍
8 pressure is measured Oil pressure is unstable in one direction (left or right).
9 When Orbitrol basic pressure is measured, oil pressure is unstable. ❍ ❍

WA500-6 40-727 ➁
TROUBLESHOOTING H-15

H-15
Wheel Brake Does Not Work or Does Not Work Well
Check for abnormality Cause
• Test the effectiveness of the brake. Refer to BRAKE SYSTEM:

Slack adjuster
Charge valve

Wheel brake
Accumulator
Brake pump

Brake valve
Measuring Brake Performance in the Testing and Adjusting section to

Others
check whether the abnormality actually occurs or is the operator's
opinion.

Ask the operator about the following:

• Has the brake suddenly not worked? a b c d e f g h i j k l m
→ Breakage of related equipment

Gas leakage from accumulator, defective seal of piston

• Did any abnormal noise occur at the time and where?
• Has the brake gradually not worked?
→ Wear of related equipment, defective seal

Checks before troubleshooting

• Is oil level and type of oil in hydraulic tank correct?

Defective accumulator charge valve

Defective operation of brake piston

• Is the play of brake pedal appropriate?
• Has oil leaked from brake piping? Is tube deformed?

Brake piston seal is defective

• Are the tire air pressure and the tread state appropriate?

Internal breakage of brake

Air intake on suction side

Defective slack adjuster

Defective brake pump

Defective brake valve

Wear of brake disc

Air in brake circuit
Improper axle oil
PTO is defective

Remedy Δ Δ Δ Δ Δ Δ Δ Δ Δ
No. Δ x Δ x
Diagnosis x x x x x x x x x
1 When the brake pedal is pressed, only a little resistance is felt. ❍ ❍ ❍ ❍ ❍ ❍ ❍
2 When the brake pedal is pressed, a heavy resistance is felt. ❍
3 To get the specified braking force, extremely strong leg power is required. ❍ ❍ ❍ ❍
4 When the brake works, an abnormal noise occurs from the brake. ❍ ❍ ❍
5 Work equipment and steering wheel does not move. ❍ ❍
6 Work equipment and steering wheel move slowly. ❍ ❍ ❍
7 Abnormal noise comes from around PTO. ❍
8 Abnormal noise comes from around hydraulic tank or brake pump. ❍ ❍
A lot of metal powders are mixed in the oil when it is drained from the axle
9 ❍
case.
When the accumulator charge pressure is measured, the oil pressure is
10 ❍ ❍ ❍
low.
11 The brake does not work immediately when the engine is stopped. ❍
12 The brake works after some time lag. ❍ ❍
13 When brake pressure is measured, the oil pressure is low. ❍
When brake piston pressure effect is measured, the pressure effect is
14 ❍ ❍
large.
15 When wear of brake disc is measured, the amount of wear is large. ❍ ❍
16 Air is discharged when the air is bled from the brake system. ❍

40-728 ➁ WA500-6
TROUBLESHOOTING H-16

H-16
Wheel Brake is Not Released or It Drags
Ask the operator about the following: Cause
• Was the brake locked suddenly?

Slack adjuster

Wheel brake
Brake valve
→ Breakage of related equipment
• Did the machine cause any abnormal noise at the time and where?

Checks before troubleshooting

• Has the brake pedal returned completely?
a c d e
• Is the parking brake turned ON?

Defective operation of slack adjuster

Defective operation of brake piston
Seizure of brake disc plate
Defective brake valve
Remedy Δ Δ Δ
No. x
Diagnosis x x x
1 The machine does not travel at all. ❍
2 The machine travels a little. ❍ ❍ ❍
When residual pressure in the brake accumulator circuit is released using only the brake pedal, the
3 ❍
brake is released.
4 When air bleeder at wheel is opened, oil leaks out and the brake is released. ❍
5 When air bleeder is opened, large amount of oil flows out. ❍
6 When wear of brake disc is measured and the brake pedal is released, the piston returns. ❍
7 When wear of brake disc is measured and the brake pedal is released, the piston does not return. ❍ ❍

WA500-6 40-729 ➁
TROUBLESHOOTING H-17

H-17
Parking Brake Does Not Work or Does Not Work Well
Ask the operator about the following: Cause
• Has the brake suddenly not worked?

Parking brake
→ Breakage of related equipment

Solenoid
Valve
• Did the machine cause any abnormal noise at the time and where?
• Has the brake gradually not worked?
→ Wear of related equipment, defective seal
a b c d e
Checks before troubleshooting

Defective parking brake emergency release valve

• Is the parking brake emergency release switch turned ON?
• Has the mechanical release of parking brake been performed?

Defective operation of parking brake piston

Defective parking brake solenoid valve

Defective parking brake spring

Wear of parking brake disc

Remedy Δ Δ
No. x x x
Diagnosis x x
1 The parking brake is not applied even if the engine stops. ❍ ❍ ❍
2 When wear of parking brake disc is checked, the disc thickness is lower than standard value. ❍
With the parking brake switch ON, there is no oil pressure.
3 When the parking brake inlet ❍ ❍
(Normal)
pressure is measured
4 With the parking brake switch ON, there is oil pressure. ❍ ❍ ❍
With the parking brake switch ON, there is no oil pressure.
5 When the parking brake solenoid (Normal) ❍ ❍
valve output pressure is measured
6 With the parking brake switch ON, there is oil pressure. ❍

40-730 ➁ WA500-6
TROUBLESHOOTING H-18

H-18
Parking Brake is Not Released or It Drags
(Includes Emergency Release System)

Check of abnormality Cause

• Is there any abnormality in the power train system?

Parking brake
→ See H-1, H-4, H-5, and H-6 (power train hydraulic system).

Solenoid

Wheel
Valve
a b c d e

Defective operation of wheel brake emergency brake switch

Defective parking brake emergency release valve

Seizure of parking brake disc and plate

Defective parking brake solenoid valve

Defective seal of parking brake piston

Remedy Δ Δ
No. x x
Diagnosis x x
The parking brake is released when the emergency release switch is turned ON.
1 ❍ ❍
(The parking brake switch does not release the brake.)
The parking brake is released when the parking brake is manually released.
2 ❍ ❍ ❍
(The parking brake switch and emergency release switch do not release the brake.)
3 When the parking brake inlet pressure is measured Oil pressure is normal. ❍ ❍
4 (while operating the parking switch) Oil pressure is low. ❍ ❍
5 When the parking brake output pressure is measured Oil pressure is normal. ❍ ❍
6 (while operating the emergency release switch) Oil pressure is low. ❍ ❍
7 When the parking brake solenoid valve output pressure is measured, the oil pressure is low. ❍
When the wheel brake piping oil pressure is measured, the oil pressure is lower than the
8 ❍
emergency brake working pressure (3.6 ±0.49 MPa [522.14 ±71.07 psi]).

★ If any abnormality is present when releasing the parking brake, check the operation of the power train also because the
power train main relief pressure is used as the parking brake release pressure. (The emergency release circuit uses the
wheel brake circuit oil pressure.)

WA500-6 40-731 ➁
TROUBLESHOOTING H-19

H-19
Lift Arm Does Not Rise
Ask the operator about the following: Cause
• Did the bucket stop suddenly?

equipment pump

Work equipment
→ Seizure or breakage of each component

Bypass valve
Tank – Work

Cylinder
• Was there an abnormal sound when the lift arm stopped? From what part?

valve
• Has the speed dropped?
→ Wear of parts and fatigue of springs

Checks before troubleshooting

a b c d e f g h i j
• Is the oil level in the hydraulic tank correct?

Defective operation of lift arm load check valve

Internal breakage of valve body (lift arm spool)
• Is the stroke of the lift arm control lever correct?

Clogging or air intake on pump suction side

• Is the engine speed correct?
• Has the machine monitor displayed any failure code?

Defective operation of main relief valve

Defective work equipment pump servo
→ See Troubleshooting by Failure Code in this section.

Damaged lift arm cylinder piston seal

Defective operation of unload valve
Defective work equipment pump

Defective operation of spool

PTO is defective
Remedy C Δ Δ Δ Δ Δ Δ
No. x x x
Diagnosis Δ x x x x x x
1 Bucket does not move and lift arm does not rise. ❍ ❍ ❍ ❍ ❍
2 Lift arm can raise chassis but does not rise. ❍ ❍
3 Bucket moves but lift arm does not rise. ❍ ❍
4 Lift arm can rise when not loaded but cannot when loaded. ❍ ❍ ❍ ❍ ❍
5 Work equipment pump is making abnormal sounds. ❍ ❍
6 Hydraulic drifts of the lift arm cylinder occur often. ❍ ❍ ❍ ❍
7 When lift arm and bucket are operated simultaneously, lift arm does not rise. ❍
When work equipment pump and servo assembly are replaced, lift arm moves
8 ❍
normally.

40-732 ➁ WA500-6
TROUBLESHOOTING H-20

H-20
Lift Arm is Low or Rising Force is Insufficient
Checks before troubleshooting Cause
• Is the stroke of the lift arm control lever correct?

equipment pump

Work equipment
Tank – Work
• Is the engine speed correct?

Cylinder
valve
Check of abnormality
• The problems with the rising force and rising speed are strongly related to each other.
The rising speed lowers first. Measure the lift arm rising speed while it is loaded.
Check the Standard Value table in Section 20 to see if the values are correct.
a b c d e f g h i

Defective operation and defective adjustment of main relief valve

Internal wear or breakage of valve body (lift arm spool)

Defective operation of lift arm load check valve
Clogging or air intake on pump suction side

Defective operation of ECSS charge valve

Defective work equipment pump servo

Damaged lift arm cylinder piston seal

Defective operation of unload valve
Defective work equipment pump

A C
Remedy C Δ Δ Δ Δ
No. Δ Δ x x
Diagnosis Δ x x x x
x x
1 Tilting force and speed of bucket are abnormal and rising speed of lift arm is low. ❍ ❍ ❍ ❍ ❍ ❍
2 Tilting force and speed of bucket are normal and rising speed of lift arm is low. ❍ ❍ ❍
3 After oil temperature rises, rising speed lowers more in Step 1. ❍
4 Work equipment pump is making abnormal sounds. ❍ ❍
5 Hydraulic drift of the cylinder is large. ❍ ❍ ❍
6 Relief oil pressure of work equipment relief valve is low. ❍ ❍ ❍ ❍ ❍
7 When work equipment pump and servo assembly are replaced, lift arm moves normally. ❍

WA500-6 40-733 ➁
TROUBLESHOOTING H-21

H-21
When Rising, Lift Arm Starts to Move Slowly at a Specific Height
Check before troubleshooting

• Deformation of appearance of lift arm cylinder

Cause

• Expansion of lift arm cylinder tube or internal damage

★ For other abnormal phenomena during lift arm rise, see H-20: Lift Arm is Low or Rising Force is Insufficient.

H-22
Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)
See H-20: Lift Arm is Low or Rising Force is Insufficient.

Check before troubleshooting

• Is the stroke of the lift arm control lever appropriate?

Cause

• Defective seat of suction valve on the lift arm cylinder head side of work equipment valve
• Oil leak from lift arm cylinder piston seal

H-23
Hydraulic Drifts of the Lift Arm Occur Often
Ask the operator about the following:

• Have hydraulic drifts suddenly started to occur often? → Waste pinched in valve or damage of parts
• Have hydraulic drifts gradually started to occur often? → Wear of parts
Check before troubleshooting

• Is the lift arm spool at the neutral holding position? → The spool detent is defective.
Check for abnormality

• Check the hydraulic drift of the lift arm in the Standard Value table.
Cause

• Oil leakage in lift arm cylinder

• Imperfect fitting of load check valve on bottom side
• Imperfect fitting of lift arm spool

40-734 ➁ WA500-6
TROUBLESHOOTING H-24

H-24
Lift Arm Wobbles During Operation
The bucket and the lift arm move up and down as the topography changes during digging or leveling with the lift arm control
lever in the HOLD position.

Diagnosis and Cause

First check the hydraulic drift and see if the lift arm cylinder can lift the machine.

1. When the hydraulic drift is more than the standard value, see H-23: Hydraulic Drifts of Lift Arm Occur Often.

2. When the lift arm cylinder cannot lift the machine, see H-20: Lift Arm Speed is Low or Rising Force is Insufficient.

3. When the lift arm cylinder starts 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 → The cause is vacuum generated inside the cylinder.
★ Frequent hydraulic drifts → The suction valve on the lift arm cylinder rod side is defective.

WA500-6 40-735 ➁
TROUBLESHOOTING H-25

H-25
Bucket Does Not Tilt Back
Ask the operator about the following: Cause
• Did the bucket stop suddenly?

equipment pump

Work equipment
→ Seizure or breakage of each component

Tank – Work

Cylinder
• Was there an abnormal sound when the bucket stopped? From what part?

valve
• Has the speed dropped?
→ Wear of parts and fatigue of springs

Checks before troubleshooting

a b c d e f g h i j
• Is the oil level in the hydraulic tank correct?

Defective operation of bucket bottom suction valve (Suction safety valve)

• Is the stroke of the bucket control lever correct?

Defective operation of bucket bottom safety valve (Suction safety valve)

• Is the engine speed correct?
• Has the machine monitor displayed any failure code?
→ See Troubleshooting by Failure Code in this section.

Internal breakage of valve body (bucket spool)

Clogging or air intake on pump suction side

Defective operation of main relief valve

Defective work equipment pump servo

Damaged bucket cylinder piston seal

Defective operation of unload valve
Defective work equipment pump
PTO is defective

C
Remedy C Δ Δ Δ Δ Δ Δ
No. Δ x x
Diagnosis Δ x x x x x x
x
1 Lift arm does not move and bucket does not tilt back. ❍ ❍ ❍ ❍ ❍
2 Bucket can raise chassis but does not tilt back. ❍ ❍
3 Lift arm moves but bucket does not tilt back. ❍ ❍
4 Bucket can tilt back when not loaded but cannot when used for digging or scooping. ❍ ❍ ❍ ❍ ❍ ❍
5 Work equipment pump is making abnormal sound. ❍ ❍
6 Hydraulic drift of bucket cylinder is large. ❍ ❍ ❍ ❍
7 When lift arm and bucket are operated simultaneously, bucket does not tilt back. ❍
When work equipment pump and servo assembly is replaced, bucket moves
8 ❍
normally.

40-736 ➁ WA500-6
TROUBLESHOOTING H-26

H-26
Bucket Speed is Low or Tilting-Back Force Is Insufficient
Checks before troubleshooting Cause
• Is the stroke of the bucket control lever correct?

equipment pump

Work equipment
Tank – Work
• Is the engine speed correct?

Cylinder
valve
Check of abnormality
• Check by actual operation that the tilting back force is insufficient.
• Measure the operating speed of the bucket and check it in the Standard Value
table.
a b c e f g h i j k

Defective operation of bucket bottom suction valve (Suction safety valve)

Defective operation of bucket bottom safety valve (Suction safety valve)
Defective operation and defective adjustment of main relief valve

Internal wear or breakage of valve body (bucket spool)

Clogging or air intake on pump suction side

Defective operation of ECSS charge valve

Defective work equipment pump servo

Damaged bucket cylinder piston seal

Defective operation of unload valve
Defective work equipment pump

A C
Remedy C Δ Δ Δ Δ Δ
No. Δ Δ x x
Diagnosis Δ x x x x x
x x
Rising force and speed of lift arm are abnormal and tilting-back force and speed of
1 ❍ ❍ ❍ ❍ ❍ ❍
bucket are low.
Rising force and speed of lift arm are normal and tilting-back force and speed of
2 ❍ ❍ ❍ ❍
bucket are low.
3 After oil temperature rises, tilting back speed lowers more in Step 1. ❍
4 Work equipment pump is making abnormal sounds. ❍ ❍
5 Hydraulic drift of the cylinder is large. ❍ ❍ ❍ ❍
6 Relief oil pressure of relief valve of work equipment valve is low. ❍ ❍ ❍ ❍ ❍ ❍ ❍
When work equipment pump and servo assembly are replaced, bucket moves
7 ❍
normally.

WA500-6 40-737 ➁
TROUBLESHOOTING H-27

H-27
Bucket Starts to Operate Slowly in the Midst of Tilting Back
Check before troubleshooting

• Deformation of appearance of bucket cylinder

Cause

• Expansion of bucket cylinder tube or internal damage

• For other abnormal phenomena during bucket operation, see H-26: Bucket Speed is Low or Tilting-Back Force is
Insufficient.

H-28
Bucket Cylinder Cannot Hold Down the Bucket
See H-26: Bucket Speed is Low or Tilting-Back Force is Insufficient.

Check before troubleshooting

• Is the stroke of the bucket control lever appropriate?

Cause

• Defective seat of suction valve (with suction valve) on the bucket cylinder head side of work equipment valve
• Oil leak from bucket cylinder piston seal

H-29
Hydraulic Drifts of the Bucket Occur Often
Ask the operator about the following:

• Have hydraulic drifts suddenly started to occur often? → Waste pinched in valve or damage of parts
• Have hydraulic drifts gradually started to occur often? → Wear of parts
Check before troubleshooting

• Is the bucket spool at the neutral position? → The spool detent is defective.
Check for abnormality

• Refer to the Standard Value table and check if the hydraulic drift of the bucket occurs often.

Cause

• Oil leak in bucket cylinder

• Improper adhesion of safety valve (with suction valve) on the bottom side
• Improper oil tight of bucket spool

40-738 ➁ WA500-6
TROUBLESHOOTING H-30

H-30
Bucket Wobbles During Travel with Load
(The work equipment valve is set to HOLD.)

Cause

• Defective seal of bucket cylinder piston

• Defective operation of safety valve (with suction valve) on bucket cylinder head side. For other abnormal phenomena,
refer to diagnoses for relevant abnormal phenomena.

H-31
During Operation of Machine, Engine Speed Drops Remarkably or Engine
Stalls
Check before troubleshooting

• Is the working equipment main relief pressure normal?

Cause

• Defective work equipment pump servo

• Defective working equipment pump unit
• Defective working equipment pump servo EPC input voltage
• Defective engine system

H-32
Large Shocks When Work Equipment Starts and Stops
Cause

• Defective operation of control valve spool

• Defective working equipment electric lever system → See Troubleshooting by Failure Code in this section.

H-33
When Work Equipment Circuit is Relieved Singly, Other Work Equipment
Moves
Cause

• Pressure is not released properly from main spool of moving equipment → Replace main spool.

WA500-6 40-739 ➁
TROUBLESHOOTING H-34

H-34
ECSS Does Not Operate; Pitching and Bouncing Occur
Ask the operator about the following: Cause
• Did pitching and bouncing occur suddenly?

Solenoid valve
Accumulator
→ Breakage of related equipment

Controller
Sensor
• Did any abnormal noise occur at the time and where?
• Has pitching and bouncing occurred gradually?
→ Wear of related equipment, defective seal

Checks before troubleshooting a b c d

Defective transmission output shaft speed sensor

• Is the state of ECSS switch correct?

Defective operation of work equipment controller

Gas leakage from accumulator, defective seal
Defective ECSS solenoid valve
Remedy A
No. x x x
Diagnosis x
1 The ECSS actuation speed (5 km/h [3 mph]) largely fluctuates. ❍ ❍
2 The ECSS does not operate under no load. ❍ ❍
When the ECSS operates under load, the lift arm lowers to the maximum distance (30 cm [11.8 in] or
3 ❍
more).
4 The ECSS does not operate at all. ❍ ❍ ❍ ❍

40-740 ➁ WA500-6
 50 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7

Removal and Installation of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
Disassembly and Assembly of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-9
COATING MATERIALS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
SPECIAL TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-14
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
Stripping Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
Wire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-25
Contact Terminal Removal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26
Crimping Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
Insertion Of Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-28
Contact Terminal Removal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-29
Crimping Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
Insertion Of Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31
ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-38
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41
Air Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-43
Cooling Fan and Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
Radiator Guard and Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-53
Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-62

WA500-6 50-1 ➁
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-74
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-82
Engine Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-84
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-86
Engine Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-89
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-95
Torque Converter and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-95
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-103
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-103
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-105
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-106
Input Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-108
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-108
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111
Torque Converter (Lockup Specification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-116
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-116
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-124
Torque Converter (Without Lockup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-134
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-134
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-141
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-149
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-149
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-168
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-189
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-189
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-199
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-212
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-212
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-213
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-214
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-214
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-216
Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-217
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-217
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-218
Differential (with Limited Slip Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-219
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-219
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-225
Differential (without Limited Slip Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-236
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-236

50-2 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-241
Final Drive (Front and Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-250
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-250
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-253
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-258
Brakes (Front and Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-258
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-258
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-260
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-261
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-265
Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-269
Brake Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-270
UNDERCARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-271
Center Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-271
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-271
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-276
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-281
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-281
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-281
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-285
Cooling Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-286
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-286
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-287
Fan Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-288
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-288
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-289
Work Equipment Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-290
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-290
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-291
Steering, Torque Converter Charge, and EPC Pump Assembly . . . . . . . . . . . . . . . . . . 50-292
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-292
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-293
Work Equipment Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-294
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-294
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-297
Work Equipment Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-298
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-298
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-303
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-303
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-305
Lift Arm and Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-308
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-308
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-311
Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-316
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-316
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-317
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-318
Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-318
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-318

WA500-6 50-3 ➁
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-322
Counterweight (Large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-324
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-324
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-325
Counterweight (Small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-326
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-326
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-326
CAB AND ITS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-327
Cab (Separate Cab and Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-327
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-327
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-334
Cab and Frame (Cab-Floor Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-335
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-335
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-340
Cab Glass (Stuck Glass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-341
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-342
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-343
Operator Seat (Upper Seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-351
Storage Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-351
Seat Pad and Backrest Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-351
Mechanical Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-352
Armrests (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-352
Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-353
Backrest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-354
Seat Angle and Seat Depth Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-355
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-357
Slide Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-358
Operator Seat (Suspension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-360
Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-360
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-360
Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-361
Bidden Pull Wires and Handle (Vertical Shock Absorber Adjustment) . . . . . . . . . 50-362
Vertical Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-364
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-366
Height Level Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-368
Compressed-Air Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-372
Bowden Pull Wires and Handle (Height Adjustment) . . . . . . . . . . . . . . . . . . . . . . . 50-375
Pneumatic Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-379
Air Tank for Additional Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-381
Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-383
Suspension System (Upper Part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-385
Suspension System (Lower Part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-387
Swinging Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-389
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-392
Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-392
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-392
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-392
Transmission Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-393
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-393

50-4 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-393
Work Equipment Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-394
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-394
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-394
Air Conditioner Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-395
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-395
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-399

WA500-6 50-5 ➁
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS

MEMORANDUM

50-6 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL

HOW TO READ THIS MANUAL

Removal and Installation of Assemblies

Special Tools

• The special tools necessary for the removal and installation work are indicated by the symbols A1, ••• X1. Their part
numbers, part names, and quantity are described in the Special Tools List table.
• The following information is also described in the table.

1. Necessity
■: Special tools that cannot be substituted and should always be used (installed).
●: Special tools that will be useful, if available, and can be substituted with commercially available tools.

2. Distinction of new and existing special tools

N: Tools newly developed for this model. They have a new part number.
R: Tools with upgraded part numbers. They are remodeled from tools already available for other models.
Blank: Tools already available for other models. They can be used without any modification.

3. Circle mark O in sketch column:

• The sketch of the special tool is presented in Sketches of Special Tools in this section.
• Part No. of special tools starting with 79*T means that these tools are made locally. These tools are not
interchangeable with tools made by Komatsu in Japan, for example, the 79*T-***-**** tools.

Remark
General tools that are necessary for removal or installation are described as [1], [2], etc. Their part names,
part numbers, and quantities are not described.

Removal

• The Removal section contains procedures and

Indicates safety-related precautions
precautions for implementing the work, expertise, and
the amount of oil or coolant to be drained. that must be followed when
implementing the work.
• General tools that are necessary for removal are
indicated by [1], [2], etc. Their part numbers, part names, ★ Technique or precautions for work.
and quantity are not described.
• Various symbols used in the Removal section are Indicates that there are instructions or
[*1]
explained and listed in the table to the right. precautions for installing parts.

Indicates the amount of oil or coolant

to be drained.

Indicates the weight of part or

component.

WA500-6 50-7 ➁
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
Installation

• Except where otherwise instructed, installation of parts is

done in the reverse order of removal. Precautions related to safety in
• Instructions and precautions for installing parts are execution of work.
shown with the [*1] mark in the Installation section,
identifying the step for which the instructions are This mark provides guidance or
★
intended. precautions when doing the procedure.
• General tools necessary for the installation work are
indicated by [1], [2], etc. Their part numbers, part names,
and quantity are not described. Type of coating material.
• Marks shown in the Installation section are listed and
explained in the table to the right.
Tightening torque.
Sketches of Special Tools

• Special tools are illustrated for the convenience of local

manufacture. Quantity of oil or coolant to be added.

50-8 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
Disassembly and Assembly of Assemblies
Special Tools

• The special tools necessary for the disassembly and assembly work are indicated by the symbols A1, ••• X1. Their part
numbers, part names, and quantity are described in the Special Tools List table.
• The following information is also described in the table.

1. Necessity
■: Special tools that cannot be substituted and should always be used (installed).
●: Special tools that will be useful, if available, and can be substituted with commercially available tools.

2. Distinction of new and existing special tools

N: Tools newly developed for this model. They have a new part number.
R: Tools with upgraded part numbers. They are remodeled from tools already available for other models.
Blank: Tools already available for other models. They can be used without any modification.

3. Circle mark O in sketch column:

• The sketch of the special tool is presented in Sketches of Special Tools in this section.
• Part No. of special tools starting with 79*T means that these tools are made locally. These tools are not
interchangeable with tools made by Komatsu in Japan, for example, the 79*T-***-**** tools.

Remark
General tools that are necessary for removal or installation are described as [1], [2], etc. Their part names,
part numbers, and quantities are not described.

Disassembly

• The Disassembly section describes the work procedures,

Indicates safety-related precautions
precautions, and expertise for carrying out disassembly
procedures, and the quantity of the oil and coolant that must be followed when
drained. implementing the work.
• General tools that are necessary for the disassembly ★ Technique or precautions for work.
work are indicated by [1], [2], etc. Their part numbers,
part names, and quantity are not described.
• The meaning of the symbols used in the Disassembly Indicates the quantity of oil or coolant
section are explained and listed in the table to the right. to be drained.

WA500-6 50-9 ➁
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
Assembly

• The Assembly section describes the work procedures,

precautions, and expertise for carrying out assembly Precautions related to safety in
procedures, and the quantity of the oil and coolant execution of work.
added.
• General tools necessary for the assembly work are This mark provides guidance or
★
indicated by [1], [2], etc. Their part numbers, part names, precautions when doing the procedure.
and quantity are not described.
• The meaning of the symbols used in the Assembly
section are listed and explained in the table to the right. Type of coating material.

Sketches of Special Tools

• Special tools are illustrated for the convenience of local Tightening torque.
manufacture.

Quantity of oil or coolant to be added.

50-10 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY COATING MATERIALS LIST

COATING MATERIALS LIST

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

Category Komatsu Code Part Number Qty Container Main Features and Applications
• Used to prevent rubber gaskets,
LT-1A 790-129-9030 150 g Tube rubber cushions, and cork plugs from
coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene,
20 g Polyethylene
LT-1B 790-129-9050 and vinyl chloride), rubber, metal, and
(2 pcs.) container
non-metal parts which require
immediate and strong adhesion.
• Features: Resistance to heat and
Polyethylene
LT-2 09940-00030 50 g chemicals.
container
• Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass,
LT-3 (Set of adhesive Can
Hardener: 500 g and plastics.
and hardener)
Polyethylene
Adhesive

LT-4 790-129-9040 250 g • Used to seal plugs.

container
• Heat-resistant seal used to repair
Holtz MH 705 790-129-9120 75 g Tube
engines.
• Quick-setting adhesive.
Polyethylene • Setting time: Within 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 50 g
container • Used mainly to stick metals, rubbers,
plastics, and woods.
• Quick-setting adhesive.
• Quick-setting type
Aron-alpha Polyethylene (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes).
• Used mainly to stick rubbers, plastics,
and metals.
• Features: Resistance to heat and
Loctite Polyethylene chemicals.
79A-129-9110 50 cc
648-50 container • Used for fitted portions used at high
temperatures.
• Used to stick or seal gaskets and
LG-1 790-129-9010 200 g Tube
packings of power train case, etc.
• Used to seal various threaded
Polyethylene portions, pipe joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows,
and nipples of hydraulic piping.
Gasket sealant

• Features: Silicon-based heat and

cold-resistant sealant.
• Used to seal flange surfaces and
LG-6 790-129-9020 200 g Tube
threaded portions.
• Used to seal oil pan, final drive case,
etc.
• Features: Silicon-based quick-setting
sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.

WA500-6 50-11 ➁
DISASSEMBLY AND ASSEMBLY COATING MATERIALS LIST

Category Komatsu Code Part Number Qty Container Main Features and Applications
• Features: Silicon-based, heat- and
LG-8
cold-resistant, vibration-resistant,
ThreeBond 419-15-18131 100 g Tube
impact-resistant sealant.
1207B
• Used to seal transfer case, etc.
• Used for rough surfaces such as the
circle gear top seal which does not
LG-9
need to be clamped, water resistance
ThreeBond 790-129-9310 200 g Tube
Gasket sealant

of the clearance at the welded area,

1206D
etc.
• Can be coated with paint.
LG-10 • Used as lubricant/sealant when the
ThreeBond 790-129-9320 200 g Tube radiator hoses are inserted.
1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11
gaskets.
ThreeBond 790-129-9330 200 g Tube
• Used for covers of the transmission
1121
case and steering case, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure
Molybdenum

lubricant
disulfide

of press-fitted portions, shrink-fitted

LM-P 09940-00040 200 g Tube portions, and threaded portions.
• Used to lubricate linkages, bearings,
etc.
• Feature: Seizure and scuffing
compound
prevention

prevention compound with metallic

Seizure

LC-G super-fine-grain, etc.

— — Can
NEVER-SEEZ • Used for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A • Feature: Lithium grease with extreme
G0-LI SYG2-160LI Various Various pressure lubrication performance.
*For cold district SYGA-160CNLI • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI (*)
• Used for parts under heavy load.
★ Caution:
• Do not apply grease to rolling
Molybdenum SYG2-400M 400 g x 10 Bellows-type bearings like swing circle
disulfide grease SYG2-400M-A 400 g x 20 container 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,
Hyper White SYG2-400T-A
400 g Bellows-type and water resistance higher than
Grease G2-T, SYG2-16CNT
container molybdenum disulfide grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since it
*For cold district SYG0-16CNT (*)
is white in color.
Biogrease
SYG2-400B • Since this grease is decomposed by
G2-B, G2-BT (*) 400 g Bellows-type
SYGA-16CNB natural bacteria in a short period, it
*For use at high container
SYG2-400BT (*) has less effects on microorganisms,
temperature and 16 kg Can
SYGA-16CNBT (*) animals, and plants.
under high load

50-12 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY COATING MATERIALS LIST

Category Komatsu Code Part Number Qty Container Main Features and Applications
• Feature: Silicone grease with wide-
using temperature range, high
resistance to thermal-oxidative
G2-S
degradation, and performance to
ThreeBond — 200 g Tube
prevent deterioration of rubber and
1855
plastic parts.
• Used for oil seals of the transmission,
Grease

etc.
• Feature: Urea (organic system)
grease with heat resistance and long
life. Enclosed type.
G2-U-S
427-12-11871 2 kg Can • Used for rubber, bearing, and oil seal
ENS grease
in damper.
★ Caution: Do not mix with lithium
grease.

Category Komatsu Code Part Number Qty Container Main Features and Applications
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: Four months after date of
container
580 SUPER manufacture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: Four months after date of
PRIMER 580 container
manufacture)
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: Four months after date of
435-95
manufacture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard
GLASS
22M-54-27240 150 ml Can polycarbonate-coated surface.
PRIMER
(Using limit: Four months after date of
435-41
manufacture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: Four months after date of
container
GP-402 manufacture)
Adhesive for cab glass

SUNSTAR • Used as adhesive for glass. “S” is used for

PENGUINE high-temperature season and “W” for low-
Polyethylene
SEAL 580 417-926-3910 320 ml temperature season.
Adhesive

container
SUPER “S” or (Using limit: Four months after date of
“W” manufacture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: Six months after date of
SUPER 560 container) manufacture)
Caulking material

SUNSTAR • Used to seal joints of glass parts.

Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: Four months after date of
container
SEAL No. 2505 manufacture)

WA500-6 50-13 ➁
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST

SPECIAL TOOLS LIST

★ Tools with part number 79*T cannot be supplied; these items are manufactured locally.
★ Necessity:
■ Cannot be substituted; should always be installed (used).
● Extremely useful if available; can be substituted with commercially available tools.
★ New/Remodel:
N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: Tools already available for other models; can be used without any modification.
★ Tools marked ❍ in the Sketch column are tools for which sketches are provided in Sketches of Special Tools in this
section.

New/Remodel
Necessity

Sketch
Qty
Work item Symbol Part No. Part Name Nature of Work, Remarks

795-630-5500 Standard puller ■ 1

Removal of fuel supply
1 01010-81090 • Bolt ■ 2
pump
01643-31032 • Washer ■ 2
Angle tightening of
2 790-331-1110 Wrench ■ 1
head bolt
3 795-931-1100 Seal puller ■ 1 Removal of oil seal
795T-521-1111 Push tool ■ 1 N ❍
4 01050-31655 Bolt ■ 3 Press fitting of engine front seal
01050-31635 Bolt ■ 3
795T-521-1150 Push tool ■ 1 N ❍ Press fitting of engine front seal
A 5
01050-31635 Bolt ■ 3 (sleeve type)
Removal and installation 795T-421-1260 Push tool ■ 1 N ❍
Press fitting of engine rear seal
of engine front seal and 6 01050-31640 Bolt ■ 4
(standard type)
engine rear seal 01643-31645 Washer ■ 8
795T-421-1240 Push tool ■ 1 N ❍
7 01050-31645 Bolt ■ 4
01643-31645 Washer ■ 4 Press fitting of engine rear seal
795T-421-1231 Push tool ■ 1 N ❍ (sleeve type)
8 01050-31645 Bolt ■ 4
01643-31645 Washer ■ 8
Disassembly and 1 795-101-2102 Puller (294 kN {30 ton}) ■ 1 Removal of turbine boss
assembly of torque F Removal and installation of
converter assembly 2 793-613-1210 Wrench ■ 1
pump nut
Operation check of clutch
1 799-301-1500 Oil leak tester ■ 1
piston
796-514-2000 Remover ■ 1 Removal of No. 3 planetary
Disassembly and 2
796-515-2140 Adapter 1 gear shaft
assembly of transmission G
790-201-1702 Push tool kit 1
790-201-1741 • Push tool 1 Press fitting of No. 3 and No. 4
3
790-101-5021 • Grip 1 carrier bushings
01010-50816 • Bolt ■ 1

50-14 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST

New/Remodel
Necessity

Sketch
Qty
Work item Symbol Part No. Part Name Nature of Work, Remarks

790-101-2501 Push puller ■ 1

790-101-2610 • Leg 1
790-101-2660 • Adapter 1
790-101-2510 • Block 1
4 Removal of output shaft
790-101-2560 • Nut 1
01643-32060 Washer ■ 2
790-101-2102 Puller (294 kN {30 ton}) ■ 2
790-101-1102 Pump ■ 6
790-101-2501 Push puller ■ 1
790-101-2540 • Washer 1
790-101-2620 • Leg 2
Disassembly and 790-101-2510 • Block 1
assembly of transfer G 790-101-2660 • Adapter 2
assembly
790-101-2560 • Nut 2
Press fitting of output shaft
5 791-112-1180 • Nut 1
bearing
791-520-4140 Screw ■ 1
793T-615-1630 Adapter ■ 1 N ❍
793T-615-1640 Push tool ■ 1 N ❍
01643-32060 Washer ■ 2
790-101-2102 Puller (294 kN {30 ton}) ■ 1
790-101-1102 Pump ■ 1
Pre-load adjustment on
6 793-615-1140 Spline wrench ■ 1
intermediate shaft bearing
Pre-load adjustment on input
7 796-720-3800 Wrench assembly ■ 1
shaft bearing
Disassembly and 790-501-5000 Repair stand ■ 1
Removal and installation of
assembly of differential 1 790-901-4110 Bracket ■ 1
differential
assembly 793T-622-2120 Plate ■ 1 N ❍
792T-422-1220 Plate ■ 1 N ❍
Press fitting of outer drum oil
2 790-101-5421 Grip ■ 1
seal
01010-81240 Bolt ■ 1
Removal and installation of
wheel hub and brake,
3 793T-622-2210 Fixture ■ 3 N Q
disassembly and assembly of
brake
H 792-520-2110 Installer ■ 1
Disassembly and
assembly of final drive 791-580-1600 Push tool ■ 1
assembly 791-580-1610 • Plate 1
791-580-1620 • Arm 4
791-580-1640 • Plate 1 Installation of floating seal
4
791-580-1650 • Plate 4 (gear side)
01010-51425 • Bolt 8
01541-21670 • Nut 4
01640-21426 • Washer 4
792-530-1630 Stud ■ 4

WA500-6 50-15 ➁
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST

New/Remodel
Necessity

Sketch
Qty
Work item Symbol Part No. Part Name Nature of Work, Remarks

792-520-2110 Installer ■ 1
793T-622-2310 Plate ■ 1 N ❍
793T-622-2320 Arm ■ 4 N ❍
Disassembly and 791-580-1640 Plate ■ 1 Installation of floating seal
assembly of brake H 5
assembly 792-530-1630 Stud ■ 4 (hub side)
01010-61425 Bolt ■ 4
01640-21426 Washer ■ 4
01580-01613 Nut ■ 4
1 793-520-2630 Bar ■ 2
2 793-520-2640 Push puller ■ 1
3 793-520-2550 Guide ■ 1
Press fitting of upper 4 790-101-2300 Push puller ■ 1
1
hinge pin 5 790-101-2310 • Block 1
6 02215-11622 • Nut 2
7 790-101-2102 Puller (294 kN {30 ton}) ■ 1
K
8 790-101-1102 Pump ■ 1
1 793-520-2530 Guide ■ 1
2 01010-31480 Bolt ■ 2
Press fitting of lower 3 01643-31445 Washer ■ 2
2
hinge pin 4 793-520-2640 Push puller ■ 1
5 790-101-2102 Puller (294 kN {30 ton}) ■ 1
6 790-101-1102 Pump ■ 1
1 790-502-1003 Repair stand ■ 1
1
2 790-101-1102 Pump 1
790-102-4300 Wrench assembly ■ 1 Removal and installation of
2
790-102-4310 Pin ■ 2 piston
Socket (Width across Removal and installation of
3 790-302-1290 ■ 1
flats: 60 mm) steering cylinder nut
1 790-201-1500 Push tool kit ■ 1 Press fitting of dust seal
2 790-201-1590 • Plate ■ 1 Steering cylinder
4 3 790-201-1680 • Plate 1 Bucket cylinder
4 790-101-5021 • Grip 1
All cylinders
Disassembly and 5 01010-50816 • Bolt 1
assembly of hydraulic U 1 790-201-1702 Push tool kit ■ 1 Press fitting of roll bushing
cylinder assembly 2 790-201-1781 • Push tool 1 Steering cylinder
5 3 790-201-1871 • Push tool 1 Bucket cylinder
4 790-101-5021 • Grip 1
All cylinders
5 01010-50816 • Bolt 1
1 790-720-1000 Expander ■ 1 Expansion of piston ring
2 796-720-1660 Ring ■ 1
Steering cylinder
3 07281-01159 Clamp ■ 1
6 4 796-720-1680 Ring ■ 1
Lift arm cylinder
5 07281-01589 Clamp ■ 1
6 796-720-1690 Ring ■ 1
Bucket cylinder
7 07281-01919 Clamp ■ 1

50-16 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST

New/Remodel
Necessity

Sketch
Qty
Work item Symbol Part No. Part Name Nature of Work, Remarks

1 793-498-1120 Clear plate ■ 2

2 2 793-498-1130 Plate ■ 2 Installation of operator's cab
Operator's cab glass X
3 793-498-1110 Magnet ■ 2 glass
3 793-498-1210 Lifter (Suction cup) ■ 2

WA500-6 50-17 ➁
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS

Remark
Komatsu does not accept any responsibility for special tools manufactured according to these sketches.

A4 Push Tool

A5 Push Tool

50-18 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Remark
Komatsu does not accept any responsibility for special tools manufactured according to these sketches.

A6 Push Tool

A7 Push Tool

WA500-6 50-19 ➁
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Remark
Komatsu does not accept any responsibility for special tools manufactured according to these sketches.

A8 Push Tool

G5 Adapter

50-20 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Remark
Komatsu does not accept any responsibility for special tools manufactured according to these sketches.

G5 Push Tool

H1 Plate

WA500-6 50-21 ➁
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Remark
Komatsu does not accept any responsibility for special tools manufactured according to these sketches.

H2 Plate

H3 Fixture

50-22 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Remark
Komatsu does not accept any responsibility for special tools manufactured according to these sketches.

H5 Plate

H5 Arm

WA500-6 50-23 ➁
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES

CONNECTOR REPAIR PROCEDURES

These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.

Stripping Insulation
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the table below.

Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)

0460 - 202 - 20141 20 AWG 3.96 - 5.53 (0.156 - 0.218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (0.156 - 0.218)

0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)

0460 - 215 - 16141 14 AWG 6.35 - 7.92 (0.250 - 0.312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (0.250 - 0.312)

0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (0.222 - 0.284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (0.222 - 0.284)

0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (0.430 - 0.492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (0.430 - 0.492)

0460 - 204 - 0490 6 AWG 10.92 - 12.47 (0.430 - 0.492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (0.430 - 0.492)

Using wire insulation strippers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed
in the "Strip Length" above.

50-24 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES

Wire Inspection
After stripping insulation from wire, inspect wire strands for:

• Corrosion, straightness and uniformity

• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.

WA500-6 50-25 ➁
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Contact Terminal Removal (HD30 Type)

1. Obtain the correct removal tool according to the wire size used in
the connector.

2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.

Remark
Using a removal tool that is too large or too small will
hinder wire removal and may damage the connector or
removal tool. Always use the correct removal tool size
for the wire gauge you are servicing.

3. In a straight line, carefully slide the removal tool along the wire
and into the grommet until a contact resistance is felt.

Remark
Do not pull on the wire or twist the tool when inserting
removal tool into the grommet. Damage to the tool or
connector may result.

4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.

5. If contact terminal-wire will not come out, remove tool and

reinsert removal tool again.

50-26 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Crimping Contact Terminal (HD30 Type)
1. After insulation has been stripped from the wire and contact
terminal is ready for crimping, raise selector knob on Crimp Tool
#HDT48-00 and rotate until arrow is aligned with wire size to be
crimped.

2. Loosen locknut, turn adjusting screw in until it stops.

3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.

4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.

5. Close crimp tool handle until crimp cycle is completed.

6. Release the tool handle and remove the crimped contact terminal.

7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.

Remark
The tool must be readjusted for each type/size of con-
tact. Use Crimp tool HDT04-08 for size 8 and 4 contacts.

WA500-6 50-27 ➁
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Insertion Of Contact Terminal (HD30 Type)
1. Grasp contact terminal approximately 25.2 mm (1 in) behind the
crimped barrel.

2. Hold connector with rear grommet facing you.

3. Insert completed contact terminal straight into connector

grommet until a positive stop is felt.

4. Once contact terminal is in connector, a slight tug will confirm

that the contact terminal is properly locked in place.

5. For unused wire cavities, insert sealing plugs for full

environmental sealing.

50-28 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Contact Terminal Removal (DT Type)
1. Remove the wedge lock using needle nose pliers or a hooked-
shaped wire.

2. Pull the wedge lock straight out and save for reinstallation.

3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.

4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.

WA500-6 50-29 ➁
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Crimping Contact Terminal (DT Type)
1. After insulation has been stripped from the wire and contact
terminal is ready for crimping, raise selector knob on Crimp Tool
#HDT48-00 and rotate until arrow is aligned with wire size to be
crimped.

2. Loosen locknut, turn adjusting screw in until it stops.

3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.

4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.

5. Close crimp tool handle until crimp cycle is completed.

6. Release the tool handle and remove the crimped contact terminal.

7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.

Remark
The tool must be readjusted for each type/size of con-
tact. Use Crimp tool HDT04-08 for size 8 and 4 contacts.

50-30 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Insertion Of Contact Terminal (DT Type)
1. Grasp the crimped contact terminal approximately 25.2 mm (1 in)
behind the crimped barrel.

2. Hold the connector with the rear grommet facing you and insert
the completed wire into the connector.

3. Push the contact terminal straight into the connector until a

"click" is felt. A slight tug will confirm that the contact terminal
is properly locked in place.

4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The
wedge lock will snap into place. Rectangular wedges are not
oriented and may fit either way.

Remark
As the connector receptacle is shown - use the same procedures for a
plug.

WA500-6 50-31 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

ENGINE AND COOLING SYSTEM

Engine

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until
the coolant cools down then drain the coolant.

Removal

1. Drain the coolant.

Coolant: Approximately 90 l (24 gal)

2. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

3. Remove the engine hood. For details, see Engine and Cooling
System: Engine Hood in this section.

4. Set jack [1] under the transmission.

5. Remove two breather tube support U-bolts (1).

6. Disconnect wiring harness clamp (2).

7. Remove bracket (3).

50-32 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
8. Remove cover (4).

9. Remove rear breather tube (5).

10. Remove right and left covers (6).

11. Remove partition plate (7).

12. Loosen the clamp and remove air connector and hose
assembly (8).

13. Loosen the clamp and remove tube (9) between the turbocharger
and air aftercooler. [*1]

14. Loosen hose clamps (10) between the air cleaner and turbocharger
and remove air cleaner band (11) and air cleaner assembly (12).
[*2]

15. Remove air cleaner bracket (13).

WA500-6 50-33 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
16. Disconnect heater hose (14).

17. Remove partition rubber plates (15) and (16).

• Disconnect partition rubber plate (16) and move it to the right.

18. Remove hose clamps (17); disconnect hoses (18); and remove
prefilter assembly (19).

19. Disconnect connector E16 (20).

20. Remove the air compressor belt; remove and move air compressor
assembly (21) outward. [*3]

21. Disconnect fuel supply hose (22).

22. Disconnect hose (23); remove the clamp and fuel return tube (24).
[*4]

50-34 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
23. Disconnect fan drive motor hoses (25).

24. Remove fan drive motor tube clamp (26) and hose clamp (27)
between the torque converter cooler and pump.

25. Remove fan pump tube (28).

26. Disconnect fuel tank breather (29) and remove crossbar (30).

27. Remove cover (31) and disconnect engine drain valve (32).

28. Remove the two clamps and disconnect aeration hose (33).

29. Loosen four hose clamps (34) and remove tube, hose, and block
assembly (35).

WA500-6 50-35 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
30. Disconnect air bleeder hose (36).

31. Loosen clamps (37) and (38); remove water pump tubes (39) and
(40). [*5]

32. Loosen clamp (41); remove engine oil cooler tube (42). [*6]

33. Disconnect heater cable (42A).

34. Disconnect starting motor cable (43).

35. Disconnect wiring harness connectors ER1 (44), ER2 (45), and
ER3 (46).

36. Disconnect wiring harness connectors JE1 (47), JE2 (48),

E11 (49), and E17 (50).

37. Remove the U-bolt and bracket (51).

38. Remove right and left engine front mounting bolts (52). [*7]

39. Remove right and left engine rear mounting bolts (53). [*8]

50-36 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
40. Sling the engine assembly and remove mounting bolt (54). [*9]

41. Lift off engine assembly (55).

• Before lifting off the engine assembly, check that all the
wiring harnesses and pipe clamps are disconnected.

Engine assembly: 1,900 kg (4,189 lb)

WA500-6 50-37 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Hose clamp: 10.5 N•m (92.93 lbf in)

[*2]

Hose clamp: 10.5 N•m (92.93 lbf in)

When installing clamp (10), direct it down.

[*3]

Adjust the air conditioner compressor belt tension. For details, see Belts: Air Conditioner Compressor Belt Tension in the
Testing and Adjusting section.

[*4]

Tube joint bolt: 24.5 – 34.3 N•m (18.07 – 25.30 lbf ft)

[*5], [*6]

Hose clamp: 10.5 N•m (92.93 lbf in)

[*7], [*8]

Mounting bolt: 662 – 829 N•m (488.27 – 611.44 lbf ft)

[*9]

Engine and transmission coupling bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

Refilling with Coolant

• Add coolant through the coolant filler to the specified level.

• Run the engine to circulate the coolant through the system.
• Check the coolant level again.
Refilling with Oil (Hydraulic Tank)

• Add oil through the oil filler to the specified level.

• Run the engine to circulate the oil through the system.
• Check the oil level again.
Bleeding Air

• Bleed air from the brake circuit; see Brake System: Bleeding Air from Brake Circuit in the Testing and Adjusting section.
• Bleed air from the fan drive motor circuit; see Hydraulic Fan: Bleeding Air from Hydraulic Drive Fan Circuit in the
Testing and Adjusting section.

50-38 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Radiator

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until
the coolant cools down then drain the coolant.

Removal

1. Drain the coolant.

Radiator: Approximately 90 l (24 gal)

2. Remove rear top hood (1).

3. Remove rubber cover (2) and covers (3), (4), and (5).

4. Remove the four clamps and aeration hoses (6) and (7).

5. Disconnect hose (8) from the bracket.

6. Remove the two clamps; disconnect hose (9) from the reservoir
tank.

7. Remove the clamp; disconnect hose (10) from the tube.

8. Disconnect air bleeder hose (11).

9. Remove the four clamps; move hose (12) toward the engine.

WA500-6 50-39 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
10. Remove air bleeder hose clamps (13) and right and left partition
plates (14).

11. Remove EGR cover (15).

12. Remove engine outlet tube fixing bracket (16).

13. Remove bracket (17).

14. Loosen four hose clamps (18); remove the tube bolts on the engine
side and tube and hose assembly (19). [*1]

15. Remove eight radiator mounting bolts and 12 bracket mounting

bolts; lift off bracket (20).

Bracket: 30 kg (66.14 lb)

50-40 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
16. Lift off radiator assembly (21) slowly.

Radiator assembly (1 piece): 30 kg (66 lb)

★ Remove the other radiator assembly in the same manner.

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Hose clamp: 10.5 N•m (92.93 lbf in)

WA500-6 50-41 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Air Aftercooler

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove the hood. For details, see Engine and Cooling System:
Engine Hood in this section.

2. Remove four partition plates (1).

3. Loosen clamp (2); remove hose and air intake connector (3). [*1]

4. Loosen clamps (4) and (5); remove pipe (6). [*2]

5. Remove two reservoir tank hose clamps (7).

6. Remove the two bolts; move receiver tank assembly (8) outward.

50-42 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
7. Sling air aftercooler assembly (9); remove its six mounting bolts;
and lift it off.

Air aftercooler assembly: 30 kg (66 lb)

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Hose clamp: 10.5 N•m (92.93 lbf in)

[*2]

Hose clamp: 10.5 N•m (92.93 lbf in)

When installing clamp (4), direct it down.

WA500-6 50-43 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Cooling Fan and Fan Motor

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

2. Remove the two mounting bolts and open grille (1).

3. Remove fan guard (2).

4. Disconnect motor hoses (3), (4), and (5).

5. Remove cover (6).

6. Remove the three wiring harness clamps; disconnect wiring

harness connector G09 (7).

50-44 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
7. Remove the three support mounting bolts; open motor, fan, fan
guard, and support assembly (8). [*1]

8. Remove lock plate (9) and nut (10). [*2]

9. Sling fan (11). Using the puller (1), disconnect and remove the fan
from the motor.

Fan: 40 kg (88 lb)

10. Remove mounting bolt (12); remove fan motor assembly (13).
[*3]

WA500-6 50-45 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Support mounting bolt: 235 – 285 N•m (173.33 – 210.20 lbf ft)

[*2]

Fan mounting nut: 132.3 – 156.8 N•m (97.58 – 115.65 lbf ft)

When setting the bolt holes of the nut lock plate, do not rotate the nut in the loosening direction but rotate it in the tightening
direction.

[*3]

Fan motor assembly mounting bolt (12): 98 – 123 N•m (72.28 – 90.72 lbf ft)

Loosen bracket mounting bolts (14); adjust the clearance between fan (11) and the shroud to more than 5.5 mm (0.22 in) all
around the periphery.

Mounting bolt (14): 245 – 309 N•m (180.70 – 227.91 lbf ft)

Refilling with Oil (Hydraulic Tank)

• Add oil through the oil filler to the specified level.

• Run the engine to circulate the oil through the system.
• Check the oil level again.

Bleeding Air

• Bleed air from the fan drive motor circuit; see Hydraulic Fan: Bleeding Air from Hydraulic Drive Fan Circuit in the
Testing and Adjusting section.

50-46 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Radiator Guard and Cooling Fan

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

2. Remove the hood. For details, see Engine and Cooling System:
Engine Hood in this section.

3. Remove right and left door locks (1).

4. Remove open-close lock (2) of the grille.

5. Lift off grille (3).

Grille: 28 kg (62 lb)

6. Remove fan guard (4).

WA500-6 50-47 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
7. Remove wiring harness connector GR1 (5).

8. Remove wiring harness cover (6).

9. Disconnect wiring harness connector G09 (7); remove the three

clamps.

10. Disconnect fan motor hoses (8), (9), and (10).

11. Remove fan motor hose clamps (11), (12), and (13).
★ The wiring harness clamp is also fixed with hose clamp (11).
• Move the disconnected hoses to the rear of the counterweight.

12. Remove the three mounting bolts of support (14). [*1]

13. Remove reservoir tank bracket (15).

14. Remove eight mounting bolts (16) of the right and left side hood
and guard.

50-48 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
15. Remove the two radiator support mounting bolts (17) from the
front. [*2]

16. Remove the eight radiator guard mounting bolts (18) from the right
and left.

17. While slinging radiator guard and cooling fan motor assembly (19)
slowly, move it toward the rear to remove it.

Radiator guard and cooling fan motor assembly:

320 kg (706 lb)

WA500-6 50-49 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Support mounting bolt: 235 – 285 N•m (173.33 – 210.20 lbf ft)

[*2]

Radiator support mounting bolt: 245 – 309 N•m (180.70 – 227.91 lbf ft)

Refilling with Oil (Hydraulic Tank)

• Add oil through the oil filler to the specified level.

• Run the engine to circulate the oil through the system.
• Check the oil level again.

Bleeding Air

• Bleed air from the fan drive motor circuit; see Hydraulic Fan: Bleeding Air from Hydraulic Drive Fan Circuit in the
Testing and Adjusting section.

50-50 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Fuel Tank

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the fuel.

Fuel tank (when full): 473 l (125 gal)

2. Remove right and left steps (1) and covers (2).

3. Disconnect fuel drain valve (3) from the frame.

4. Disconnect fuel tank breather (4) from the frame.

5. Disconnect the three clamps of radiator drain hose (5).

6. Disconnect wiring harness connector R16 (6).

WA500-6 50-51 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
7. Remove the two bolts; move receiver tank assembly (7) outward.

8. Disconnect fuel return hose (8) of the fuel tank from the tube.

9. Disconnect fuel supply hose (9) of the fuel tank from the tube;
disconnect the two clamps.

10. Disconnect hoses (10) between the fuel tank and water separator
from the water separator; disconnect the clamp.

11. Sling fuel tank assembly (11) with the nylon sling; support its front
bottom with jack [1]; and remove the four mounting bolts. [*1].

12. While adjusting the jack height so that the bottom of fuel tank
assembly (11) is parallel with the ground, lower the crane slowly.
• Check that all the wiring harnesses, pipings, etc. are
disconnected.

Fuel tank assembly (Empty): 230 kg (507 lb)

50-52 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
13. Place fuel tank assembly (11) on a palette truck [2], etc. and pull it
out of the machine.

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Reduce the clearance between the fuel tank and rear frame to below 0.5 mm (0.02 in) with shims.

Fuel tank mounting bolt: 785 – 980 N•m (578.99 – 723 lbf ft)

WA500-6 50-53 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Engine Hood

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove rear hood (1).

2. Lift off front hood, muffler, and precleaner assembly (2).

Front hood, muffler, and precleaner assembly: 70 kg (154 lb)

3. Remove right and left side panels (3).

50-54 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
4. Disconnect air conditioner hose clamp (4).

5. Disconnect six reservoir hose clamps (5).

6. Remove rubber cover (6).

7. Remove partition covers (7), (8), and (9).

8. Remove covers (10) and (11).

9. Remove support (12).

10. Remove covers (13) and (14).

WA500-6 50-55 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
11. Disconnect torque converter cooler air bleeder hose clamps (15).

12. Disconnect reservoir tank bracket (16).

13. Disconnect bracket (17) of the pipe between the turbocharger and
aftercooler.

14. Disconnect dust indicator (18) and block together.

15. Remove right and left intermediate covers (19).

16. Disconnect right and left gas springs (20) and rods (21).

50-56 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
17. Sling right and left side hood and door assemblies (22); remove
their mounting bolts; and lift them off.

Right and left side hood and door assemblies: 80 kg (176 lb)

18. Remove cover and support assembly (23).

Installation
★ Carry out installation in the reverse order of removal.

WA500-6 50-57 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Fuel Supply Pump

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

795-630-5500 Standard puller ■ 1

A 1 01010-81090 • Bolt ■ 2
01643-31032 • Washer ■ 2

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Open the inspection door of the right side hood.

2. Remove the partition plates (1) and (2).

3. Disconnect connector E16 (3).

4. Remove the air conditioner compressor belt (4); disconnect the

wiring harness clamp. [*1]

5. Remove air conditioner compressor assembly (5) and bracket (6)

together and move them outward.

50-58 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
6. Disconnect wiring harness clamps (7) and (8); remove fuel
prefilter (9) and bracket (10) together; and move them outward.

7. Remove fuel tube (11); disconnect fuel tube (12) and fuel main
filter head assembly (13). [*2]

8. Remove engine oil filler bracket (14).

9. Disconnect fuel supply hose (15). [*3]

10. Disconnect clamps (16), (17), (18), (19), and (20); remove oil
tubes (21), (22), (23), and (24). [*4]

11. Remove fuel tubes (25) and (26). [*5]

WA500-6 50-59 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
12. Remove the wiring harness clamp; disconnect connectors
PCV1 (27), PCV2 (28), and G (29).

13. Remove bracket (30).

14. Remove bracket (31) and clamps (32), (33), and (34). [*6]

15. Remove two high-pressure pipes (35). [*7]

16. Remove cover (36).

17. Rotate the crankshaft forward and set intermediate point (a)
between stamps 2/5 TOP and 3/4 TOP on damper (37) to
pointer (38).
• At this time, check that the drive gear forcing tap is set to the
bolt hole at the top of cover (36). (If the drive gear forcing tap
is not set in this manner, rotate the crankshaft one more turn.)
★ At this point, the pump shaft key is at 15° to the right from the
top.

50-60 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
18. Remove nut (37). [*8]
★ Be careful not to drop the removed parts into the case.

19. Install tool A1 and tighten center bolt to remove gear (39).
• Keep tool A1 installed until the gear is installed again.

20. Remove four fuel supply pump mounting bolts (40) and fuel
supply pump assembly (41). [*9]

WA500-6 50-61 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Adjust the air conditioner compressor belt tension. For details, see Belts: Air Conditioner Compressor Belt Tension in the
Testing and Adjusting section.

[*2]

Joint bolt of fuel tubes (11) and (12) (supply pump side): 14.8 – 19.6 N•m (10.92 – 14.46 lbf ft)

Joint bolt of fuel tubes (11) and (12) (Filter side): 24.5 – 34.3 N•m (18.07 – 25.30 lbf ft)

[*3]

Joint bolt of fuel supply hose (15): 14.8 – 19.6 N•m (10.92 – 14.46 lbf ft)

[*4]

Sleeve nut of oil tube (22): 43 – 47 N•m (31.72 – 34.67 lbf ft)

Sleeve nut of oil tube (21): 34.3 – 44.1 N•m (25.30 – 32.53 lbf ft)

[*5]

Joint bolt of fuel tubes (25) and (26): 7.9 – 12.7 N•m (69.92 – 112.40 lbf in)

Mounting bolt of tube clamps (17), (18), and (19): 9.8 ±1.0 N•m (86.74 – 8.85 lbf in)

[*6], [*7]

1. Finger-tighten tube (35) first and then tighten it permanently.

High-pressure pipe sleeve nut (supply pump side): 39.2 – 49.0 N•m (28.91 – 36.14 lbf ft)

High-pressure pipe sleeve nut (common rail side): 39.2 – 58.8 N•m (28.91– 43.37 lbf ft)

50-62 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
2. Finger-tighten tube clamps (32), (33), and (34) first and then tighten them permanently.

Tube clamp mounting bolt: 9.8 ±1.0 N•m (86.74 – 8.85 lbf in)

3. Direct the notch of the scatter prevention cover on the supply pump side toward the block and direct that on the common
rail side down.

[*8], [9]

1. Remove the center screw of tool A1.

2. Leave tool A1 installed to the gear; set the key of fuel supply pump (41) up; and insert the supply pump along the gear
groove.

3. Tighten fuel supply pump assembly mounting bolts (40).

Supply pump mounting bolt: Adhesive (LT-2)

4. Remove tool A1.

5. Tighten the timing gear nut.

Nut: 176 – 196 N•m (129.81 – 144.56 lbf ft)

6. Check that each high-pressure pipe is at least 10 mm (0.39 in) from the wiring harnesses around it.
Bleeding Air

Bleed air from the fuel circuit. For details, see Fuel System: Bleeding Air from Fuel Circuit in the Testing and Adjusting
section.

Checking for Fuel Leakage

Check the fuel circuit for leakage. For details, see Fuel System: Testing Leakage in Fuel Circuit in the Testing and Adjusting
section.

WA500-6 50-63 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Cylinder Head
Special Tool

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

A 2 790-331-1110 Wrench (angle) ● 1

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until
the coolant cools down then drain the coolant.

Removal

1. Drain the coolant.

Coolant: Approximately 90 l (24 gal)

2. Remove the hood. For details, see Engine and Cooling System:
Engine Hood in this section.

3. Remove partition plates (1), (2), (3) and (4).

4. Remove tube (5) between the turbocharger and air aftercooler.

[*1]

5. Remove EGR covers (6), (7), (8), (9), and (10).

50-64 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
6. Loosen hose clamps (11) between the air cleaner and turbocharger;
remove air cleaner fixing bands (12) and air cleaner assembly (13).
[*2]

7. Remove the muffler fixing band and four mounting bolts; lift off
muffler assembly (14).

Muffler assembly: 46 kg (101 lb)

8. Remove cover (15).

9. Remove fuel prefilter assembly (16) and head together and move
them outward.

WA500-6 50-65 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
10. Disconnect supply pump connectors PCV1 (18), PCV2 (19), and
G (20); remove the wiring harness clamp.

11. Disconnect air compressor connector E16 (21); remove the wiring
harness clamp.

12. Disconnect EGR valve connectors SBP (22), BP (23), SEGR (24),
and EGR (25); remove the wiring harness clamp.

13. Disconnect electrical intake air heater wiring harness (26); remove
the wiring harness clamp.

14. Disconnect EGR gas pressure sensor connector (27) and wiring
harness clamp.

15. Disconnect fuel tube (28); remove fuel filter and bracket
assembly (29). [*3]

16. Disconnect two tubes (30); remove corrosion resistor and bracket
assembly (31).

50-66 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
17. Remove oil tubes (32) and oil filter and bracket assembly (33).
• Make match marks on these tubes since their tops, bottoms,
inlets, and outlets are indistinguishable from each other.

18. Disconnect fuel return tube (34). [*4]

19. Remove muffler bracket (35).

20. Remove air cleaner bracket (36).

21. Remove blow-by breather (37).

22. Remove air connector (38) and electrical intake air heater.

23. Remove bracket (39), clamps (40), and EGR tubes (41) and (42).
[*5]

24. Remove clamps (43), (44), (45), (46), and (47) and brackets (48),
(49), (50), (51), and (52).

WA500-6 50-67 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
25. Remove upper bypass valve assembly (53) and the tube together.
[*6]

26. Remove tubes (54) and (55).

27. Remove lower bypass valve assembly (56) and the tube together.
[*7]

28. Remove bypass valve assembly mounting plate (57).

29. Remove blow-by tube (58).

50-68 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
30. Remove oil filter assembly mounting bracket (59).

31. Lift off air intake connector assembly (60) and joint housing
together.

Air intake connector assembly: 35 kg (77 lb)

32. Unplug connectors TIM (61), PIM (62), and TFUEL (63).

33. Remove bracket (64).

34. Remove ten high-pressure pipe clamps (65) and seven

brackets (66). [*8]

WA500-6 50-69 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
35. Remove six high-pressure pipe clamps (67); remove brackets (68).
[*9]

36. Remove spill pipe (69). [*10]

37. Remove six wiring harness clamps (70); unplug six injector
connectors (71) and move them toward the hydraulic tank.
• Insert flat-head screwdriver [3] in shoulder (a).
• While pressing stopper (b), move the screwdriver in
direction (X). Connector (c) is disconnected.
• (d): Fuel injector wiring side

38. Remove four tube clamps (72) and turbocharger lubrication

tube (73). [*11]

50-70 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
39. Sling air intake manifold assembly (74); remove its mounting
bolts; and lift it off. [*12]
★ The two high-pressure pipe brackets are mounted together.

Air intake manifold assembly: 50 kg (110 lb)

40. Unplug connector (75); remove dust indicator hose (76).

41. Remove connector (77) and bracket (78). [*13]

42. Remove stay (79) and bracket (80).

43. Remove bracket (81) and EGR cooler inlet tube (82). [*14]

44. Disconnect turbocharger drain tube (83).

WA500-6 50-71 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
45. Sling exhaust manifold and turbocharger assembly (84); remove
its mounting bolts; and lift it off. [*15]

Exhaust manifold and turbocharger assembly: 65 kg (143 lb)

46. Remove air bleeding tube (85). [*16]

47. Remove the scatter prevention cover and high-pressure pipes (86).
[17]

48. Remove head cover (87). [*18]

50-72 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
49. Remove the three mounting bolts and rocker arm and shaft
assembly (88). [*19]
• Loosen locknut (89) and then loosen adjustment screw (90)
two to three turns so that an excessive force is not applied to
the push rod when the rocker arm is installed.

50. Remove push rods (91). [*20]

51. Remove crossheads (92). [*21]

52. Remove two nuts (93) from the solenoid valve of the fuel injector.
[*22]
• Loosen the nuts alternately.

53. Pull out spring clamp (94).

54. Disconnect clamp (95).

55. Remove the fixing bolt and holder of connector (96); push in the
connector; and remove the injector wiring harness. [*23]

56. Loosen mounting bolt (98) of holder (97). [*24]

57. Insert a small L-bar under the connector of the fuel injector and pry
out fuel injector assembly (99) slowly. [*25]
• Do not grip the solenoid valve at the top of the injector with pliers (or any other tool) to pull off the injector.

58. Remove mounting bolts (100), auxiliary bolts, and cylinder head
assembly (101). [*26]

59. Remove cylinder head gasket. [*27]

WA500-6 50-73 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Tube hose clamp: 10.5 N•m (92.93 lbf in)

When installing the clamp, direct it down.

[*2]

Air cleaner hose clamp: 8.8 ±0.5 N•m (77.89 ±4.43 lbf in)

[*3]

Tube joint bolt: 24.5 – 34.3 N•m (18.07 – 25.30 lbf ft)

[*4]

Tube joint bolt: 24.5 – 34.3 N•m (18.07 – 25.30 lbf ft)

[*5]

Tube joint bolt: 24.5 – 34.3 N•m (18.07 – 25.30 lbf ft)

Tube sleeve nut: 54 – 93 N•m (39.83 – 68.59 lbf ft)

(Centralized housing bracket side)

Tube sleeve nut: 24 – 27 N•m (17.70 – 19.91 lbf ft)

(Front cover side)

[*6], [*7]

EGR valve mounting bolt: 59 – 74 N•m (43.52 – 54.58 lbf ft)

[*8]

Bracket mounting bolt: 9.8 ±1.0 N•m (86.74 ±8.85 lbf in)

High-pressure pipe clamp mounting bolt: 9.8 ±1.0 N•m (86.74 ±8.85 lbf in)

50-74 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
[*9]

High-pressure pipe clamp mounting bolt: 9.8 ±1.0 N•m (86.74 ±8.85 lbf in)

[*10]

Spill pipe joint bolt: 9.8 – 12.7 N•m (86.74 – 112.40 lbf in)

[*11]

Lubrication tube joint bolt: 24.5 – 34.3 N•m (18.07 – 25.30 lbf ft)

[*12]

1. Install the gasket with the UP mark up.

2. Tighten the air intake manifold assembly mounting bolts in the

order of [1] – [24] as shown in this figure.

Air intake manifold mounting bolt:

58.8 – 73.5 N•m (43.37 – 54.21 lbf ft)

[*13]

Connector hose clamp: 8.8 ±0.5 N•m (77.89 ±4.43 lbf in)

[*14]

EGR cooler mounting bolt: 44.1 – 53.9 N•m (32.53 – 39.75 lbf ft)

Bracket mounting bolt: 44.1 – 53.9 Nm (32.53 – 39.75 lbf ft)

[*15]

1. Apply heat-resistant sealant to the fitting parts of the exhaust

manifold (between ports No. 2 and No. 3 and between ports No. 4
and No. 5).

Fitting parts: Heat-resistant sealant (HOLTZ MH705)

2. Tighten the three bolts of [1] – [3] shown in the figure temporarily
in the numeric order and then tighten other bolts [4] – [24]
temporarily in the numeric order.

WA500-6 50-75 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
3. Tighten all bolts [1] – [24] to the specified torque in the numeric order.

Threads of mounting bolt: Anti-seizure compound (LC-G)

Exhaust manifold mounting bolt: 58.8 – 73.5 N•m (43.37 – 54.21 lbf ft)

[*16]

Air bleeding tube joint bolt: 9.8 – 12.7 N•m (86.74 – 112.40 lbf in)

[*17]

1. Before installing the high-pressure pipe, check it for the following

defects. If there are any of these defects, it can cause fuel leakage.
If the high-pressure pipe has defects, replace it.
• Check the taper seal of the connecting part (part (a): part
2 mm (0.08 in) from the end) for visible lengthwise slit (b)
and dent (c).
• Check part (d) (end of the taper seal: part 2 mm (0.08 in) from
the end) for stepped-type wear (fatigue) which you can feel
with your nail.

2. Fit the O-ring to the sleeve of high-pressure pipe (86). While

setting the sleeve to the injector connector, tighten the sleeve nut
temporarily. Tighten the sleeve nut on the common rail side
temporarily also.

O-ring: Engine oil (EO30)

3. Tighten the high-pressure pipe sleeve nut permanently with a spanner-type torque wrench.

Sleeve nut: 39.2 – 49 N•m (28.91 – 36.14 lbf ft)

4. Check that the O-ring is not projected from the sleeve.

5. Install the scatter prevention cover on the injector side with the notch down and that on the common rail side with the
notch directed toward the cylinder block.

[*18]

Head cover mounting bolt: 29.4 – 34.3 N•m (21.68 – 25.30 lbf ft)

Tighten the bolts temporarily; these bolts are also used to fix the wiring harness clamp.

50-76 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
[*19]

• Before tightening the mounting bolts, check that the adjustment screw ball is fitted in the push rod socket.

Rocker arm and shaft assembly mounting bolt: 93 – 103 N•m (68.59 – 75.97 lbf ft)

• For adjustment of the valve clearance, see Engine Components: Adjusting Valve Clearance in the Testing and Adjusting
section.

[*20]

Check that the push rod is in the cam follower.

[*21]

Adjust the crosshead according to the following procedure.

1. Loosen the locknut and return the adjustment screw.

2. While holding the crosshead top lightly, tighten the adjustment screw.

3. After the adjustment screw touches the valve stem, tighten it 20° more.

4. Tighten the locknut.

Locknut: 58.7 ±5.9 N•m (43.29 ±4.35 lbf ft)

[*22]

1. Take up the slack of the wiring harness and press it against the injector.

2. Tighten the nuts alternately.

Wiring harness terminal nut: 2.0 ±0.2 N•m (17.70 ±1.77 lbf in)

[*23]

Since the injector wiring harness fitted with the O-ring is difficult to
insert from inside, install it according to the following procedure.

1. Remove O-ring (102) from connector (96) and pass the wiring
harness out from inside of the cylinder head and then fit the O-
ring.

O-ring: Engine oil (EO30)

2. Install holder (103) to connector (96) and push the connector into
the position where the O-ring is fitted.

3. Fix the holder with mounting bolt (104).

WA500-6 50-77 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
[*24], [*25]

Install the injector assembly according to the following procedure.

1. Check that there is no dirt in the injector sleeve.

2. Install gasket (105) and O-ring (106) to fuel injector (99).

O-ring: Engine oil (EO30)

3. Insert holder (97) in the fuel injector and insert the injector
connector, directing it toward the high-pressure pipe insertion
hole.

4. Install the spherical washer to bolt (98) and tighten holder (97)
temporarily.

Spherical washer: Engine oil (EO30)

5. Insert high-pressure pipe sleeve (107) through the high-pressure

pipe insertion part, setting it to injector connector (108) and tighten
it temporarily.
• Tighten the sleeve nut on the common rail side also and be
careful that the high-pressure pipe does not slant.

6. Tighten holder (98) permanently.

• While pulling the high-pressure pipe in the opposite direction
to the injector, tighten the bolt.

Holder mounting bolt: 58.8 – 73.5 N•m (43.37 – 54.21 lbf ft)

• After tightening the holder, remove the high-pressure pipe.

[*26]

1. Check the cylinder head mounting bolts for the following items. If
they are out of the standard, do not use them but replace them.
Number of tightening times must be five or less (number of punch
marks denoting the number of tightening times must be five or
less).
Usable limit length of bolt stem (e):
Short bolt: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170.8 mm (6.72 in)
Long bolt: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205.8 mm (8.10 in)

Cylinder head mounting bolt: Molybdenum disulfide grease

(LM-P)

50-78 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
2. Tighten the mounting bolts in the order of 1 – 6 shown in the
figure.
1st time: . . . . . . . . . . . . . . . . . . . 137 – 157 N•m (101.05 – 115.80 lbf ft)
2nd time: . . . . . . . . . . . . . . . . . . 284 – 294 N•m (209.47 – 216.84 lbf ft)
3rd time: . . . . . . . . . . . . Using tool A2, tighten the bolts by 90° (+30°/0).

When not using tool A2, make marks (a) and (b) on each bolt and
cylinder head with paint, and then tighten the bolts by 90° (+30°/0).

3. After tightening bolts 1 – 6, tighten bolt 7.

Bolt 7: . . . . . . . . . . . . . . . . . . . . . . . . 66.6 ±7.4 N•m (49.12 ±5.46 lbf ft)

[*27]

• Check that there is no dirt or foreign matter on the cylinder head

mounting face and in the cylinder, and then set the gasket to the
cylinder head.
• When fitting the gasket, check that the grommets are fitted
correctly.
Refilling with Coolant

• Add coolant to the specified level.

• Run the engine to circulate the coolant through the system.
• Check the coolant level again.

Bleeding Air

• Bleed air from the fuel system. For details, see Fuel System: Bleeding Air from Fuel Circuit in the Testing and Adjusting
section.
• Before starting the engine, check that the wiring harnesses are at least 10 mm (0.39 in) from each high-pressure pipe.

WA500-6 50-79 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Fuel Injector
Removal
WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

1. Remove the hood. For details, see Engine and Cooling System:
Engine Hood in this section.

2. Remove the muffler fixing band and four mounting bolts; lift off
muffler assembly (1).

Muffler assembly: 50 kg (110 lb)

3. Loosen hose clamps (2) between the air cleaner and turbocharger;
remove the air cleaner fixing band and air cleaner assembly (3).
[*1]

4. Remove air cleaner bracket (4) and muffler bracket (5).

5. Remove the EGR gas pressure sensor tube. For details, see Step 26
in the Removal procedure for the cylinder head (Engine and
Cooling System: Cylinder Head: Removal in this section).
★ Perform this only for the removal and installation of the No. 1
fuel injector assembly.

50-80 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
6. Remove the wiring harness clamp and unplug connector (10).
Unplug the injector connector according to the following
procedure.

A. Apply flat-head screwdriver [1] to the shoulder (part (a)).

B. While pressing stopper (1a), move flat-head screwdriver [1] in

direction (X) to unplug the connector.

7. Remove the high-pressure pipe clamp and scatter prevention

cover; pull out high-pressure pipe sleeve (11). [*2]

8. Remove cylinder head cover (12). [*3]

9. Remove the three mounting bolts and rocker arm and shaft
assembly (13). [*4]
• Loosen the locknut and then loosen the adjustment screw two
to three turns so that an excessive force is not applied to the
push rod when the rocker arm is installed.

10. Remove two nuts (14) from the solenoid valve of the fuel injector.
[*5]
• Loosen nuts (14) alternately.

11. Remove wiring harness clamp (15).

12. Remove the mounting bolts of holder (16) and then remove fuel
injector (17) and holder (16) together. [*6]
• Insert a small L-bar under the connector of the fuel injector
and pry out the fuel injector assembly slowly.
• Do not grip the solenoid valve at the top of the injector with
pliers (or any other tool) to pull off the injector.

WA500-6 50-81 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Air cleaner hose clamp: 8.8 ±0.5 N•m (77.89 ±4.43 lbf in)

[*2]

Before installing the high-pressure pipe, check it for the following

defects. If there are any of these defects, it can cause fuel leakage. If the
high-pressure pipe has defects, replace it.

• Check the taper seal of the connecting part (part (a): part of 2 mm
(0.08 in) from the end) for visible lengthwise slit (b) and dent (c).
• Check part (d) (end of the taper seal: part at 2 mm (0.08 in) from
the end) for stepped-type wear (fatigue) which you can feel with
your nail.

High-pressure pipe sleeve O-ring: Engine oil (EO30)

High-pressure pipe sleeve nut: 39.2 – 49 N•m (28.91 – 36.14 lbf ft)

High-pressure pipe clamp mounting bolt: 9.8 ±1.0 N•m (86.74 ±8.85 lbf in)

[*3]

Cylinder head cover mounting bolt: 29.4 – 34.3 N•m (21.68 – 25.30 lbf ft)

[*4]

• Before tightening the mounting bolts, check that the adjustment screw ball is fitted in the push rod socket.

Rocker arm mounting bolt: 93 – 103 N•m (68.59 – 75.97 lbf ft)

• For adjustment of the valve clearance, see Engine Components: Adjusting Valve Clearance in the Testing and Adjusting
section.

[*5]

1. Take up the slack of the wiring harness and press it against the injector.

2. Tighten the nuts alternately.

Terminal nut: 2.0 ±0.2 N•m (17.70 ±1.77 lbf in)

50-82 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
[*6]

Check that there is no dirt in the injector sleeve.

Injector sleeve O-ring: Engine oil (EO30)

Injector holder mounting bolt: 58.8 – 73.5 N•m (43.37 – 54.21 lbf ft)

WA500-6 50-83 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Engine Front Oil Seal

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

3 795-931-1100 Seal puller ■ 1

795T-521-1111 Push tool ■ 1 N ❍
4 01050-31655 Bolt ■ 3
A
01050-31635 Bolt ■ 3
795T-521-1150 Push tool ■ 1 N ❍
5
01050-31635 Bolt ■ 3

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove right and left partition covers (1) and cover mounting
supports.

2. Remove damper (2).

50-84 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
3. Remove front seal (3) from housing (4) according to the following
procedure.
★ Be careful during the removal procedure not to damage front
seal (3) installation position on housing (4) and the seal
contact face on crankshaft (5).

A. Before removing the seal, slightly drive the front seal in once
to free it from fixation.

B. When front seal (3) is fixed too hard to the housing (4), do the
following procedure.
• Drill a through hole of approximately 3 mm (0.12 in)
diameter on front seal (3).
• Replace the tip of tool A3 with the drill type one.
• Insert the top end of tool A3 into the drilled hole and
remove the front seal by the impact of slide
hammer (SH). (Apply the slide hammer evenly in order
not to tilt the front seal.)

C. Remove the metal powders completely.

D. When the sleeve is attached, cut sleeve (6) using a chisel and
hammer to remove it.
★ Be careful not to damage crankshaft (5).

WA500-6 50-85 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Installation

1. Check the seal by checking the wear of the shaft and replace it
with the standard seal or sleeved seal.
If the shaft is worn to the degree of luster (if wear that you feel
with your finger is less than 10 mm (0.39 in)) and does not have
any flaw, install standard seal A. In other cases, install sleeved seal
B.
• (7): Plastic inside cylinder (also used as installation guide)
• (6): Sleeve.

2. Do not remove installation guide (7) from front seal (3) before
installing the front seal.

3. Handle front seal (3) and sleeve (6) as an assembly and never
separate them from each other.

Procedure for Installing Standard Seal

★ Before installing the seal, check that the end corners and lip sliding
surfaces of the crankshaft are free from flaw, burr, and rust of the
housing.
★ When installing the seal, do not apply oil or grease to the shaft and
seal lip. Wipe off the oil from the shaft.
★ Never remove inside plastic cylinder (7) of the replacement seal
before installing the seal.

1. Set large inside diameter side (b) of plastic inside cylinder (7) to
the end of crankshaft (5).
★ Be careful not to mistake the direction of the plastic inside
cylinder.

50-86 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
2. Hold the metal ring of front seal (3) with both hands and push it in
evenly as if you are passing over the large inside diameter side of
plastic inside cylinder (7).

3. After pushing in the seal, remove plastic inside cylinder (7).

★ When removing the inside cylinder, be careful not to damage
the seal lip.

4. Using tool A4, tighten the three bolts evenly to press-fit seal (3)
until the end of tool A4 reaches the end of crankshaft (5).

A. Tighten tool A4 first until the 55-mm bolts stop; replace the
55-mm bolts with the 35-mm bolts; and tighten them.
Seal driving distance (a) from crankshaft: . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 – 10.1 mm (0.36 – 0.40 in)

B. When press-fitting the seal, be careful not to damage the lip of

the seal with the tool set, etc.

C. After press-fitting the seal, remove the red sealant layer from
its periphery.

Procedure for installing sleeved seal

★ When installing the front seal, do not apply oil or grease to the
shaft, inside cylinder surface of sleeve (6), and seal lip.

1. Set sleeve (6) and front seal (3) assembly to tool A5 (for fitting the
sleeved seal).

Sleeve (6) inside cylinder surface: Gasket sealant (LG-7)

2. Set the sleeve of the front seal to the end of crankshaft (5) and
tighten the three bolts evenly to press-fit the sleeve and front seal
assembly (9) until the end of tool A5 reaches the end of
crankshaft (5).
• Tighten tool A5 (for press-fitting the sleeved seal) until the
35-mm bolt stops.

WA500-6 50-87 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
3. Remove tool A5 (for press-fitting the sleeved seal) and install tool
A4 (for press-fitting the seal).

4. Tighten the 35-mm bolts of tool A4 evenly to press-fit seal and

sleeve assembly (9) until the end of tool A4 reaches the end of
crankshaft (5).
Seal driving distance (a) from crankshaft: . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 – 10.1 mm (0.36 – 0.40 in)

A. When press-fitting the seal, be careful not to damage the lip of

the seal with the tool set, etc.

B. After press-fitting the seal, remove the red sealant layer from
its periphery.

5. Install damper (2).

50-88 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

Engine Rear Seal

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

2 790-331-1110 Wrench ■ 1
3 795-931-1100 Seal puller ■ 1
795T-421-1260 Push tool ■ 1 N ❍
6 01050-31640 Bolt ■ 4
01643-31645 Washer ■ 8
A 795T-421-1240 Push tool ■ 1 N ❍
7 01050-31645 Bolt ■ 4
01643-31645 Washer ■ 4
795T-421-1231 Push tool ■ 1 N ❍
8 01050-31645 Bolt ■ 4
01643-31645 Washer ■ 8

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove the engine assembly. For details, see Engine and Cooling
System: Engine in this section.

2. Remove ring gear (1).

WA500-6 50-89 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
3. Install eyebolt [1] to flywheel (2) and sling it. Remove bolts (3)
and flywheel (2).

4. While moving flywheel (2) toward this side, lift it off.

★ Since the socket part of the flywheel is shallow, it may fall
suddenly. Be careful not to catch your fingers in the flywheel.

Flywheel: 59 kg (130 lb)

5. Remove rear seal (4) from flywheel housing (5) according to the
following procedure.
★ Be careful not to damage rear seal (4) installation position on
flywheel housing (5) and the seal contact face on
crankshaft (5).

A. Before removing the seal, slightly drive the rear seal in once to
free it from fixation.

B. When rear seal (4) is fixed too hard to the flywheel

housing (5), do the following procedure.

i. Drill throughhole of approximately 3 mm (0.12 in)

diameter on rear seal (4).

ii. Replace the tip of tool A3 with the drill type one.

iii. Insert the top end of tool A3 into the drilled hole and
remove the front seal by the impact of slide
hammer (SH). (Apply the slide hammer evenly in order
not to tilt the rear seal.)

C. Remove the metal powders completely.

D. When the sleeve is attached, cut sleeve (7) using a chisel and hammer to remove it.
★ Be careful not to damage crankshaft (6).

★ Tool A3 (illustrated in figure to the right)

50-90 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
★ Seals (illustrated in figure to the right)
• Left: Standard seal
• Right: Sleeved seal

Installation
★ Carry out the following installation in the reverse order of removal.

1. Check the Teflon seal (laydown lip seal) by checking the wear of the shaft and replace it with the standard seal or sleeved
seal.
If the shaft is worn to the degree of luster (if wear that you feel with your finger is less than 10 mm (0.39 in)) and does not
have any flaw, install standard seal A. In other cases, install sleeved seal B.
• (8): Plastic inside cylinder (also used as installation guide)
• (6): Sleeve

2. Do not remove plastic inside cylinder (8) from rear seal (4) before
installing the rear seal.

3. Handle rear seal (4) and sleeve (7) as an assembly and never
separate them from each other.
★ Seals (illustrated in the figure to the right)
• Left: Standard seal
• Right: Sleeved seal

4. Clean, degrease, and dry the contact surface against the flywheel
housing.

5. Clean, degrease, and dry the seal lip surface (periphery of the
crankshaft).

6. Check that the end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and rust of the housing.

WA500-6 50-91 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
Procedure for Installing Standard Seal

★ When installing rear seal (4), do not apply oil or grease to the shaft
and seal lip.

1. Set large inside diameter side (b) of guide (8) of rear seal (4) to the
end of crankshaft (6).
★ Be extremely careful not to mistake the direction of the plastic
inside cylinder.

2. Hold the metal ring of rear seal (4) with both hands and push it in
evenly.

3. After pushing in the seal, remove guide (8).

★ When removing the inside cylinder, be careful not to damage
the seal lip.

4. Tighten the four bolts evenly to press-fit rear seal (4) until the end
of tool A6 (for press-fitting the seal) reaches the end of
crankshaft (6).

A. Tighten tool A6 (for press-fitting the seal) first until the bolt
without washer stops and then tighten the 25-mm bolt with
two washers.

B. When press-fitting the seal, be careful not to damage the lip

with the tool set, etc.

C. After press-fitting the seal, remove the red sealant layer from
its periphery.

50-92 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
Procedure for Installing Sleeved Seal

★ When installing the rear seal, do not apply oil or grease to the
shaft, inside cylinder surface (C) of the sleeve (7), and seal lip.

1. Set sleeve and rear seal assembly (9) to tool A7 (for fitting the
sleeved seal).

Sleeve inside cylinder surface (C): Gasket sealant (LG-7)

2. Set sleeve (7) of the rear seal to the end of crankshaft (6) and
tighten the four bolts evenly to press-fit sleeve and rear seal
assembly (9) until the end of tool A7 reaches the end of
crankshaft (6).
★ Tighten tool A7 (for press-fitting the sleeved seal) until the
bolt with washer stops.

3. Remove tool A7 (for press-fitting the sleeved seal) and install tool
A8 (for press-fitting the seal).

4. Tighten the four bolts evenly to press-fit sleeve and rear seal
assembly (9) until the end of tool A8 reaches the end of
crankshaft (6).

A. Tighten tool A8 (for press-fitting the seal) first until the bolt
without washer stops and then tighten the bolt with two
washers.

B. After press-fitting the seal, remove the red sealant layer from
its periphery.
Rear seal driving depth: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 13.2 ±0.2 mm (0.52 ±0.01 in) from end of crankshaft

C. When installing, set the dowel pin of the crankshaft to the dowel hole of the flywheel.

WA500-6 50-93 ➁
DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM
Flywheel

1. Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (2); install it to
the crankshaft; and tighten bolts (3).
★ If there are five punch marks on a bolt, do not use that bolt but
replace it.

Threads and seat of bolt: Engine oil SAE No. 30

2. Tighten the mounting bolts according to the following procedure.

Flywheel mounting bolts
• 1st time: 118 ±4.9 N•m (87.03 ±3.61 lbf ft)
• 2nd time:
A. When using tool A2 (see Special Tools List in this section):
• Retighten each bolt by 90° (+30°/0) in the order of [1] –
[8].

B. When not using tool A2:

• Make marks on each bolt and flywheel with paint then
retighten each bolt by 90° (+30°/0) in the order of [1] –
[8].

3. After tightening, make one punch mark (9) on each bolt head to
indicate the number of tightening times.

4. After installing the flywheel, measure the facial runout and radial
runout with tool [2].
Radial runout: . . . . . . . . . . . . . . . . . . . . . Maximum 0.30 mm (0.012 in)
Facial runout: . . . . . . . . . . . . . . . . . . . . . Maximum 0.30 mm (0.012 in)

50-94 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

POWER TRAIN

Torque Converter and Transmission

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until
the coolant cools down then drain the coolant.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the coolant.

Coolant: Approximately 90 l (24 gal)

2. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

3. Drain the transmission oil.

Transmission oil: Approximately 76 l (20 gal)

4. Remove the hood. For details, see Engine and Cooling System:
Engine Hood in this section.

5. Remove the cab and floor frame assembly. For details, see Cab
and Its Attachments: Cab and Floor Frame in this section.

6. Remove the hydraulic tank assembly. For details, see Hydraulic

System: Hydraulic Tank in this section.

7. Remove the right and left mudguard seats.

8. Remove cover (1).

WA500-6 50-95 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
9. Remove guard (2).

10. Sling center drive shaft (3); remove its mounting bolts (4); and lift
it off. [*1]
★ Before removing the drive shaft, make a match mark on the
coupling.

Center drive shaft: 50 kg (110 lb)

11. Support rear drive shaft (5) with transmission jack [1]; remove its
mounting bolts (6); and lift it off. [*2]
★ Before removing the drive shaft, make a match mark on the
coupling.

Rear drive shaft: 45 kg (99 lb)

12. Remove bracket (7) and transmission oil feed tube (8).

13. Disconnect hoses (9) and (10).

14. Disconnect hose (11).

15. Disconnect parking brake hose (12).

50-96 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
16. Unplug wiring harness connectors RJ1 (13) and RJ2 (14); remove
the two wiring harness clamps.

17. Disconnect hoses (15) and (16).

18. Disconnect tube (17).

19. Lift off transmission filter and bracket assembly (18).

Transmission filter and bracket assembly: 45 kg (99 lb)

20. Loosen hose clamp (19) and remove U-bolt (20) and transmission
suction tube (21).

21. Disconnect wiring harness bracket (22).

WA500-6 50-97 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
22. Disconnect work equipment pump hoses (23), (24), and (25).

23. Disconnect hose clamp (26).

24. Disconnect hose (27) and remove brackets (28) and (29) and work
equipment pump outlet tube (30).

25. Unplug wiring harness connector RT1 (31).

26. Remove wiring harness clamps (32) and bracket (33).

27. Remove pump inlet tube (34).

28. Disconnect pump outlet hoses (35) and (36).

29. Disconnect hose (37).

50-98 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
30. Remove pump inlet tube (38).

31. Disconnect pump inlet tube (39).

32. Disconnect pump outlet hoses (40), (41), and (42).

33. Disconnect hose (43) and remove bracket (44).

34. Sling torque converter charging and EPC pump assembly (45) and
remove its mounting bolts. At this time, leave two bolts installed.

Torque converter charging and EPC pump assembly:

30 kg (66 lb)

35. Remove tube (46).

36. Disconnect hose (47).

37. Remove U-bolts (48) and bracket (49).

WA500-6 50-99 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
38. Remove U-bolt (50) and disconnect oil cooler tube (51).

39. Sling the torque converter and transmission assembly; loosen lock
bolts (52); and remove right and left mounting brackets (53). [*3]

40. Remove connecting bolts (54) of the engine and torque converter
and transmission assembly. [*4]

41. Remove torque converter and transmission assembly (55).

★ Check that all the wiring harness and pipings are disconnected
from the machine and be careful that the assembly does not
interfere with the machine.

Torque converter and transmission assembly:

1,950 kg (4,299 lb)

50-100 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Center drive shaft mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

[*2]

Rear drive shaft mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

Tighten the drive shaft according to the following procedure.

1. Check that the seats of the mating yoke and drive shaft spider are free from rust, foreign matter (masking material), bruise,
etc.

2. Set the keyway of the yoke vertically; place the drive shaft on the bottom of the yoke socket; and fit the key in the keyway.

3. Insert the four upper and lower bolts and finger tighten them until the seats of the spider and yoke are fitted.
• At this time, if the keyway and socket of the yoke are tight and the spider is not fitted easily, drive in the spider with a
plastic or copper hammer. (Do not use a steel hammer which can damage the cross bearing.)
• If the spider is not fitted perfectly at this time, it will float and its seat will be parted from the yoke when the other
parts are tightened. Tighten the spider securely.

4. Tighten the bolts in the diagonal order.

[*3]

Bracket (53) mounting bolt: 235 – 285 N•m (173.33 – 210.20 lbf ft)

Transmission mounting bolt: 662 – 829 N•m (488.27 – 611.44 lbf ft)

1. Adjust the clearance between bracket (53) and lock adjustment bolt (52) to 1.0 – 1.5 mm (0.039 – 0.059 in).

2. Tighten the locknut.

Threaded part of lock adjustment bolt: Adhesive (LT-2)

[*4]

Connecting bolt of engine and torque converter and

transmission assembly: 98 – 123 N•m (72.28 – 90.72 lbf ft)

WA500-6 50-101 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
Refilling with Coolant

1. Add coolant through the coolant filler to the specified level.

2. Run the engine to circulate the coolant through the system.

3. Check the coolant level again.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Refilling with Oil (Transmission)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Bleeding Air

Bleed air from the circuit. For details, see these procedures in the Testing and Adjusting section.

• Fuel System: Bleeding Air from Fuel Circuit

• Hydraulic System: Bleeding Air from Hydraulic Drive Fan Circuit

50-102 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Power Train

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Preparation

1. Set torque converter and transmission assembly (1).

Torque converter and transmission assembly:

1,700 kg (3,748 lb) (with lockup)
1,650 kg (3,638 lb) (without lockup)

2. Loosen drain valve to drain the oil.

Transmission case: Approximately 76 l (20 gal)

3. Remove right and left transmission mounts (3).

4. Disconnect each ECMV of transmission control valve and remove

wiring harness (4).

5. Remove hoses (5) and (6) and pipes (7), (8), (9), (10), and (11).

6. Remove transmission control valve (12) and lubricating oil relief

valve (13). [*1]
★ The three bolts marked with * are used to clamp other parts
also.

WA500-6 50-103 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
★ Lockup specification (figure to the right)

★ Without lockup specification (figure to the right)

7. Remove pipes (14) and (15), block (16), and heater plug (17).

8. Remove torque converter regulator valve (19).

50-104 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
9. Remove pipe (20).

Disconnection

1. Set torque converter and transmission assembly (1).

Torque converter and transmission assembly:

1,700 kg (3,748 lb) (with lockup)
1,650 kg (3,638 lb) (without lockup)

2. Torque converter assembly

A. Remove two upper mounting bolts (2a) and 15 lower

mounting bolts (2b).

B. Lift off torque converter assembly (3).

Torque converter assembly:

460 kg (1,014 lb) (with lockup)
420 kg (926 lb) (without lockup)

3. Input transfer

A. Remove 13 mounting bolts (4). [*4]

B. Lift off input transfer (5).

Input transfer: 140 kg (309 lb)

WA500-6 50-105 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
4. Transmission assembly

A. Remove four upper mounting bolts (6a) and eight lower

mounting bolts (6b); disconnect the case by using forcing
screws. [*5]

B. Sling transmission assembly (7) and lift it off from transfer

assembly (8).

Transmission assembly: 550 kg (1,213 lb)

Transfer assembly: 440 kg (970 lb)

Connection
★ Carry out connection in the reverse order of disconnection.
★ Before fitting the O-ring, apply grease (G2-LI) to it.

[*1]

Install the transmission control valve by using guide bolts [1].

★ The three bolts marked with * are used to clamp other parts also.

★ Lockup specification (figure to the right)

50-106 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
★ Without lockup specification (figure to the right)

[*2]

Joint bolt A: 24.5 – 34.3 N•m (18.07 – 25.30 lbf ft)

Joint bolt B: 34.3 – 44.1 N•m (25.30 – 32.53 lbf ft)
Joint bolt C: 19.6 – 29.4 N•m (14.46 – 21.68 lbf ft)

[*3]

(Only lockup specification)

Input shaft seal ring: Grease (G2-LI)

Project the seal ring evenly from the shaft.

★ If the seal ring is pushed forcibly, it may be broken. Be careful.

Torque converter mounting bolts (2a), (2b): 98 – 122.5 N•m (72.28 – 90.35 lbf ft)

[*4]

Input transfer mounting bolt (4): 98 – 122.5 N•m (72.28 – 90.35 lbf ft)

[*5]

Transmission mounting bolts (6a), (6b): 98 – 122.5 N•m (72.28 – 90.35 lbf ft)

Transmission shaft (Spline): Grease (LM-G)

Refilling with Oil

Transmission case: 76 l (20 gal)

Power train oil (TO30)

WA500-6 50-107 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Input Transfer
Disassembly

1. Disconnect the input transfer assembly from the power train unit.
For details, see the Power Train disconnection and connection
procedures in this section.

2. Input shaft

A. Remove input shaft speed sensor (1) and input shaft (2).

B. Remove seal rings (3) from input shaft (2).

★ Lockup specification

★ Without lockup specification (figure to the right)

3. Bearing cage assembly (drive gear side)

A. Remove six mounting bolts (4).

B. Using forcing screw [1], remove bearing cage (5) and

shim (6).
★ Check the thickness and quantity of the shims at each
position and keep those shims.

50-108 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Remove outer race (7) from bearing cage (5).

4. Drive gear assembly

A. Remove drive gear assembly (8).

B. Remove bearings (9) and (10) from drive gear assembly (8).

5. Outer race (drive gear side)

Using puller [2], remove outer race (19) from the case.

WA500-6 50-109 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
6. Bearing cage assembly (Driven gear side)

A. Reverse input transfer case (11).

B. Remove six mounting bolts (12).

C. Using forcing screws [3], remove bearing cage (13) and

shim (14).
★ Check the thickness and quantity of the shims at each
position and keep those shims.

D. Remove outer race (15) from bearing cage (13).

7. Driven gear assembly

A. Remove driven gear assembly (16).

B. Remove bearings (17) and (18) from driven gear

assembly (16).

50-110 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
8. Outer race
• Using puller [4], remove outer race (20) from the case.

Assembly

1. Outer race (driven gear side)

• Using push tool [1] (outside diameter: 124 mm [4.88 in]),
press-fit outer race (20) to the case.

2. Driven gear assembly

A. Using push tool [2], press-fit bearings (17) and (18) to driven
gear (21).

B. Install driven gear assembly (16).

WA500-6 50-111 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
3. Bearing cage assembly (driven gear side)

A. Using push tool [3] (outside diameter: 124 mm [4.88 in]),

press-fit outer race (15) to bearing cage (13).

B. Adjust the shim of bearing cage (13) according to the

following procedure.

i. Install bearing cage (13) without setting any shim and

tighten mounting bolts (12) to 4.8 ±0.98 N•m
(42.48 ±8.67 lbf in).
After installing the bearing, drop 6 cc of transmission oil
(TO30) onto it and rotate it ten turns.

ii. Rotate driven gear (21) 20 turns.

iii. Check again that tightening torque of mounting bolts (12)

is 4.8 ±0.98 N•m (42.48 ±8.67 lbf in).

iv. If the tightening torque has changed, repeat Steps Bi and Bii.

v. Using thickness gauge [4], measure the clearance of

bearing cage (13) at the three places marked with (*).
Obtain shim thickness (b) from average clearance (a).
★ Check that the bearing is not leaning.
★ If the dispersion of the above measured values is
larger than 0.15 mm (0.006 in), check if the bearing
is fitted fully or check for another cause and then set
the bearing normally.

Shim thickness (b): . . . . . . . . . a + (0.15 to 0.20) mm [0.006 – 0.008 in]

Standard shim thickness: . . . . . . . . . . . . . . . . . . . . . .1.0 mm (0.039 in)
Standard clearance: . . . . . . . . . . . . .0.60 – 1.80 mm (0.024 – 0.071 in)

vi. Install shim (14) of the thickness obtained by the above

procedure and tighten mounting bolts (12).

Mounting bolt: 98.0 – 122.5 N•m (72.28 – 90.35 lbf ft)

50-112 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
vii. Install input shaft (2) to driven gear (21) and measure the
rotation torque.

Rotation torque: 1.47 – 2.45 N•m (13.01 – 21.68 lbf in)

4. Outer race (drive gear side)

Using push tool [5] (outside diameter: 139 mm [5.47 in]), press-fit
outer race (19) to the case.

5. Drive gear assembly

A. Using push tool [6], press-fit bearings (9) and (10) to drive
gear (22).

B. Install drive gear assembly (8).

WA500-6 50-113 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
6. Bearing cage assembly (drive gear side)

A. Using push tool [7] (outside diameter: 149 mm [5.87 in]),

press-fit outer race (7) to bearing cage (5).

B. Adjust the shim of bearing cage (5) according to the following

procedure.
★ Since the shim adjustment and torque measurement are
carried out on the drive gear independently, remove the
drive gear.

i. Install bearing cage (5) without setting any shim and

tighten mounting bolts (4) to 4.8 ± 0.98 N•m (42.48 ±8.67
lbf in).
★ After installing the bearing, drop 6 cc of transmission
oil (TO30) onto it and rotate it ten turns.

ii. Rotate drive gear (22) 20 turns.

iii. Check again that tightening torque of mounting bolts (4) is 4.8 ± 0.98 N•m (42.48 ±8.67 lbf in).

iv. If the tightening torque has changed, repeat Steps Bi and Bii.

v. Using thickness gauge [8], measure the clearance of

bearing cage (5) at the three places marked with (*).
Obtain shim thickness (d) from average clearance (c).
★ Check that the bearing is not leaning.
★ If the dispersion of the above measured values is
larger than 0.15 mm (0.006 in), check if the bearing
is fitted fully or check for another cause and then set
the bearing normally.

Shim thickness (d): . . . . . . . . (c) + (0.15 to 0.20) mm [0.006 – 0.008 in]

Standard shim thickness: . . . . . . . . . . . . . . . . . . . . . .1.0 mm (0.039 in)
Standard clearance: . . . . . . . . . . . . . .0.40 – 1.60 mm (0.016 – 0.063 in)

vi. Install shim (6) of the thickness obtained by the above

procedure and tighten mounting bolts (4).

Mounting bolt: 98.0 – 122.5 N•m (72.28 – 90.35 lbf ft)

50-114 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
vii. Install input shaft (2) to drive gear (22) and measure the
rotation torque.

Rotation torque: 1.47 – 2.45 N•m (13.01 – 21.68 lbf in)

7. Input shaft

A. Install seal ring (3) to input shaft (2).

★ Lockup specification

Seal ring: Grease (G2-LI)

Input shaft (Spline): Grease (LM-G)

★ Without lockup specification (figure to the right)

B. Install input shaft (2).

C. Install input shaft speed sensor (1).

★ Finger-tighten input shaft speed sensor (1) to the end and
then return it by 1/2 turn and lock it with locknut (1a).

Locknut: Gasket sealant (LG-5)

Locknut: 49 – 68.6 N•m (36.14 – 50.60 lbf ft)

8. Connect the input transfer assembly to the power train unit. For details, see the Power Train disconnection and connection
procedures in this section.

WA500-6 50-115 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Torque Converter (Lockup Specification)

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

Puller
1 790-101-2102 ■ 1
F (294 kN {30 ton})
2 793-613-1210 Wrench ■ 1

Disassembly

1. Disconnect the torque converter assembly from the power train

unit. For details, see the Power Train disconnection and
connection procedures in this section.

2. Torque converter assembly

A. Set torque converter assembly (1) on the block.

B. Remove 12 mounting bolts (2).

3. Housing

A. Using eyebolts [1], sling housing (3).

B. Using forcing screws [2], remove housing (3).

4. Pilot

A. Remove eight mounting bolts (4).

B. Using forcing screws [3], remove pilot (65).

50-116 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
5. Torque converter assembly

A. Remove 16 mounting bolts (5) from the lower part.

B. Using eyebolts [4], remove torque converter assembly (6).

Torque converter assembly: 180 kg (397 lb)

★ Steps 6 – 11 are disassembly procedures for the torque converter.

6. Turbine assembly

A. Remove 36 lower mounting bolts (7). (Leave the two bolts on

the right and left sides.)

B. Remove the left two bolts and turbine assembly (8), using
eyebolts [5].

7. Snap ring and spacer

• Remove snap ring (9) and spacer (10).

8. Turbine boss assembly

A. Using tool F1 and push tool [6] (outside diameter: 104 mm

[4.09 in]), remove turbine boss assembly (11).

WA500-6 50-117 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Remove snap ring (12).

C. Remove 20 mounting bolts (13) and turbine (14).

9. Drive case assembly

A. Remove 30 mounting bolts (15).

B. Using eyebolts [7], remove piston housing (16).

C. Remove piston (17) and bearing (18) from piston

housing (16).
★ Do not remove dowel pin (64) since it is a complete part.

D. Remove piston rings (19a) and (19b).

E. Remove disc (20).

50-118 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
10. Stator assembly

A. Remove stator assembly (21).

B. Remove snap ring (22) from stator assembly (21).

C. Remove race (23) from stator assembly (21).

D. Remove freewheel (24) from race (23).

★ When removing the freewheel, be careful with ball (25).

11. Pump assembly

A. Install the bolts to the pump case and lock them with bar [8].

B. Using tool F2, remove nut (26).

WA500-6 50-119 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Remove spacer (27).
★ When removing the spacer, be careful with ball (28).

D. Using push tool [9], remove stator shaft (29).

E. Remove inner race (30).

F. Remove 16 mounting bolts (31) and gear (32).

G. Remove bearing (33).

50-120 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
H. Remove inner race (34) and seal ring (35) from stator
shaft (29).

12. PTO gear A assembly

A. Remove eight mounting bolts (36).

B. Using forcing screws [10], disconnect PTO gear A

assembly (37).

C. Using eyebolts [11], remove PTO gear A assembly (37).

D. Remove snap ring (38a) and spacer (39).

E. Remove gear (40) and bearing (41).

F. Remove snap ring (38b) and bearing (57).

WA500-6 50-121 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
G. Remove snap ring (42) and outer race (43) on the case side.

13. PTO gear B assembly

A. Remove eight mounting bolts (44).

B. Using forcing screws [12], disconnect PTO gear B assembly.

C. Using eyebolts [13], remove PTO gear B assembly (45).

D. Remove snap ring (46a) and spacer (47).

E. Remove gear (48) and bearing (49).

F. Remove snap ring (46b) and bearing (58).

50-122 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
G. Remove snap ring (50) and outer race (51) on the case side.

14. Idler gear

A. Remove mounting bolt (52).

B. Using forcing screw [14], pull out the shaft down and remove
gear (53).

C. Remove bearings (54a) and (54b) from gear (53).

WA500-6 50-123 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Assembly

1. Idler gear

A. Install bearings (54a) and (54b) to gear (53).

B. Set gear (53) to the case.

C. Fit the O-ring to shaft (55) and press-fit them.

O-ring: Grease (G2-LI)

D. Reverse the case and install mounting bolt (52).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 153 – 190 N•m (112.85 – 140.14 lbf ft)

2. PTO gear B assembly

A. Install snap ring (50) to the case.

B. Using push tool [1] (outside diameter: 99 mm [3.90 in]),

press-fit outer race (51) on the case side.

C. Using push tool [2] (inside diameter: 56 mm [2.20 in]), press-

fit bearing (49) to the gear.

50-124 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
D. Using push tool [4] (outside diameter: 124 mm [4.88 in]),
press-fit bearing (58) to the cover.

E. Install snap ring (46b).

F. Using push tool [5] (inside diameter: 71 mm [2.80 in]), press-

fit cover assembly (59) to gear (48).

G. Install spacer (47) and snap ring (46a).

H. Fit the O-ring; install PTO gear B assembly (45) using

eyebolts [13].

O-ring: Grease (G2-LI)

3. PTO gear A assembly

A. Install snap ring (42) to the case.

B. Using push tool [6] (outside diameter: 99 mm [3.90 in]),

press-fit outer race (43) on the case side.

C. Using push tool [7] (inside diameter: 56 mm [2.20 in]), press-

fit bearing (41) to the gear.

WA500-6 50-125 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
D. Using push tool [8] (outside diameter: 149 mm [5.87 in]),
press-fit bearing (57) to the cover.

E. Install snap ring (38b).

F. Using push tool [9] (inside diameter: 71 mm [2.80 in]), press

fit cover assembly (60) to gear (40).

G. Install spacer (39) and snap ring (38a).

H. Fit the O-ring; install PTO gear A assembly (37) using

eyebolts [11].

O-ring: Grease (G2-LI)

★ Steps 4 – 10 are assembly procedures for the torque converter.

4. Pump assembly

A. Using push tool [10] (outside diameter: 215 mm [8.46 in]),

press-fit bearing (33) to gear (32).

50-126 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
★ After press-fitting bearing (33), measure
dimension (a) at four places on the periphery and
check that the error is not larger than 0.05 mm
(0.002 in).

B. Install gear (32) to the pump case and tighten 16 bolts (31).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 59 – 74 N•m (43.52 – 54.58 lbf ft)

C. Using push tool [11] (inside diameter: 121 mm [4.76 in]),

press-fit inner race (34) to stator shaft (29).

D. Install seal ring (35).

Seal ring: Grease (G2-LI)

E. Install pump case (61) to stator shaft (29).

WA500-6 50-127 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
F. Using push tool [12] (inside diameter: 121 mm [4.76 in]),
press-fit inner race (66) to stator shaft (29).

• Match the product Nos. (c) and match symbols “A” (d) of
the inner and outer races of bearing (33); use those races
as an assembly.

G. Install spacer (27).

• When installing, set ball (28) correctly.

H. Install the bolts to the pump case and lock them with bar [8].

I. Using tool F2, tighten nut (26).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 441 – 490 N•m (325.26 – 361.40 lbf ft)

• After tightening nut (26), drop 6 cc of TO30 or TO10

onto the bearing and rotate the bearing ten turns. Check
the tightening torque for nut (26) again (441 – 490 N•m
[325.26 – 361.40 lbf ft]).

50-128 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
5. Stator assembly

A. Install freewheel (24) to race (23).

★ When inserting freewheel (24), use your hand. Do not use
a hammer or other tool.
★ When inserting the freewheel, be careful with ball (25).

• When installing the one-way clutch, direct arrow (b) of

the free rotation direction on the front face of the cage
toward the input side (turbine side).
Clockwise: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Free rotation
Counterclockwise: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locked
★ Do not remove the sprag (d).
• When inserting, take care that drag clip (c) on the
periphery of the one-way clutch is not hitched in the ball
groove.

B. Install stator assembly (21).

6. Turbine assembly

A. Install snap ring (12).

B. Install turbine (14) to the turbine boss and tighten 20

mounting bolts (13).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 59 – 74 N•m (43.52 – 54.58 lbf ft)

WA500-6 50-129 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
7. Drive case assembly

A. Using eyebolts [13], install drive case (63) to turbine boss

assembly (11).

B. Apply tool [14] (outside diameter: 150 mm [5.91 in], height:

129 mm [5.08 in]) to the bottom of turbine boss assembly (11)
to hold the latter.
★ This secures a space for installing the disc to drive
case (63).

C. Install disc (20).

8. Piston housing assembly

A. Install seal ring (19a) to piston housing complete (16).

★ Do not remove dowel pin (64) since it is a complete part.

Periphery of seal ring: Grease (G2-LI)

50-130 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Install seal ring (19b) to piston (17).
• Set pressure receiving side (e) of the seal ring in the arrow
direction as shown in the figure.

Periphery of seal ring: Grease (G2-LI)

C. Using eyebolts [15], install piston housing (16).

D. Tighten 30 mounting bolts (15).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 59 – 74 N•m (43.52 – 54.58 lbf ft)

E. Using push tool [16] (outside diameter: 179 mm [7.05 in]),

press-fit bearing (18).

• After press-fitting bearing (18), measure dimension (e) at

four places on the periphery and check that the error is not
larger than 0.05 mm (0.002 in).

WA500-6 50-131 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
9. Snap ring and spacer

Install spacer (10) and snap ring (9).

10. Turbine assembly

A. Using eyebolts [5], install turbine assembly (8).

B. Tighten 36 lower mounting bolts (7).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 49 – 58.8 N•m (36.14 – 43.37 lbf ft)

Drain plug (2 pieces): 9.8 – 12.7 N•m (86.74 – 112.40 lbf in)

11. Pilot

Install pilot (65) and tighten eight mounting bolts (4).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 98 – 122.5 N•m (72.28 – 90.35 lbf ft)

12. Torque converter assembly

A. Set torque converter case (66).

50-132 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Install guide bolt [17] to stator shaft (29).

C. Using eyebolts [18] and positioning with guide bolt [17],

install torque converter assembly (6).

Torque converter assembly: 180 kg (397 lb)

D. Tighten 16 mounting bolts (5) from the underside.

Mounting bolt: Adhesive (LT-2)

13. Housing

A. Fit the O-ring and install housing (3), using eyebolts [19].

B. Tighten 12 mounting bolts (2).

O-ring: Grease (G2-LI)

Mounting bolt: 98 – 122.5 N•m (72.28 – 90.35 lbf ft)

14. Connect the torque converter assembly to the power train unit. For
details, see the Power Train disconnection and connection procedures in this section.

WA500-6 50-133 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Torque Converter (Without Lockup)

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

Puller
1 790-101-2102 ■ 1
F (294 kN {30 ton})
2 793-613-1210 Wrench ■ 1

Disassembly

1. Disconnect the torque converter assembly from the power train

unit. For details, see the Power Train disconnection and
connection procedures in this section.

2. Housing

A. Set torque converter assembly (1) on the block.

B. Remove 12 mounting bolts (2).

C. Remove housing (3).

3. Pilot

A. Remove eight mounting bolts (4).

B. Remove pilot (5).

4. Torque converter assembly

A. Remove 16 mounting bolts (6) from the lower part.

B. Remove torque converter assembly (8) from case (7).

Torque converter assembly: 150 kg (331 lb)

50-134 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
★ Steps 5 – 10 are disassembly procedures for the torque converter.

5. Turbine assembly

A. Remove 36 lower mounting bolts (9). (Leave the two bolts on

the right and left sides.)

B. Remove the last two bolts and lift off turbine assembly (10).

6. Snap ring and spacer

• Remove snap ring (11) and spacer (12).

7. Turbine boss assembly

A. Using tool F1 and push tool [1] (outside diameter: 104 mm

[4.09 in]), remove turbine boss assembly (13).

B. Remove snap ring (14).

C. Remove 20 mounting bolts (15) and turbine (16).

WA500-6 50-135 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
8. Drive case assembly
• Remove bearing (17) from drive case (63).

9. Stator

A. Remove snap ring (18).

B. Remove stator (19).

10. Pump assembly

A. Install the bolts to the pump case and lock them with bar [2].

B. Using tool F2, remove nut (20).

C. Remove spacer (21).

★ When removing the spacer, be careful with ball (22).

50-136 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
D. Using push tool [3], remove stator shaft (23).

E. Remove inner race (24).

F. Remove 16 mounting bolts (25) and gear (26).

G. Remove bearing (27).

H. Remove inner race (28) and seal ring (29) from stator
shaft (23).

I. Remove collar (52).

WA500-6 50-137 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
11. PTO gear A assembly

A. Remove eight mounting bolts (30).

B. Using forcing screws [4], disconnect PTO gear A

assembly (31).

C. Using eyebolts [5], remove PTO gear A assembly (31).

D. Remove snap ring (32a) and spacer (33).

E. Remove gear (34) and bearing (35).

F. Remove snap ring (32b) and bearing (36).

G. Remove snap ring (37) and outer race (38) on the case side.

50-138 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
12. PTO gear B assembly

A. Remove eight mounting bolts (39).

B. Using forcing screws [6], disconnect PTO gear B assembly.

C. Using eyebolts [7], remove PTO gear B assembly (40).

D. Remove snap ring (41a) and spacer (42).

E. Remove gear (43) and bearing (44).

F. Remove snap ring (41b) and bearing (45).

G. Remove snap ring (46) and outer race (47) on the case side.

WA500-6 50-139 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
13. Idler gear

A. Remove mounting bolt (48).

B. Using forcing screw [8], pull out the shaft down and remove
gear (49).

C. Remove bearings (50a) and (50b) from gear (49).

50-140 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Assembly

1. Idler gear

A. Install bearings (50a) and (50b) to gear (49).

B. Set gear (49) to the case.

C. Fit the O-ring to shaft (51) and press-fit them.

O-ring: Grease (G2-LI)

D. Reverse the case and install mounting bolt (48).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 153 – 190 N•m (112.85 – 140.14 lbf ft)

2. PTO gear B assembly

A. Install snap ring (46) to the case.

B. Using push tool [1] (outside diameter: 99 mm [3.90 in]]),

press-fit outer race (47) on the case side.

C. Using push tool [2] (inside diameter: 56 mm [2.20 in]), press-

fit bearing (44) to the gear.

WA500-6 50-141 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
D. Using push tool [3] (outside diameter: 124 mm [4.88 in]),
press-fit bearing (45) to the cover.

E. Install snap ring (41b).

F. Using push tool [4] (inside diameter: 71 mm [2.80 in]), press-

fit cover assembly (52) to gear (43).

G. Install spacer (42) and snap ring (41a).

H. Fit the O-ring and install PTO gear B assembly (40), using
eyebolts [7].

O-ring: Grease (G2-LI)

3. PTO gear A assembly

A. Install snap ring (37) to the case.

B. Using push tool [5] (outside diameter: 99 mm [3.90 in]),

press-fit outer race (38) on the case side.

C. Using push tool [6] (inside diameter: 56 mm [2.20 in]), press-

fit bearing (35) to the gear.

50-142 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
D. Using push tool [8] (outside diameter: 149 mm [5.87 in]),
press-fit bearing (36) to the cover.

E. Install snap ring (32b).

F. Using push tool [9] (inside diameter: 71 mm [2.80 in]), press-

fit cover assembly (53) to gear (34).

G. Install spacer (33) and snap ring (32a).

H. Fit the O-ring and install PTO gear A assembly (31), using
eyebolts [5].

O-ring: Grease (G2-LI)

★ Steps 4 – 10 are assembly procedures for the torque converter.

4. Pump assembly

A. Using push tool [10] (outside diameter: 215 mm [8.46 in]),

press-fit bearing (27) to gear (26).

WA500-6 50-143 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
• After press fitting bearing (27), measure dimension (a) at
four places on the periphery and check that the error is not
larger than 0.05 mm (0.002 in).

B. Install gear (26) to the pump case and tighten 16 bolts (25).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 59 – 74 N•m (43.52 – 54.58 lbf ft)

C. Using push tool [11] (inside diameter: 121 mm [4.76 in]),

press-fit inner race (28) to stator shaft (23).

D. Install seal ring (29).

Seal ring: Grease (G2-LI)

E. Install collar (52).

F. Install pump case (54) to stator shaft (23).

50-144 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
G. Using push tool [12] (inside diameter: 121 mm [4.76 in]),
press-fit inner race (55) to stator shaft (23).

• Match the product Nos. (c) and match symbols “A” (d) of
the inner and outer races of bearing (27); use those races
as an assembly.

H. Install spacer (21).

★ When installing, set ball (22) correctly.

I. Install the bolts to the pump case and lock them with bar [2].

J. Using tool F2, tighten nut (20).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 441 – 490 N•m (325.26 – 361.40 lbf ft)

K. After tightening nut (20), drop 6 cc of TO30 or TO10 onto the

bearing and rotate the bearing ten turns. Check the tightening
torque for nut (20) again (441 – 490 N•m [325.26 – 361.40 lbf
ft]

WA500-6 50-145 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
5. Stator

A. Install stator (19).

B. Install snap ring (18).

6. Turbine assembly

A. Install snap ring (14).

B. Install turbine (16) to the turbine boss and tighten 20

mounting bolts (15).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 59 – 74 N•m (43.52 – 54.58 lbf ft)

7. Drive case assembly

A. Install drive case (63) to turbine boss assembly (13).

B. Using push tool [13] (outside diameter: 179 mm [7.05 in]),

press-fit bearing (17) to drive case (63).

50-146 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
• After press fitting bearing (17), measure dimension (e) at
four places on the periphery and check that the error is not
larger than 0.05 mm (0.002 in).

8. Snap ring and spacer

Install spacer (12) and snap ring (11).

9. Turbine assembly

A. Sling and install turbine assembly (10).

B. Tighten 36 lower mounting bolts (9).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 49 – 58.8 N•m (36.14 – 43.37 lbf ft)

Drain plug (2 pieces): 9.8 – 12.7 N•m (86.74 – 112.40 lbf in)

10. Pilot
• Install pilot (5) and tighten 8 mounting bolts (4).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 98 – 122.5 N•m (72.28 – 90.35 lbf ft)

WA500-6 50-147 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
11. Torque converter assembly

A. Set torque converter case (56).

B. Install guide bolt [14] to stator shaft (23).

C. Positioning with guide bolt [14], install torque converter

assembly (8) to case (7).

Torque converter assembly: 150 kg (331 lb)

D. Tighten 16 mounting bolts (6) from under side.

Mounting bolt: Adhesive (LT-2)

12. Housing

A. Fit the O-ring to housing (3).

B. Sling housing (3) and install it to torque converter

assembly (1).

C. Tighten 12 mounting bolts (2).

O-ring: Grease (G2-LI)

Mounting bolt: 98 – 122.5 N•m (72.28 – 90.35 lbf ft)

13. Connect the torque converter assembly to the power train unit. For details, see the Power Train disconnection and
connection procedures in this section.

50-148 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Transmission
Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

1 799-301-1500 Oil leak tester ■ 1

769-514-2000 Remover ■ 1
2
796-515-2140 Adapter 1
G 790-201-1702 Push tool kit 1
790-201-1741 • Push tool 1
3
790-101-5021 • Grip 1
01010-50816 • Bolt ■ 1

Disassembly

1. Disconnect the transmission assembly from the power train unit.

For details, see the Power Train disconnection and connection
procedures in this section.

2. Sleeves
• Using forcing screw [1], remove five sleeves (1).

3. Transmission assembly

A. Remove six mounting bolts (3) from the lower output shaft
side of transmission assembly (2).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Set transmission assembly (2) on block [2].

C. Remove 18 mounting bolts (4) from the upper input shaft side.

D. Remove two tie bolts (6).

E. Install eyebolts [3] to the holes of the removed tie bolts and
remove transmission assembly (5).
★ Do not use an impact wrench to loosen the tie bolts
because it could damage the cushion sleeve and cause the
tie bolts to seize.

Transmission assembly: 410 kg (904 lb)

4. Check of clutch piston operation

• Using tool G, check the operating condition of the piston
before disassembling the transmission.

5. Input shaft and No. 1 carrier housing assembly

A. Remove 13 other tie bolts (6).

★ Do not use an impact wrench to loosen the tie bolts
because it can damage the cushion sleeve.

B. Using eyebolt [4], remove the input shaft and No. 1 carrier
housing assembly (7).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Disassemble No. 1 carrier housing assembly according to the
following procedure.

i. Remove snap ring (9).

ii. Remove No. 2 sun gear (10).

iii. Support housing (11) and push out input shaft (12) with
push tool [5].

iv. Remove snap ring (13) on the inner race side.

v. Support housing (11) and push out No. 1 carrier

assembly (14) with push tool [6] (inside diameter: 91 mm
[3.58 in]).

vi. Remove spacer (15).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
vii. Remove snap ring (16).

viii. Remove bearing (17).

ix. Remove seal ring (18) from housing (11).

D. Disassemble No. 1 carrier assembly (14) according to the

following procedure.

i. Remove spacer (21) and seal ring (22).

ii. Remove snap ring (19) and No. 1 ring gear (20).

iii. Using a round rod, drive pin (24) into shaft (23).

iv. Remove shaft (23) from No. 1 carrier (14).

v. Remove pin (24) from shaft (23).

★ Be careful not to lose pin (24).

vi. Remove two thrust washers (25), needle roller

bearing (26), and planetary gear (27).

vii. Remove sun gear (28) and spacer (29).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
viii. Using push tool [7] (outside diameter: 64 mm [2.52 in]),
remove the spacer and bearing assembly (30).

ix. Remove snap ring (31).

x. Using push tool [8], remove bearing (32).

xi. Remove snap ring (33) from No. 1 carrier (14).

xii. Using push tool [9], remove bearing (34).

6. No. 1 spring
• Remove ten No. 1 springs (35).

7. No. 1 plate, spring and No. 1 disc

• Remove seven No. 1 discs (36), 35 springs (37), and six No. 1
plates (38).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
8. Guide pin and piston

A. Remove five guide pins (39) and piston (40).

B. Remove seal ring (41) from piston (40).

9. No. 1 and No. 2 piston housing assembly

A. Using eyebolts [10], remove No. 1 and No. 2 piston housing

assembly (42).
★ When disconnecting the dowel pin, drive it out with a
copper hammer.
★ When slinging the housing assembly, be careful that the
No. 2 piston does not fall.

B. Remove seal rings (43) and (44) from No. 1 and No. 2 piston
housing (42).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Remove 15 cushion sleeves (166) from No. 2 piston
housing (42).

• When removing cushion sleeve (166) from No. 2 piston

housing (42), check slit position (A).

10. No. 2 piston

A. Remove No. 2 piston (45).

B. Remove seal ring (46) from No. 2 piston (45).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
11. No. 2 spring
• Remove ten No. 2 springs (47).

12. No. 2 disc, spring and No. 2 plate

• Remove seven No. 2 discs (48), 35 springs (49), and six No. 2
plates (50).

13. No. 2 carrier and housing assembly

A. Using eyebolts [11], remove the No. 2 carrier and housing

assembly (51).

B. Remove snap ring (52) on the bearing inner race side.

C. Support No. 2 housing assembly (53) and push out No. 2

carrier assembly (54) with push tool [12] and the press.
• Push the No. 2 carrier.

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
D. Disassemble No. 2 housing assembly (55) according to the
following procedure.

i. Remove snap ring (56).

ii. Support No. 2 housing assembly (55) and push out

bearing (57) with push tool [13] (outside diameter:
179 mm [7.05 in]) and the press.

iii. Remove seal ring (58) from No. 2 housing (55).

E. Disassemble No. 2 carrier assembly (54) according to the

following procedure.

i. Remove spacer (59).

ii. Remove ring gear (61).

iii. Insert rods in four snap ring removing holes (a) of ring
gear (64) and push out snap ring (63).

iv. Remove No. 2 carrier assembly (62) from ring gear (64).

WA500-6 50-157 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
v. Remove pin (65) and shaft (66) from No. 2 carrier (62).
★ Be careful not to lose pin (65).

vi. Remove two thrust washers (67), needle roller

bearing (68), and planetary gear (69).

14. Guide pin and plate

• Remove five guide pins (70) and upper plate (71).

15. No. 3 spring

• Remove ten No. 3 springs (72).

16. No. 3 disc, spring and No. 3 plate

• Remove four No. 3 discs (74), 20 springs (73), and three No. 3
plates (75).

17. Plate
• Remove lower plate (76).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
18. No. 3 ring gear
• Remove No. 3 ring gear (77).

19. No. 3 and No. 4 housing and piston assembly

Using eyebolts [13], remove No. 3 and No. 4 housing and piston
assembly (78).
★ When disconnecting the dowel pin, drive it out with a copper
hammer.

20. No. 3 piston assembly

A. Remove No. 3 piston assembly (79) and seal rings (80) and
(81) from No. 3 and No. 4 housing (78).

B. Remove No. 4 piston assembly (82) and seal rings (83) and
(84) from No. 3 and No. 4 housing (78).

21. Plate
• Remove upper plate (85).

22. No. 4 spring

• Remove ten No. 4 springs (86).

23. No. 4 disc, spring and No. 4 plate

• Remove three No. 4 discs (88), 15 springs (87), and two No. 4
plates (89).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
24. Plate
• Remove lower plate (90).

25. No. 3 and No. 4 carrier assembly

A. Using eyebolts [14], sling No. 3 and No. 4 carrier

assembly (91) temporarily.

B. Using bar [15], push up No. 3 and No. 4 carrier assembly (91)
to remove it.

C. Disassemble No. 3 and No. 4 carrier assembly (91) according

to the following procedure.

i. Using tool G2, pull out No. 3 shaft (92).

★ Be careful not to lose ball (93).

ii. Remove two thrust washers (94), needle roller

bearing (95), and planetary gear (96).

★ When No. 3 and No. 4 carrier assembly (91) is

disassembled, bearing (104) comes out to the end of
planetary gear (96). Be careful that bearing (104)
does not contact the thrust washer.

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
iii. Using a round rod, drive pin (97) into No. 4 shaft (98).

iv. Using round rod [16], drive out No. 4 shaft (98) from the
No. 3 shaft carrier side.

v. Remove two thrust washers (101), needle roller

bearing (102), and No. 4 planetary gear (103).

vi. Using push tool [17], push out bearing (104) with the
press.

vii. Remove seal ring (106) from No. 3 and No. 4

carrier (105).

viii. Remove bushing (107).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
26. No. 4 sun gear

A. Remove snap ring (108) and spacer (109).

B. Remove No. 4 sun gear (110).

C. Remove seal ring (111) from spacer (109).

27. No. 4 ring gear

A. Remove four mounting bolts (112) and cover (113).

B. Remove No. 4 ring gear (114).

28. No. 5 housing and No. 5 piston assembly

A. Using eyebolts [17], remove No. 5 housing assembly (115).

★ When slinging the housing, be careful that the No. 5
piston does not fall.

B. Using eyebolts (17a), remove No. 5 piston (116) from No. 5

housing assembly (115).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Remove seal ring (117) from No. 5 piston (116).

D. Remove seal ring (118) from No. 5 housing (115).

29. No. 5 plate

• Remove No. 5 upper plate (119).

30. No. 5 spring

• Remove ten No. 5 springs (120).

31. Remove three No. 5 discs (121), 15 springs (122), and two No. 5
plates (123).

32. Remove five guide pins (124).

33. Remove No. 5 ring gear (125).

34. Remove No. 5 plate (126).

35. Remove bearing (127).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
36. No. 5 sun gear

A. Remove spacer (160) and No. 5 sun gear (161).

B. Remove bearing (127) and seal ring (162) from spacer (160).

37. No. 5 carrier assembly

A. Remove 11 mounting bolts (128).

B. Using eyebolts [18], remove No. 5 carrier assembly (129).

★ When disconnecting the dowel pin, drive it out with a
copper hammer.

C. Disassemble No. 5 carrier assembly (129) according to the

following procedure.

i. Remove snap ring (130).

ii. Remove shaft (131), ball (132), and plug (133) from
No. 5 carrier assembly (129).
★ Be careful not to lose ball (132).

iii. Remove four thrust washers (134), needle roller

bearing (135), and planetary gear (136).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
38. No. 6 plate
• Remove No. 6 upper plate (137).

39. No. 6 spring

• Remove ten No. 6 springs (138).

40. Remove four No. 6 discs (139), 20 springs (140), and three No. 6
plates (141).

41. Remove 5 guide pins (142).

42. No. 6 piston

A. Remove No. 6 piston (143).

B. Remove seal ring (144) from No. 6 piston (143).

C. Remove seal ring (146) from No. 6 housing (145).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
43. No. 6 hub
• Remove No. 6 hub (147).

44. Output shaft

A. Remove snap ring (148).

B. Support the cage and drive out output shaft (149) with push
tool [19] and a hammer.
★ Place a receiver to receive the shaft which will fall down.

C. Remove bearing (150) from output shaft (149).

45. Cage assembly

A. Remove snap ring (151).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Support No. 6 housing assembly (152) and push out cage
assembly (153) with push tool [20] (outside diameter:
139 mm [5.47 in]) and the press.

C. Remove seal ring (154) from cage assembly (153).

46. No. 6 housing assembly

A. Remove snap ring (155) from No. 6 housing assembly (152).

B. Using push tool [21], remove bearing (157), bushing (158),

and ball (159) from housing (156).
★ Be careful not to lose ball (159).

WA500-6 50-167 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Assembly

1. No. 6 housing assembly

A. Using push tool [1] (outside diameter: 189 mm [7.44 in]),

press-fit bearing (157) to No. 6 housing (156).

B. Using push tool [2] (outside diameter: 199 mm [7.83 in]),

press-fit bushing (158) and ball (159) to No. 6 housing (156).

C. Install snap ring (155) to No. 6 housing (152).

2. Cage assembly

A. Install two seal rings (154) to cage (153).

Seal ring: Grease (G2-LI)

B. Using push tool [3] (inside diameter: 141 mm [5.55 in]),

press-fit No. 6 housing assembly (152) to cage
assembly (153).
★ Press the inner race of bearing (157).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Install snap ring (151).

3. Output shaft

A. Using push tool [4] (inside diameter: 71 mm [2.80 in]), press-

fit bearing (150) to output shaft (149).

B. Set No. 6 housing assembly (152) to tool [5].

C. Using push tool [4] (inside diameter: 71 mm [2.80 in]), press-

fit output shaft and bearing assembly (149).
★ Press bearing (150) of the output shaft.

4. Seal ring

A. Install seal ring (146) to No. 6 housing assembly (145).

B. Install seal ring (144) to No. 6 piston assembly (143).

Seal ring: Grease (G2-LI)

★ Set groove (a) of the seal ring in pressure-receiving

direction (b).

WA500-6 50-169 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
5. Guide pin
• Install five guide pins (142).

6. No. 6 pin
• Install No. 6 piston (143).

7. No. 6 hub
• Install No. 6 hub (147).

8. No. 6 plate, spring, and No. 6 disc

• Install three No. 6 plates (141), 20 springs (140), and four
No. 6 discs (139).

9. No. 6 spring
• Install ten No. 6 springs (138).

10. No. 6 plate

• Install No. 6 upper plate (137).

11. No. 5 carrier assembly

A. Assemble No. 5 carrier assembly (129) according to the

following procedure.

i. Install needle roller bearing (135) to planetary gear (136).

ii. Fit two thrust washers (134) each to both sides of

planetary gear (136) and set them to the No. 5 carrier.
• Align each part with the shaft hole.

iii. Fit plug (133) and ball (132) to shaft (131) and install
them.
★ Check that the planetary gear rotates smoothly.

50-170 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
iv. Install snap ring (130) to No. 5 carrier assembly (129).

B. Using eyebolts [18] and setting the dowel pin, install No. 5
carrier assembly (129).

C. Install 11 mounting bolts (128).

★ Drive in the dowel pin with a copper hammer.

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 157 – 177 N•m (115.80 – 130.55 lbf ft)

12. No. 5 sun gear

A. Install No. 5 sun gear (161).

B. Install bearing (127) and seal ring (162) to spacer (160).

WA500-6 50-171 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
13. Install the bearing and spacer assembly (127).

14. Install No. 5 plate (126).

15. Install No. 5 ring gear (125).

16. Install five guide pins (124).

17. Install two No. 5 plates (123), three No. 5 discs (121), and
15 springs (122) alternately.

18. Install ten No. 5 springs (120).

19. No. 5 plate

• Install No. 5 upper plate (119).

20. Install No. 5 housing and No. 5 piston assembly.

A. Install seal ring (117) to No. 5 piston (116).

B. Install seal ring (118) to No. 5 housing (115).

Seal ring: Grease (G2-LI)

50-172 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
★ Set groove (c) of the seal ring in pressure-receiving
direction (d).

C. Using eyebolt [7], install No. 5 housing (115) and No. 5

piston (116).
★ While installing, use your hand to support No. 5
piston (116) to prevent it from falling.

21. No. 4 ring gear

A. Install snap ring (163).

B. Install No. 4 ring gear (114).

C. Install cover (113).

D. Install four mounting bolts (112).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 59 – 74 N•m (43.52 – 54.58 lbf ft)

WA500-6 50-173 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
22. No. 4 sun gear and spacer

A. Install seal ring (111) to spacer (109).

Seal ring: Grease (G2-LI)

B. Install No. 4 sun gear (110).

C. Install spacer (109).

D. Install snap ring (108).

23. Plate
• Install lower plate (90).

24. No. 4 plate, spring, and No. 4 disc

• Install two No. 4 plates (89), 15 springs (87), and three No. 4
discs (88).

25. No. 4 spring

• Install ten No. 4 springs (86).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
26. Plate
• Install upper plate (85).

27. No. 3 piston and No. 4 piston assembly

A. Install seal rings (81) and (84) to No. 3 and No. 4

housing (78).

B. Install seal ring (80) to No. 3 piston (79) and then install them
to No. 3 and No. 4 housing (78).

C. Install seal ring (83) to No. 4 piston (82) and then install them
to No. 3 and No. 4 housing (78).

Seal ring: Grease (G2-LI)

★ Set groove (e) of the seal ring in pressure-receiving

direction (f).

28. No. 3 and No. 4 housing assembly

A. Using eyebolts [8], install No. 3 and No. 4 housing

assembly (78).
★ While installing, use your hand to support No. 4
piston (80) to prevent it from falling.

B. Drive in the dowel pin with a copper hammer.

WA500-6 50-175 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
29. No. 3 and No. 4 carrier assembly

A. Assemble the No. 3 and No. 4 carrier assembly according to

the following procedure.

i. Install seal ring (106) to No. 3 and No. 4 carrier (164).

Seal ring: Grease (G2-LI)

ii. Using push tool G3, press-fit bushing (107) to No. 3 and
No. 4 carrier (164).

iii. Using push tool [9], press-fit bearing (104) to No. 3 and
No. 4 carrier (164).

iv. Install needle roller bearing (102) to planetary gear (103).

v. Fit two thrust washers (101) to both sides of planetary

gear (103) and set them to the No. 3 and No. 4 carrier.
★ Align each part with the shaft hole.

vi. While setting the pin holes, install shaft (98).

50-176 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
vii. Install pin (97).

★ If pin (97) was removed from carrier (164), remove

the burrs from edge (g) with sandpaper.
★ Do not apply sandpaper to inside surface (h).

viii. Install needle roller bearing (95) to planetary gear (96).

ix. Put two thrust washers (94) to both sides of the planetary
gear and set them to the No. 3 and No. 4 carriers.

x. Install shaft (92) and ball (93).

★ Check that the planetary gear rotates smoothly.

xi. Install No. 3 and No. 4 carrier assembly (129).

★ Apply push tool [10] to No. 3 and No. 4 carrier
assembly (129) and press-fit the bearing inner race to
the output shaft.

WA500-6 50-177 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
30. Guide pin
• Install 5 guide pins (70).

31. No. 3 ring gear

• Install No. 3 ring gear (77).

32. Plate
• Install lower plate (76).

33. No. 3 plate, spring, and No. 3 disc

• Install three No. 3 plates (75), 20 spring (73), and four No. 3
discs (74).

34. No. 3 spring

• Install ten No. 3 springs (72).

35. Plate
• Install upper plate (71).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
36. No. 2 carrier and housing assembly

A. Assemble the No. 2 carrier assembly according to the

following procedure.

i. Set snap ring (63) to No. 2 carrier assembly (62) and

install ring gear (64).

ii. Install snap ring (63) to the groove of ring gear (64)
securely.

iii. Install needle roller bearing (68) to planetary gear (69).

iv. Fit two thrust washers (67) to both sides of planetary

gear (69) and set them to the No. 2 and No. 4 carrier (62).
★ Align each part with the shaft hole.

v. While setting the pin holes, install shaft (66).

vi. Install pin (65).

★ Check that the planetary gear rotates smoothly.

★ If pin (65) was removed from carrier (62), remove

the burrs from edge (m) with sandpaper.
★ Do not apply sandpaper to inside surface (n).

WA500-6 50-179 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
vii. Install spacer (59) and ring gear (61) to the No. 2 carrier
assembly.

B. Assemble the No. 2 housing assembly according to the

following procedure.

i. Install seal ring (58) to No. 2 housing (55).

Seal ring: Grease (G2-LI)

ii. Support No. 2 housing assembly (55) and press-fit

bearing (57) with push tool [12].

iii. Install snap ring (56).

iv. Support No. 2 carrier assembly (165) and press-fit No. 2

housing (54) with push tool [13].
★ Press fit the bearing inner race.

v. Install snap ring (52).

50-180 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Using eyebolts [14], install No. 2 carrier and housing
assembly (51).

37. No. 2 disc, spring, and No. 2 plate

A. Install six No. 2 plates (50), seven No. 2 discs (48), and
35 springs (49) alternately.

B. Install ten springs (47).

38. No. 1 and No. 2 piston housing assembly

A. Assemble No. 1 and No. 2 piston housing assembly according

to the following procedure.

i. Install seal rings (43) and (44) to No. 1 and No. 2 piston
housing (42).

Seal ring: Grease (G2-LIs

ii. Install seal ring (41) to No. 1 piston (40).

Seal ring: Grease (G2-LI)

iii. Install seal ring (46) to No. 2 piston (45).

Seal ring: Grease (G2-LI)

iv. Install No. 1 piston (40) and No. 2 piston (45) to No. 1 and No. 2 piston housing (42).

WA500-6 50-181 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
★ Set groove (j) of the seal ring in pressure-receiving
direction (k).

v. Install 15 cushion sleeves (166) to No. 2 piston

housing (42).

★ When installing cushion sleeve (166) to No. 2 piston

housing (42), set slit (A) to the position which you
checked when you removed it.

39. Using eyebolts [15], install No. 1 and No. 2 piston housing
assembly (42).
★ While installing, use your hand to support No. 2 piston (45) to
prevent it from falling.
★ Drive in the dowel pin with a copper hammer.

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
40. No. 1 carrier assembly

A. Assemble the No. 1 carrier assembly according to the

following procedure.

i. Using push tool [16], press-fit bearing (34) to No. 1

carrier (14).

ii. Install snap ring (33) to No. 1 carrier (14).

iii. Install needle roller bearing (26) to planetary gear (27).

iv. Fit two thrust washers (25) to both sides of planetary

gear (27) and set them to the No. 1 carrier (14).
★ Align each part with the shaft hole.

v. While setting the pin holes, install shaft (23).

vi. Install pin (24).

★ Check that the planetary gear rotates smoothly.

★ If pin (24) was removed from carrier (14), remove

the burrs from edge (r) with sandpaper.
★ Do not apply sandpaper to inside surface (s).

WA500-6 50-183 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
vii. Set No. 1 ring gear (20) to No. 1 carrier assembly (14)
and install snap ring (19).

41. Input shaft

• Support No. 1 carrier (14) and press-fit input shaft (12) with
push tool [22].

42. Spacer and sun gear

• Install spacer (29) and sun gear (28).

43. Bearing and spacer

A. Using push tool [18] (inside diameter: 66 mm [2.60 in]),

press-fit bearing (32) to spacer (30).

B. Using push tool [19] (inside diameter: 66 mm [2.60 in]),

press-fit spacer (30).

C. Install snap ring (31) to spacer (30).

★ After assembling, check that the bearing rotates lightly.

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
44. No. 2 sun gear

A. Install No. 2 sun gear (10).

B. Install snap ring (9).

45. Input shaft and No. 1 carrier assembly

• Using eyebolts [20], install the input shaft and No. 1 carrier
assembly (167).

46. Guide pin

• Install five guide pins (39).

47. No. 1 plate, spring, and No. 1 disc

• Install six No. 1 plates (38), 35 springs (37), and seven No. 1
discs (36) alternately.

48. No. 1 spring

• Install ten No. 1 springs (35).

49. No. 1 housing

A. Install seal ring (18) to No. 1 housing (11).

Seal ring: Grease (G2-LI)

B. Using push tool [23] (outside diameter: 149 mm [5.87 in]),

press-fit bearing (17).

WA500-6 50-185 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Install snap ring (16) to fix bearing (17).

D. Using eyebolts [24], install No. 1 housing (11).

E. Install eyebolt [25] to the input shaft; sling the input shaft; and
install snap ring (13).

F. Install 13 tie bolts (6).

★ Do not install two tie bolts (6a) to install the eyebolts.

i. Finger tighten the tie bolts until they reach the tap hole.
★ Make sure that the bolts do not damage the cushion
sleeves.
★ Use an impact wrench after the threads are engaged
perfectly.
★ Do not degrease the threads of the tie bolts.

Mounting bolt: 157 – 177 N•m (115.80 – 130.55 lbf ft)

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
50. Check operation and stroke of clutch piston
• Using tool G, check the operation and stroke of the clutch
piston.
Air pressure: . . . . . . . . . . . . . . . . . 0.29 – 0.49 MPa (42.06 – 71.07 psi)

Piston Stroke (mm)

No. 1 7
No. 2 7
No. 3 4.2
No. 4 3
No. 5 3
No. 6 4

51. Transmission assembly

A. Install dowel pin (168) from the output shaft side.

B. Install the eyebolts to the bolt holes marked with (*).

C. Set transmission case (169) on block [26].

D. Using eyebolts [27], install transmission assembly (5).

E. Set dowel pin (168) and install the transmission assembly.

F. Install six lower mounting bolts (3) and 18 upper mounting

bolts (4).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

Shaft (Spline): Grease (LM-G)

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G. Install two tie bolts (170) which were removed to install the
eyebolts.

i. Finger tighten the tie bolts until they reach the tap hole.
★ Make sure that the bolts do not damage the cushion
sleeves.
★ Use an impact wrench after the threads are engaged
perfectly.
★ Do not degrease the threads of the tie bolts.

Mounting bolt: 157 – 177 N•m (115.80 – 130.55 lbf ft)

52. Sleeve
• Using forcing screw [1], install 5 sleeves (1).

53. Couple the transmission assembly with the power train unit. For
details, see the Power Train disconnection and connection
procedures in this section.

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Parking Brake
Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

790-101-2501 Push puller ■ 1

790-101-2610 • Leg 1
790-101-2660 • Adapter 1
790-101-2510 • Block 1
4 790-101-2560 • Nut 1
01643-32060 Washer ■ 2
Puller
790-101-2102 ■ 2
(294 kN {30 ton})
790-101-1102 Pump ■ 6
790-101-2501 Push puller ■ 1
790-101-2540 • Washer 1
790-101-2620 • Leg 2
G 790-101-2510 • Block 1
790-101-2660 • Adapter 2
790-101-2560 • Nut 2
791-112-1180 • Nut 1
5
791-520-4140 Screw ■ 1
793T-615-1630 Adapter ■ 1 N ❍
793T-615-1640 Push tool ■ 1 N ❍
01643-32060 Washer ■ 2
Puller
790-101-2102 ■ 1
(294 kN {30 ton})
790-101-1102 Pump ■ 1
6 793-615-1140 Spline wrench ■ 1
7 796-720-3800 Wrench assembly ■ 1

Disassembly

1. Disconnect the transfer and parking brake assembly from the

power train unit. For details, see the Power Train disconnection
and connection procedures in this section.

2. Remove strainer (1) and drain valve (2).

WA500-6 50-189 ➁
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3. Remove speed sensor (3).

4. Input shaft bearing cage assembly

A. Remove six mounting bolts (4).

B. Using forcing screws [1], remove bearing cage assembly (5).

C. Remove shim (6).

★ Check the thickness and quantity of the shims at each
position; keep these shims.

D. Using push tool [2], remove outer race (7) from bearing cage
assembly (5).

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5. Input shaft gear assembly

A. Remove input shaft gear assembly (8).

B. Remove bearings (10) and (11) from input shaft gear

assembly (8).

6. Outer race (input shaft side)

• Remove outer race (12) from the case.

7. Cover (input shaft side)

A. Reverse the transfer case.

B. Remove three mounting bolts (13) and cover (14).

8. Intermediate shaft bearing cage assembly

A. Remove eight mounting bolts (15).

B. Using forcing screws [3], remove bearing cage assembly (16).

WA500-6 50-191 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Remove shim (17).
★ Check the thickness and quantity of the shims at each
position; keep these shims.

D. Remove outer race (18) and O-ring (86) from bearing cage
assembly (16).

9. Intermediate shaft gear assembly

A. Remove intermediate shaft gear assembly (19).

B. Remove bearings (20) and (21) from intermediate shaft gear

assembly (19).

10. Outer race (intermediate shaft side)

• Remove outer race (22) from the case.

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★ Steps 11 – 22 are disassembly procedures for the parking brake.

11. Parking brake emergency release valve

A. Reverse the case.

B. Remove mounting bolts (32) and parking brake emergency

release valve (33).

C. Remove O-ring (87) from the mating face.

D. Using forcing screw [4], remove sleeve (34).

E. Remove O-rings (88) from sleeve (34).

12. Coupling (rear side)

• Remove bolt (35), holder (36), and coupling (37).

13. Parking brake assembly

A. Remove 12 mounting bolts (38).

★ Do not remove four hexagon socket head bolts (39).

B. Using forcing screws [5], disconnect parking brake

assembly (40).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Remove the forcing screws used in the above step from
parking brake assembly (40) and lift off the parking brake
assembly, using eyebolts [6].

D. Remove O-ring (89).

14. Cover assembly

A. Remove mounting bolts (41) and remove oil seal (43), dust
seal (44), and O-ring (45) from cage (42).

B. Install stopper bolts [7] and remove four hexagon socket head
bolts (39).

C. Loosen stopper bolts [7] gradually to disconnect cover

assembly (46) from the case. (The cover assembly is lifted up
from the case about 21 mm (0.83 in) by the spring.)

D. Lift off cover assembly (46).

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
E. Remove bearing (47), dowel pin (48), and O-ring (90) from
cover assembly (46).

15. Spring
• Remove 18 outer springs (49) and 18 inner springs (50).

16. Spacer assembly

A. Remove spacer assembly (51).

B. Using push tool [8], remove inner race (53) from spacer (52).

17. Piston

A. Using eyebolts [9], lift off piston (54).

B. Remove seal rings (55) and (56).

WA500-6 50-195 ➁
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18. Gear
• Remove gear (77).

19. Plate

A. Reverse the housing.

B. Remove four mounting bolts (57) and plate (58).

20. Snap ring and end plate

• Remove snap ring (59) and end plate (60).

21. Plate, disc, and wave spring

• Remove five plates (61), five discs (62), and five wave
springs (63) alternately.

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
22. End plate

A. Remove end plate (64).

B. Remove snap ring (91).

23. Coupling (front side)

• Remove bolt (23), holder (24), and coupling (25).

24. Seal cage

A. Remove four bolts (80) and seal cage (81).

B. Remove shim (82).

★ Check the thickness and quantity of the shims; keep these
shims.

WA500-6 50-197 ➁
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C. Remove O-ring (29), oil seal (87), and dust seal (84) from seal
cage (81).

25. Output shaft

• Using tool G4, remove output shaft (65).

26. Output shaft bearing cage assembly

A. Remove six mounting bolts (66).

B. Using forcing screws [10], remove bearing cage

assembly (67).

C. Using push tool [11], remove outer races (68a) and (68b),
collar (68c), and bearings (68d) and (68e) from bearing
cage (69).
★ Since the two bearings are not interchangeable, keep
them and their respective cages as sets.

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27. Output shaft gear

A. Remove output shaft gear (70) and spacer (71).

B. Remove three mounting bolts (72) and oil plate (73).

Assembly

1. Outer race (intermediate shaft side)

• Using push tool [1] (outside diameter: 179 mm [7.05 in]),
press-fit outer race (22) to the case.

2. Intermediate shaft gear assembly

A. Press-fit bearings (20) and (21) to intermediate shaft gear

assembly (19).

B. Install intermediate shaft gear assembly (19).

Bearing: Grease (LM-G)

WA500-6 50-199 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
3. Bearing cage assembly (intermediate shaft gear side)

A. Using push tool [2] (outside diameter: 179 mm [7.05 in]),

press-fit outer race (18) to bearing cage (16).

B. Fit O-ring (86).

O-ring: Grease (G2-LI)

C. Install intermediate shaft bearing cage assembly (16) without

setting any shim.

D. Adjusting preload on intermediate shaft bearing

Adjust the shim of bearing cage (16) according to the
following procedure.

i. Install bearing cage (16) without setting shim (17) and

tighten the mounting bolts to 4.9 N•m (43.37 lbf in).
★ After installing the bearing, drop 6 cc of transmission
oil (TO30) onto it and rotate it about ten turns.

ii. Rotate intermediate shaft gear (19) 20 turns and check the
tightening torque of 4.9 N•m (43.37 lbf in) for the
mounting bolts again.

iii. If the tightening torque has changed, repeat Steps Di and Dii.

iv. If the tightening torque has not changed, set shim (17)
and tighten the mounting bolts to the specified torque.
Shim standard thickness: . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.039 in)

v. Using tool G6 and the torque wrench, measure the

rotation torque of intermediate shaft gear (19).

Rotation torque: 0.49 – 0.98 N•m (4.34 – 8.67 lbf in)

Standard shim thickness: . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.039 in)

Standard clearance: . . . . . . . . . . . . .0.63 – 1.37 mm (0.025 – 0.054 in)
★ Check that the gear has no play.

vi. After adjusting the preload, remove intermediate shaft

gear (19) and bearing cage (16) (since the preload on each gear must be adjusted independently).

50-200 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
4. Cover (input shaft side)
• Fit the O-ring; install cover (14); and tighten the mounting
bolts (13).

O-ring: Grease (G2-LI)

5. Outer race (input shaft side)

A. Reverse the case.

B. Using push tool [3] (outside diameter: 159 mm [6.26 in]),

press-fit outer race (12) to the case.

6. Input shaft gear assembly

A. Press-fit bearings (10) and (11) to input shaft gear (8).

B. Install input shaft gear (8).

Bearing: Grease (LM-G)

WA500-6 50-201 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
7. Bearing cage assembly (input shaft gear side)

A. Using push tool [4] (outside diameter: 159 mm [6.26 in]),

press-fit outer race (7) to bearing cage (5).

B. Install input shaft bearing cage assembly (5) without setting

the shim.

C. Adjusting preload on input shaft bearing

Adjust the shim of bearing cage (5) according to the following
procedure.

i. Install bearing cage (5) without setting shim (6) and

tighten the mounting bolts to 4.9 N•m (43.37 lbf in).
★ After installing the bearing, drop 6 cc of transmission
oil (TO30) onto it and rotate it about ten turns.

ii. Rotate input shaft gear (8) 20 turns and check the
tightening torque of 4.9 Nm (43.37 lbf in) for the
mounting bolts again.

iii. If the tightening torque has changed, repeat Steps Ci and

Cii.

iv. If the tightening torque has not changed, set shim (6) and
tighten the mounting bolts to the specified torque.
Shim standard thickness: 2 mm (0.079 in)

v. Using tool G7 and the torque wrench, measure the

rotation torque of input shaft gear (8).

Rotation torque: 0.49 – 0.98 N•m (4.34 – 8.67 lbf in)

Standard shim thickness: . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.079 in)

Standard clearance: . . . . . . . . . . . . .1.61 – 2.39 mm (0.063 – 0.094 in)
★ Check that the gear has no play.

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DISASSEMBLY AND ASSEMBLY POWER TRAIN
8. Output shaft gear assembly

A. Put spacer (71), output shaft gear (70), and oil plate (73) in the
case.

B. Tighten three mounting bolts (72).

Mounting bolt: Adhesive (LT-2)

9. Outer race and output shaft

A. Using push tool [5], press-fit outer race (68a) to bearing

cage (69).

B. Install output shaft (65) and support it on block [6].

10. Output shaft bearing cage assembly

• Fit the O-ring and install bearing cage assembly (69).

O-ring: Grease (G2-LI)

WA500-6 50-203 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
11. Output shaft bearing

A. Using tool G5, press-fit bearing (68d).

B. Install collar (68c).

C. Press-fit bearing (68e) in the same manner.

12. Outer race

• Using push tool [6], press-fit outer race (68b).
★ After installing the bearing, drop 6 cc of transmission oil
(TO30) onto it and rotate it about ten turns.

13. Seal cage

A. Using the push tool, press-fit oil seal (83) and dust seal (84) to
seal cage (81).

Oil seal: Grease (G2-LI)

Oil seal fitting surface: Gasket sealant (THREEBOND 1110B)

★ Apply the gasket sealant thinly over the inside surface of

the housing hole and wipe off the projected part.

Dust seal: Grease (G2-LI)

50-204 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Adjust the shim according to the following procedure.

i. Fit the O-ring and install seal cage (81) without setting
the shim.
★ Do not tighten the mounting bolts.

O-ring: Grease (G2-LI)

ii. Rotate the shaft about 20 turns.

iii. Using thickness gauges, measure clearance (a) between

the seal cage (81) and fitting surface.
Shim thickness (b): . . . . . . . a – (0.05 to 0.10) mm (0.0020 – 0.0039 in)

iv. Set shim (82) of thickness (b), obtained by the above

procedure, and tighten bolts (80).
Standard shim thickness: . . . . . . . . . . . . . . . . . . . . . . .0.5 mm (0.02 in)
Standard clearance: . . . . . . . . . . . . .0.48 – 1.32 mm (0.019 – 0.052 in)

14. Coupling (front side)

A. Fit the O-ring and install coupling (25), holder (24), and
bolt (23).

O-ring: Grease (G2-LI)

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 824 – 1,030 N•m (607.75 – 759.69 lbf ft)

15. Intermediate shaft gear assembly

• Refer to Step 2 and install the intermediate shaft gear assembly which was removed.
★ Steps 16 – 29 are assembly procedures for the parking brake.

16. Cover
• Assemble the cover assembly according to the following
procedure.

A. Using push tool [1] (outside diameter: 189 mm [7.44 in]),

press-fit bearing (47) to cover (46).

B. Install two dowel pins (48).

WA500-6 50-205 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
17. Spacer assembly

A. Using push tool [2] (inside diameter: 106 mm [4.17 in]),

press-fit inner race (53) to spacer (52).

B. Install spacer assembly (51) to cover assembly (46).

18. Spring

A. Install 18 outer springs (49) and 18 inner springs (50).

B. Install O-ring (90).

O-ring: Grease (G2-LI)

19. Piston

A. Install seal rings (55) and (56) to piston (54).

★ Set groove (c) of the seal ring as shown in the figure.

Seal ring: Grease (G2-LI)

B. Install piston (54) to cover assembly (46).

20. Plug

A. Remove two plugs (74).

B. Install the washers to two parking brake assembly mounting

bolts and tighten them into the plug holes.
★ Tighten the bolts gradually and alternately.
★ Pull the piston by tightening the bolts.

50-206 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
21. Housing

A. Install housing (75) to cover (46).

B. Install four hexagon socket head bolts (76).

22. Gear
• Install gear (77).

23. Plate, disc, and wave spring

A. Install snap ring (91).

B. Install end plate (64).

WA500-6 50-207 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Install five plates (61), five discs (62), and five wave
springs (63) alternately.

24. Snap ring and end plate

• Install end plate (60) and fix it with snap ring (59).

25. Plate

A. Install plate (58) and tighten four mounting bolts (57).

Mounting bolt: Adhesive (LT-2)

B. Reverse the parking brake assembly.

C. Remove the two bolts used to install the spring and install
plugs (74).

Plug: Gasket sealant (LG-5)

50-208 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
26. Seal cage

A. Press fit oil seal (43) and dust seal (44) to seal cage (42).

Oil seal: Grease (G2-LI)

Oil seal fitting surface: Gasket sealant (THREEBOND 1110B)

Dust seal: Grease (G2-LI)

★ Apply the gasket sealant thinly over the inside surface of the oil seal fitting part of the cover and wipe off the
projected part.

B. Install seal cage (42) and tighten four mounting bolts (41).

27. Parking brake assembly

A. Fit O-ring (89).

O-ring: Grease (G2-LI)

B. Using eyebolts [6], install parking brake assembly (40).

WA500-6 50-209 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Install 12 mounting bolts (38).

Mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

28. Sleeve

A. Fit O-ring (88) to sleeve (34).

O-ring: Grease (G2-LI)

B. Using forcing screw [4], install sleeve (34).

C. Fit O-ring (87) and install parking brake emergency release

valve (33).

O-ring: Grease (G2-LI)

29. Coupling (rear side)

Fit the O-ring and install coupling (37), holder (36), and bolt (35).
★ Set coupling (37) to the position of the coupling on the
opposite side.

O-ring: Grease (G2-LI)

Mounting bolt: Adhesive (LT-2)

50-210 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Mounting bolt: 824 – 1,030 N•m (607.75 – 759.69 lbf ft)

30. Speed sensor

A. Tighten speed sensor (3) until it touches the gear lightly and
then return it by 1/2 - 1 turn to make clearance (d).
Clearance (d): . . . . . . . . . . . . . . . . . . . . .0.75 – 1.5 mm (0.03 – 0.06 in)

B. Tighten locknut (85).

Locknut: 49.0 – 68. 6 N•m (36.14 – 50.60 lbf ft)

31. Install strainer (1) and drain valve (2).

32. Connect the transfer and parking brake assembly to the power train
unit. For details, see the Power Train disconnection and
connection procedures in this section

WA500-6 50-211 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Front Axle

WARNING! Stop the machine on level ground and lower the bucket to the ground.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Start the engine; dump the bucket gradually to raise the machine
body; and set stands [1] securely under the front frame.

WARNING! Apply the parking brake and lock the rear tires
with chocks.

2. Install a nylon sling around front tire and wheel assembly (1); sling
it; remove its mounting bolts; and lift it off. Remove both of the
right and left tires. [*1]

Front tire and wheel assembly: 830 kg (1,830 lb)

3. Remove front frame front cover (2).

50-212 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
4. Disconnect brake hose (3).

5. Remove the mounting bolts and disconnect front drive shaft (4).
[*2]
★ When disconnecting the drive shaft, make a match mark
between it and the coupling.

6. Sling front axle assembly (5); remove its eight mounting bolts (6);
and lift it off. [*3]

Front axle assembly: 2,300 kg (5,071 lb)

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Front tire mounting bolt: 824 – 1,030 N•m (607.75 – 759.69 lbf ft)

[*2]

Drive shaft mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

[*3]

Front axle mounting bolt: 2,450 – 3,038 N•m (1,807.03 – 2,240.71 lbf ft)

Bleeding Air

• Bleed air from the brake circuit. For details, see Brake System: Bleeding Air from Brake Circuit in the Testing and
Adjusting section.

WA500-6 50-213 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Rear Axle

WARNING! Stop the machine on level ground and lower the bucket to the ground.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Start the engine; dump the bucket gradually to raise the machine
body; and set stands [1] securely under the front end of the rear
frame.

2. Tilt the bucket slowly until the front tires are fully lowered to the
ground and the rear tires are floated.

3. Set jack [2] under the counterweight to support the rear end of the
rear frame.

WARNING! Apply the parking brake and lock the rear tires
with chocks.

4. Install a nylon sling around rear tire and wheel assembly (1); sling
it; remove its mounting bolts; and lift it off. Remove both of the
right and left tires. [*1]

Rear tire and wheel assembly: 830 kg (1,830 lb)

50-214 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
5. Disconnect brake hoses (2) and (3).

6. Unplug wiring harness connector R17 (4) and remove the two
wiring harness connectors.

7. Disconnect grease tubes (5) and (6)

8. Disconnect rear drive shaft (7). [*2]

9. Sling rear axle assembly (8) and support rear support (9) with
jack [3].

10. Remove support mounting bolts (10); disconnect the support and
rear axle assembly from the machine; and lower the jack and crane
slowly to remove the assembly. [*3]

11. Sling the left (right) side of the axle housing; support the other side
with a jack or a forklift; and pull out the rear axle and support
assembly to the side of the machine.

Rear axle and support assembly: 2,400 kg (5,291 lb)

WA500-6 50-215 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Rear tire mounting bolt: 824 – 1,030 N•m (607.75 – 759.69 lbf ft)

[*2]

Drive shaft mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

[*3]

Axle (support) mounting bolt: 1,519 – 1,911 N•m (1,120.36 – 1,409.48 lbf ft)

Bleeding Air

1. Bleed air from the brake circuit. For details, see Brake System: Bleeding Air from Brake Circuit in the Testing and
Adjusting section.

50-216 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Front Differential
★ This section describes the removal and installation procedures for the front differential assembly. Remove and install the
rear differential assembly in the same manner.

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal

Removal

1. Remove the front axle assembly. For details, see the Front Axle removal and installation procedures in this section.

2. Remove plug (1) and drain the axle oil. [*1]

★ Set the drain plug at the bottom.

Axle oil:
Front: Approximately 98 l (26 gal)
Rear: Approximately 85 l (23 gal)

3. Remove seven bolts (2). [*2]

4. Remove cover (3).

5. Using forcing screw [1], pull out drive shaft (4).

• Pull out the drive shaft by about 200 mm (8 in).
• Pull out the drive shaft on the opposite side in the same
manner.

6. Remove 18 mounting bolts (5). [*3]

7. Using eyebolts [2], remove front differential assembly (6). [*4]

Front differential assembly:
Without LSD* specification: . . . . . . . . . . . . . . . . . . . . . . . 370 kg (816 lb)
LSD specification: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 kg (882 lb)
* (LSD: Limited Slip Differential)
★ Remove the O-ring from the mating face of the housing.

WA500-6 50-217 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Plug (1): 58.8 – 78.4 N•m (43.37 – 57.82 lbf ft)

[*2]

Mounting bolt (2): 98 – 123 N•m (72.28 – 90.72 lbf ft)

[*3]

Mounting bolt (5): 490 – 608 N•m (361.40 – 448.44 lbf ft)

[*4]

Adjusting Clearance Adjustment Bolt

1. Tighten clearance adjustment bolt (7) to cap (9) and then return it
by 20 – 30° to make clearance (a).
Clearance (a): . . . . . . . . . . . . . . . . . .0.08 – 0.13 mm (0.003 – 0.005 in)

2. Tighten nut (8).

Nut (8): 343 – 441 N•m (252.98 – 325.26 lbf ft)

Refilling with Oil

Axle oil:
Front: 98 l (26 gal)
Rear: 85 l (23 gal)

50-218 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Differential (with Limited Slip Differential)

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

790-501-5000 Repair stand ■ 1

H 1 790-901-4110 Bracket ■ 1
793T-622-2120 Plate ■ 1 N ❍

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Disassembly

1. Set differential assembly (1) to tool H1.

Differential assembly: 430 kg (948 lb)

2. Differential gear and case assembly

★ Perform the following work on the right and left sides in a
similar manner.

A. Remove mounting bolts (2) and remove lock (3).

WA500-6 50-219 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Loosen nut (4) with a bar until you can rotate it with your
fingers.

C. Sling the differential gear and case assembly.

D. Remove mounting bolts (5) and cap (6).

★ Make marks on the right and left caps.

E. Remove nut (4).

F. Using sling [1], remove differential gear and case

assembly (7).
★ Be careful not to drop bearing outer race (8).

Differential gear and case assembly: 210 kg (463 lb)

3. Gear case cover A

A. Remove 24 mounting bolts (9).

B. Remove gear case cover A (10).

C. Remove bearing (11).

D. Remove thrust plate (12) and dowel pin (13) from gear case
cover A (10).

50-220 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
4. Disc and plate
• Remove three discs (14) and four plates (15).

5. Pressure ring A
• Remove pressure ring A (16).

6. Side gear A
• Remove side gear A (17).

7. Cross shaft and pinion gear

• Remove cross shaft (18) and pinion gear (19) together.

WA500-6 50-221 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
8. Side gear B
• Remove side gear B (20).

9. Pressure ring B
• Remove pressure ring B (21).

10. Disc and plate

• Remove four plates (22) and three discs (23).

11. Gear case cover B

A. Remove thrust plate (25) and dowel pin (26) from gear case
cover B (24).

50-222 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Reverse the gear case and remove bearing (27).

C. Remove 20 mounting bolts (28).

D. Remove gear case cover B (29) from bevel gear (30).

12. Coupling

A. Remove mounting bolt (31) and holder (32).

B. Remove shim (33), O-ring (34), and coupling (35).

13. Pinion assembly

A. Remove 18 mounting bolts (36).

B. Using forcing screws [2], disconnect pinion assembly (37).

C. Using eyebolts [3], remove pinion assembly (37).

Pinion assembly: 95 kg (209 lb)

D. Remove shim (38).

★ Check the thickness and quantity of the shim.

WA500-6 50-223 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
E. Remove differential carrier (47) from tool H1.

Differential carrier assembly: 85 kg (187 lb)

F. Disassemble the pinion assembly according to the following

procedure.

i. Using tool [4] (inside diameter: 321 mm [12.63 in]),

support pinion case (39).

ii. Using push tool [5], pull out pinion shaft (40).

iii. Using puller [6] (294 kN [30 ton]), pull out bearing (41).

iv. Remove dust seal (42), oil seal (43), and bearing (44).

v. Remove bearing outer race (45).

50-224 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Assembly

1. Bevel gear assembly

A. Using push tool [10] (inside diameter: 131 mm [5.16 in]),

press fit bearing (27) to gear case cover B (29).
★ Press fit the inner race of the bearing.

B. Install gear case cover B (29) to bevel gear (30).

C. Tighten 20 mounting bolts (28).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 490 – 608 N•m (361.40 – 448.44 lbf ft)

2. Gear case cover B

A. Install dowel pin (26) to gear case cover B (24).

B. Install thrust plate (25).

3. Disc and plate

• Install three discs (23) and four plates (22) alternately.

Both sides of plate and disc: AXO80

WA500-6 50-225 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
4. Pressure ring B
• Install pressure ring B (21).

5. Side gear B
• Install side gear B (20).
★ When installing, mesh the internal teeth of the disc with
the gear spaces.

6. Cross shaft and pinion gear

• Install cross shaft (18) and pinion gear (19) together.

7. Side gear A
• Install side gear A (17).

50-226 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
8. Pressure ring A
• Install pressure ring A (16).

9. Disc and plate

A. Install four plates (15) and three discs (14) alternately.

★ When installing, mesh the internal teeth of the disc with
the gear spaces.

Both sides of plate and disc: AXO80

B. Adjusting clearance between plate and disc (adjusting internal

clearance of LSD)

i. Using depth gauge [1], measure level difference (A2)

between the case and washer.

ii. Using depth gauge [1], measure level difference (A1) of

the cover.
Clearance (A): . . . . . . . . . . . A2 – A1 = 0.2 to 0.8 mm (0.008 – 0.031 in)
★ Measure the clearance at four places equally spaced
on the periphery and obtain the average.

WA500-6 50-227 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
iii. If the clearance is out of the standard range, adjust it by using plates of different thickness.
Part No. 425-22-37450: . . . . . . . . . . . . . . . . . . . . . . . .3.4 mm (0.13 in)
Part No. 425-22-37460: . . . . . . . . . . . . . . . . . . . . . . . .3.5 mm (0.14 in)
★ Be sure to use plates of the same thickness for the lower side (see the table).
★ When assembling the plates and discs, minimize the clearance.

Standard After After

(Before adjustment adjustment
Combination of adjustment) (Sample 1) (Sample 2)
Plates
Flange Cover Flange Cover Flange Cover
side side side side side side
425–22–37450
2 2 1 1 4 4
(3.4 mm)
425–22–37460
2 2 3 3 0 0
(3.5 mm)

C. Adjusting clearance between thrust washer and cover

i. Install thrust washer (12) to cover (10) temporarily.

ii. Using depth gauge [1], measure level difference (B1)

between the cover and washer.

iii. Using depth gauge [1], measure level difference (B2)

between the case and washer.
Clearance (B): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (B2 – B1) + (A/2)
★ Measure the bottom side in the same manner.
★ Measure the clearance at four places equally spaced on
the periphery and obtain the average.

iv. If the clearance is out of the standard range, adjust it by

using plates of different thickness.
Part No. 425-22-37390: . . . . . . . . . . . . . . . . . . . . . . .3.75 mm (0.15 in)
Part No. 425-22-37380: . . . . . . . . . . . . . . . . . . . . . . . .4.0 mm (0.16 in)
Part No. 425-22-37370: . . . . . . . . . . . . . . . . . . . . . . .4.25 mm (0.17 in)

50-228 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
10. Gear case cover A

A. Using push tool [11] (inside diameter: 131 mm [5.16 in]),

press fit bearing (11) to gear case cover (A) (10).
★ Press-fit the inner race of the bearing.

B. Install dowel pin (13) and thrust plate (12) to gear case
cover A (10).
★ When installing, apply grease (G2-LI) thinly to the thrust
plate to prevent it from falling.

C. Install gear case cover A (10).

D. Tighten 24 mounting bolts (9).

Mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

E. Measuring differential rotation torque

i. Using the bearing, cap, and nut, install the differential

gear and case assembly temporarily to the differential
carrier.

ii. Fix either side gear of the differential gear case assembly
with shaft [1]. (Stop the rotation of the side gear.)

iii. Measure the rotation torque of the side gear on the

opposite side with torque wrench [2].
★ Set the case so that it can rotate freely.
★ You can use a measuring instrument which satisfies
the measurement condition and can be fixed to the
side gear.

Differential rotation torque: Maximum 34 N•m (25.08 lbf ft)

WA500-6 50-229 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
11. Differential gear and carrier assembly
★ Perform the following work on the right and left sides in the
same manner.

A. Set differential carrier (47) to tool H1.

Differential carrier assembly: 85 kg (187 lb)

B. Using sling [1], install differential gear and case assembly (7).
★ Be careful not to drop bearing outer race (8).

Differential gear and case assembly: 210 kg (463 lb)

C. Install nut (4) to the threaded part on the differential carrier

side.

D. Install cap (6) and tighten mounting bolts (5).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 1,520 – 1,910 N•m (1,121.09 – 1,408.74 lbf ft)

★ Set the match mark on cap (6).

★ Drop 6 cc of axle oil (AXO80) onto the bearing and rotate
it about ten turns.
★ Before tightening mounting bolts (5), rotate the bevel gear 20 – 30 turns to run in the bearing.

E. Adjust the preload on the differential bearing according to the

following procedure.

i. Using tool [12], tighten nut (4).

50-230 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
ii. Apply push-pull scale [13] to the tip of bevel gear (30)
and measure starting torque (b).

Starting torque (b): 53.9 – 83.4 N•m (39.75 – 61.51 lbf ft)

★ If the measured value is out of the above range,

adjust it by rotating nut (4).

★ Precautions for adjusting starting torque

• If the nut is tightened too much for starting torque
adjustment or the starting torque is adjusted
defectively, return the nut to the condition before the
adjustment work.
• At this time, hit the bevel gear lightly with a plastic
hammer while rotating it.
• At this time, check that there is no clearance in
part (c) and adjust the preload again.

12. Pinion assembly

A. Assemble the pinion assembly according to the following

procedure.

i. Using push tool [6] (inside diameter: 101 mm [3.98 in]),

press-fit bearing (41) to pinion shaft (40).

ii. Press-fit bearing (44) and bearing outer race (45) to

pinion case (46).
★ Drop 6 cc of axle oil (AXO80) onto the bearing and
rotate it about ten turns.

WA500-6 50-231 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
iii. Using push tool [7] (inside diameter: 76 mm [2.99 in]),
press-fit pinion case (46) to pinion shaft (40).
★ Press-fit the inner race of bearing (44).

iv. Install dust seal (42) and oil seal (43).

★ Using the jig, press-fit the oil seal so that its
height (a) is 14 ±0.5 mm (0.55 ±0.02 in).
★ Install the dust seal so that its height (b) is the same
as the oil seal.

Oil seal: Grease (G2-LI)

Oil seal fitting surface: Gasket sealant (THREEBOND 1110B)

Dust seal: Grease (G2-LI)

★ Apply the gasket sealant thinly over the inside surface of the oil seal fitting part of the pinion case and wipe
off the projected part.

B. Coupling

i. Install coupling (35).

ii. Install O-ring (34) and shim (33) which was removed
during disassembly.

iii. Install holder (32) and tighten mounting bolts (31).

★ While rotating the pinion shaft 20 – 30 turns, tighten
mounting bolts (31) gradually.

O-ring: Grease (G2-LI)

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 824 – 1,030 N•m (607.75 – 759.69 lbf ft)

50-232 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Adjust the preload on the pinion shaft according to the
following procedure.

i. Install measuring bolt [8] to pinion assembly (37).

ii. Using push-pull scale [9], measure starting torque (a).

Starting torque (a): 49.0 – 127.4 N•m (36.14 – 93.97 lbf ft)

★ If the measured value is out of the above range,

adjust it by increasing or decreasing the shims.

D. Install shim (38) removed for disassembly.

Shim adjustment allowance: . . . . . . .0.71 – 2.21 mm (0.028 – 0.087 in)

E. Fit the O-ring and install pinion assembly (37).

O-ring: Grease (G2-LI)

Pinion assembly: 110 kg (243 lb)

F. Tighten 18 mounting bolts (36).

Mounting bolt: 245 – 309 N•m (180.70 – 227.91 lbf ft)

13. Adjusting tooth contact and backlash

★ Adjust the backlash and tooth contact simultaneously.

A. Adjust the backlash according to the following procedure.

i. Move the bevel gear with adjustment nuts (4a) and (4b).
★ Rotate adjustment nuts (4a) and (4b) by the same
amount, in the same direction, so that the adjusted
preload on the bearing does not change.

ii. Apply dial gauge [14] perpendicularly to the tooth surface

on the reverse side at the outer end of the bevel gear.

iii. Adjust adjustment nut (4) so that dial gauge [14] indicates
the following range (backlash).
Standard backlash: . . . . . . . . . . . . . .0.36 – 0.51 mm (0.014 – 0.020 in)

WA500-6 50-233 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
★ Adjust the backlash at three to four places and measure it
with the pinion gear fixed.
• When backlash is less than standard range:
Loosen the adjustment nut on the bevel gear side and
tighten the adjustment nut on the opposite side by the
same angle (to move the bevel gear in direction (A)).
• When the backlash is above standard range:
Loosen the adjustment nut on the opposite side and
tighten the adjustment nut on the bevel gear side by the
same angle (to move the bevel gear in direction (B)).

B. Checking tooth contact

i. Apply red lead thinly to the surface of the pinion gear and
turn the bevel gear in the forward and reverse directions,
and then check the tooth contact pattern on the bevel gear.

ii. The center of the tooth contact must be at the middle of

the tooth height and at a point about 33% of the tooth
length (x) from small end (C). The tooth contact width
must be 30 – 60% of the tooth length (y).
★ Check that there is no strong contact at tip (A),
bottom (B), small end (C), or large end (D).
• If the tooth contact is adjusted in this way, the teeth
come in contact with each other correctly when they
are loaded.

iii. Adjusting tooth contact

• If the tooth contact pattern is not correct, adjust it
according to the following procedure.
★ After adjusting the tooth contact, check the backlash
again.
★ If bevel pinion is too far from bevel gear
• The tooth contact pattern is illustrated in the figure.
• Decrease the shims of the bevel pinion to move the
bevel pinion in direction (C).
• Move the bevel gear in direction (D).

★ If bevel pinion is too close to bevel gear

• The tooth contact pattern is illustrated in the figure.
• Increase the shims of the bevel pinion to move the
bevel pinion in direction (E).
• Move the bevel gear in direction (F).

50-234 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
★ If bevel gear is too close to bevel pinion
• The tooth contact pattern is illustrated in the figure.
• Decrease the shims of the bevel pinion to move the
bevel pinion in direction (C).
• Move the bevel gear in direction (D).

★ If bevel gear is too far from bevel pinion

• The tooth contact pattern is illustrated in the figure.
• Increase the shims of the bevel pinion to move the
bevel pinion in direction (E).
• Move the bevel gear in direction (F).

14. Lock
• After finishing all adjustments, install lock (3) and tighten
mounting bolts (2).

Mounting bolt: 27 – 34 N•m (19.91 – 25.08 lbf ft)

15. Differential assembly

• Remove differential assembly (1) from tool H1.

Differential assembly: 430 kg (948 lb)

WA500-6 50-235 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Differential (without Limited Slip Differential)

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

790-501-5000 Repair stand ■ 1

H 1 790-901-4110 Bracket ■ 1
793T-622-2120 Plate ■ 1 N ❍

Disassembly

1. Set differential assembly (1) to tool H1.

Differential assembly: 390 kg (860 lb)

2. Differential gear and case assembly

★ Perform the following work on the right and left sides in a
similar manner.

A. Remove mounting bolts (2) and remove lock (3).

B. Loosen nut (4) with a bar until you can rotate it with your
fingers.

C. Sling the differential gear and case assembly.

D. Remove mounting bolts (5) and cap (6).

★ Make distinctive marks on the right and left caps.

E. Remove nut (4).

50-236 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
F. Using sling [1], remove differential gear and case
assembly (7).
★ Be careful not to drop bearing outer race (8).

Differential gear and case assembly: 180 kg (397 lb)

3. Gear case cover A

A. Remove eight mounting bolts (9).

B. Remove gear case cover A (10).

C. Remove bearing (11).

D. Remove dowel pin (13) from gear case cover A (10).

E. Remove thrust plate (12).

WA500-6 50-237 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
4. Side gear A
• Remove side gear A (14).

5. Cross shaft and pinion gear

• Remove cross shaft (15), pinion gear (16), and washer (17)
together.

6. Side gear B
• Remove side gear B (18).

7. Gear case cover B

A. Remove thrust plate (20) and dowel pin (21) from gear case
cover B (19).

50-238 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Remove bearing (22).

C. Remove 20 mounting bolts (23).

D. Remove gear case cover B (24) from bevel gear (25).

8. Coupling

A. Remove mounting bolt (31) and holder (32).

B. Remove shim (33), O-ring (34), and coupling (35).

9. Pinion assembly

A. Remove 18 mounting bolts (36).

B. Using forcing screws [2], disconnect pinion assembly (37).

C. Using eyebolts [3], remove pinion assembly (37).

Pinion assembly: 95 kg (209 lb)

D. Remove shim (38).

★ Check the thickness and quantity of the shim.

WA500-6 50-239 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
E. Remove differential carrier (47) from tool H1.

Differential carrier assembly: 85 kg (187 lb)

F. Disassemble the pinion assembly according to the following

procedure.

i. Using tool [4] (inside diameter: 321 mm [12.63 in]),

support pinion case (39).

ii. Using push tool [5], pull out pinion shaft (40).

iii. Using puller [6] (294 kN [30 ton]), pull out bearing (41).

iv. Remove dust seal (42), oil seal (43), and bearing (44).

v. Remove bearing outer race (45).

50-240 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Assembly

1. Bevel gear assembly

A. Using push tool [10] (inside diameter: 131 mm [5.16 in]),

press fit bearing (22) to gear case cover B (24).
★ Press fit the inner race of the bearing.

B. Install gear case cover B (24) to bevel gear (25).

C. Tighten 20 mounting bolts (23).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 490 – 608 N•m (361.40 – 448.44 lbf ft)

2. Gear case cover B

A. Install dowel pin (21) to gear case cover B (19).

B. Install thrust plate (20).

3. Side gear B
• Install side gear B (18).

WA500-6 50-241 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
4. Cross shaft and pinion gear
• Install cross shaft (15), pinion gear (16), and washer (17)
together.

5. Side gear A
• Install side gear A (14).

6. Gear case cover A

A. Using push tool [11] (inside diameter: 131 mm [5.16 in]),

press fit bearing (11) to gear case cover (A) (10).
★ Press-fit the inner race of the bearing.

B. Install dowel pin (13) and thrust plate (12) to gear case
cover A (10).
★ When installing, apply grease (G2-LI) thinly to the thrust
plate to prevent it from falling.

50-242 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
C. Install gear case cover A (10).

D. Tighten eight mounting bolts (9).

Mounting bolt: 490 – 608 N•m (361.40 – 448.44 lbf ft)

7. Differential gear and carrier assembly

★ Perform the following work on the right and left sides in the
same manner.

A. Set differential carrier (47) to tool H1.

Differential carrier assembly: 85 kg (187 lb)

B. Using sling [1], install differential gear and case assembly (7).
★ Be careful not to drop bearing outer race (8).

Differential gear and case assembly: 180 kg (397 lb)

C. Install nut (4) to the threaded part on the differential carrier

side.

D. Install cap (6) and tighten mounting bolts (5).

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 1,520 – 1,910 N•m (1,121.09 – 1,408.74 lbf ft)

★ Set the match mark on cap (6).

★ Drop 6 cc of axle oil (AXO80) onto the bearing and rotate
it about ten turns.
★ Before tightening mounting bolts (5), rotate the bevel gear 20 – 30 turns to run in the bearing.

WA500-6 50-243 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
E. Adjust the preload on the differential bearing according to the
following procedure.

i. Using tool [12], tighten nut (4).

ii. Apply push-pull scale [13] to the tip of bevel gear (30)
and measure starting torque (b).

Starting torque (b): 53.9 – 83.4 N•m (39.75 – 61.51 lbf ft)

★ If the measured value is out of the above range,

adjust it by rotating nut (4).

★ Precautions for adjusting starting torque

• If the nut is tightened too much for starting torque
adjustment or the starting torque is adjusted
defectively, return the nut to the condition before the
adjustment work.
• At this time, hit the bevel gear lightly with a plastic
hammer while rotating it.
• At this time, check that there is no clearance in
part (c) and adjust the preload again.

8. Pinion assembly

A. Assemble the pinion assembly according to the following

procedure.

i. Using push tool [6] (inside diameter: 101 mm [3.98 in]),

press-fit bearing (41) to pinion shaft (40).

50-244 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
ii. Press-fit bearing (44) and bearing outer race (45) to
pinion case (46).
★ Drop 6 cc of axle oil (AXO80) onto the bearing and
rotate it about ten turns.

iii. Using push tool [7] (inside diameter: 76 mm [2.99 in]),

press-fit pinion case (46) to pinion shaft (40).
★ Press-fit the inner race of bearing (44).

iv. Install dust seal (42) and oil seal (43).

Oil seal: Grease (G2-LI)

Oil seal fitting surface: Gasket sealant (THREEBOND 1110B)

Dust seal: Grease (G2-LI)

★ Apply the gasket sealant thinly over the inside

surface of the oil seal fitting part of the pinion case
and wipe off the projected part.

B. Coupling

i. Install coupling (35).

ii. Install O-ring (34) and shim (33) which was removed
during disassembly.

iii. Install holder (32) and tighten mounting bolts (31).

★ While rotating the pinion shaft 20 – 30 turns, tighten
mounting bolts (31) gradually.

O-ring: Grease (G2-LI)

WA500-6 50-245 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 824 – 1,030 N•m (607.75 – 759.69 lbf ft)

C. Adjust the preload on the pinion shaft according to the

following procedure.

i. Install measuring bolt [8] to pinion assembly (37).

ii. Using push-pull scale [9], measure starting torque (a).

Starting torque (a): 49.0 – 127.4 N•m (36.14 – 93.97 lbf ft)

★ If the measured value is out of the above range,

adjust it by increasing or decreasing the shims.

D. Install shim (38) removed for disassembly.

Shim adjustment allowance: . . . . . . .0.71 – 2.21 mm (0.028 – 0.087 in)

E. Fit the O-ring and install pinion assembly (37).

O-ring: Grease (G2-LI)

Pinion assembly: 110 kg (243 lb)

F. Tighten 18 mounting bolts (36).

Mounting bolt: 245 – 309 N•m (180.70 – 227.91 lbf ft)

9. Adjusting tooth contact and backlash

★ Adjust the backlash and tooth contact simultaneously.

A. Adjust the backlash according to the following procedure.

i. Move the bevel gear with adjustment nuts (4a) and (4b).
★ Rotate adjustment nuts (4a) and (4b) by the same
amount, in the same direction, so that the adjusted
preload on the bearing does not change.

50-246 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
ii. Apply dial gauge [14] perpendicularly to the tooth surface
on the reverse side at the outer end of the bevel gear.

iii. Adjust adjustment nut (4) so that dial gauge [14] indicates
the following range (backlash).
Standard backlash: . . . . . . . . . . . . . .0.36 – 0.51 mm (0.014 – 0.020 in)

★ Adjust the backlash at three to four places and measure it

with the pinion gear fixed.
• When backlash is less than standard range:
Loosen the adjustment nut on the bevel gear side and
tighten the adjustment nut on the opposite side by the
same angle (to move the bevel gear in direction (A)).
• When the backlash is above standard range:
Loosen the adjustment nut on the opposite side and
tighten the adjustment nut on the bevel gear side by the
same angle (to move the bevel gear in direction (B)).

B. Checking tooth contact

i. Apply red lead thinly to the surface of the pinion gear and
turn the bevel gear in the forward and reverse directions,
and then check the tooth contact pattern on the bevel gear.

ii. The center of the tooth contact must be at the middle of

the tooth height and at a point about 33% of the tooth
length (x) from small end (C), and the tooth contact width
must be 30 – 60% of the tooth length (y).
★ Check that there is no strong contact at tip (A),
bottom (B), small end (C), or large end (D).
• If the tooth contact is adjusted in this way, the teeth
come in contact with each other correctly when they
are loaded.

iii. Adjusting tooth contact

• If the tooth contact pattern is not proper, adjust it
according to the following procedure.
★ After adjusting the tooth contact, check the backlash
again.
★ If bevel pinion is too far from bevel gear
• The tooth contact pattern is illustrated in the figure.
• Decrease the shims of the bevel pinion to move the
bevel pinion in direction (C).
• Move the bevel gear in direction (D).

WA500-6 50-247 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
★ If bevel pinion is too close to bevel gear
• The tooth contact pattern is illustrated in the figure.
• Increase the shims of the bevel pinion to move the
bevel pinion in direction (E).
• Move the bevel gear in direction (F).

★ If bevel gear is too close to bevel pinion

• The tooth contact pattern is illustrated in the figure.
• Decrease the shims of the bevel pinion to move the
bevel pinion in direction (C).
• Move the bevel gear in direction (D).

★ If bevel gear is too far from bevel pinion

• The tooth contact pattern is illustrated in the figure.
• Increase the shims of the bevel pinion to move the
bevel pinion in direction (E).
• Move the bevel gear in direction (F).

10. Lock
• After finishing all adjustments, install lock (3) and tighten
mounting bolts (2).

Mounting bolt: 27 – 34 N•m (19.91 – 25.08 lbf ft)

50-248 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
11. Differential assembly
• Remove differential assembly (1) from tool H1.

Differential assembly: 390 kg (860 lb)

WA500-6 50-249 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN

Final Drive (Front and Rear)

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

H 3 793T-622-2210 Fixture ■ 3 N ❍

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Disassembly

1. Tire wheel assembly

A. Raise the machine body with the work equipment or a jack

and set a stand under the axle.

B. Using a sling, sling tire wheel assembly (1); remove the hub
mounting bolts; and lift off the tire wheel assembly.

Tire wheel assembly: 850 kg (1,874 lb)

2. Draining oil

A. Remove drain plug (2) and drain the oil.

B. Set the drain plug at the bottom.

Axle oil
Front: Approximately 98 l (26 gal)
Rear: Approximately 85 l (23 gal)

3. Cover
• Remove seven bolts (3) and cover (4).

50-250 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
4. Drive shaft

A. Using forcing screw [2], pull out drive shaft (5).

B. Using sling [3], remove drive shaft (5).

C. Remove spacer (6), sun gear (7), and snap ring (8) from drive
shaft (5).

5. Planetary carrier assembly

A. Remove three hexagonal head bolts (9).

B. Using forcing screws [4], disconnect planetary carrier

assembly (10) from the wheel hub.

C. Using sling [5], remove planetary carrier assembly (10).

Planetary carrier assembly: 110 kg (243 lb)

D. Disassemble the planetary carrier assembly according to the

following procedure.

i. Using a press, pull out shaft (11) and remove planetary

gear (12), ball (13), and bearing (14).
★ Be careful not to lose ball (13).
• Write a number on the case. Arrange and keep the
removed parts separate to prevent them from mixing
with other parts.
• Since the bearing has been fitted to the mating part,
make a distinctive mark on it.

WA500-6 50-251 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
6. Ring gear

A. Using tools H3, fix wheel hub (15) and brake housing (16).
• Install tools H3 to three places at regular intervals.
• Keep tools H3 installed until Step 6 is finished.

B. Remove eight mounting bolts (17).

C. Remove retainer (18) and shim (19).

★ Check the thickness and quantity of the shim.

D. Using sling [9], remove ring gear assembly (20).

E. Disassemble the ring gear assembly according to the

following procedure.

i. Remove 12 mounting bolts (21) and six lock plates (22).

ii. Using sling [6], remove ring gear hub (23).

50-252 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
iii. Remove bearing (24) from ring gear hub (23).

Assembly

1. Ring gear

A. Assemble the ring gear assembly according to the following

procedure.

i. Using push tool [7] (inside diameter: 221 mm [8.70 in]),

press-fit bearing (24) to ring gear hub (23).
★ After press-fitting the bearing, check that there is no
clearance between it and the hub.

ii. Before installing, measure thickness (a) of retainer (18).

★ Measure the thickness at two places and obtain the
average.

iii. Using sling [6], install ring gear hub (23).

iv. Install six lock plates (22) and tighten 12 mounting

bolts (21).
★ Install each lock plate (22) with the wider end in.
★ Degrease the bolt holes thoroughly.

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 27 – 34 N•m (19.91 – 25.08 lbf ft)

WA500-6 50-253 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
B. Using sling [9], install ring gear assembly (20).
★ Drop 6 cc of axle oil (AXO80) onto the bearing and rotate
it about ten turns.

C. Adjustment procedure for wheel bearing

i. Install retainer (18) and tighten three mounting bolts (17)

temporarily without setting the shim.

ii. Remove tool H3 which has been fixing wheel hub (15)
and brake housing (16).

iii. While rotating wheel hub (15) 20 – 30 turns, tighten

mounting bolts (17) alternately and evenly to the
following torque.

Mounting bolt: 62.7 ±4.9 N•m (46.25 ±3.61 lbf ft)

50-254 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
iv. Insert depth micrometer [10] or a dial gauge in the
measurement hole of retainer (18) and measure
distance (b) between retainer (18) and tube (26) to obtain
shim thickness (C).
★ Measure the distance at two places and obtain the
average.
Shim thickness (C): . . . . . . . . . . . . . . . . . . . (b – a) + 0.3 mm (0.012 in)
★ Dimension (a) was measured in Step 1.

v. Install tool H3 and fix wheel hub (15) and brake

housing (16) again.

vi. Remove retainer (18) and install shim (19) of the

thickness obtained in Step Civ.
★ Assemble the shims so that the number of them are
minimized.

vii. Install retainer (18) again and tighten eight mounting

bolts (17) alternately and evenly to the following torque.

Mounting bolt: Adhesive (LT-2)

Mounting bolt: 245 – 309 N•m (180.70 – 227.91 lbf ft)

viii. Remove tool H3 which has been fixing wheel hub (15)
and brake housing (16).

WA500-6 50-255 ➁
DISASSEMBLY AND ASSEMBLY POWER TRAIN
2. Planetary carrier

A. Assemble the planetary carrier assembly according to the

following procedure.

i. Set planetary gear (12) and bearing (14) to the carrier

case.

ii. Fit ball (13) to shaft (11) and press-fit them to the carrier
case.
• Press-fit shaft (11) with the ball hole out. Stop before
the hole and adjust the hole.
• After press-fitting the shaft, check that the planetary
gear rotates lightly.

B. Using sling [5], install planetary carrier assembly (10).

• Using guide bolt [4], set the bolt holes.

Planetary carrier assembly: 110 kg (243 lb)

C. Tighten three hexagon head bolts (9).

Mounting bolt: 59 – 74 N•m (43.52 – 54.58 lbf ft)

3. Drive shaft

A. Install snap ring (8), sun gear (7), and spacer (6) to drive
shaft (5).

B. Using sling [1], install drive shaft (5).

C. Using guide bolt [2], set the spline at the end of drive shaft (5)
and push it in.
★ If the sun gear does not mesh with the planetary gear, use
your hand to rotate the wheel hub to mesh those gears.

4. Cover

A. Fit the O-ring; install cover (4); and tighten seven bolts (3).
O-ring: Grease (G2-LI)

Mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

B. Install drain plug (2).

★ Set the drain plug at the bottom.
Drain plug (2): 58.8 – 78.4 N•m (43.37 – 57.82 lbf ft)

50-256 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY POWER TRAIN
5. Refilling with oil

A. Remove level plug (27).

B. Remove oil filler plug (28) and add oil to the specified level.

Axle oil
Front: 98 l (26 gal)
Rear: 85 l (23 gal)

C. Install level plug (27) and oil filler plug (28).

Level plug (27): 127.4 – 176.4 N•m (93.97 – 130.11 lbf ft)

Oil filler plug (28): 127.4 – 176.4 N•m (93.97 – 130.11 lbf ft)

6. Tire wheel assembly

A. Using the sling, set tire wheel assembly (1) to the wheel hub
and tighten the hub mounting bolts temporarily.

Tire wheel assembly: 850 kg (1,874 lb)

B. Raise the machine body with the work equipment or the jack;
remove the stand under the axle; and lower the tire to the
ground.

C. Tighten the hub mounting bolts to the specified torque.

Hub mounting bolt: 824 – 1,034 N•m (607.75 – 762.64 lbf ft)

WA500-6 50-257 ➁
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM

BRAKE SYSTEM

Brakes (Front and Rear)

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal
Special Tools

New/Remodel
Necessity

Sketch
Qty

Symbol Part No. Part Name

H 3 793T-622-2210 Fixture ■ 3 N ❍

1. Remove the final drive assembly. For details, see the Final Drive
(Front and Rear) disassembly and assembly procedures in this
section.

2. Leave tool H3 (used to fix the wheel hub and brake housing),
installed for the above work, in position.

3. Disconnect brake tube (1). [*1]

50-258 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM
4. Remove cover (2).

5. Remove brake disc wear indicator (3). [*2]

6. Remove 15 mounting bolts (6). [*3]

7. Using sling [1], remove brake and wheel hub assembly (7).

Brake and wheel hub assembly: 350 kg (772 lb)

8. Remove eight O-rings (16) from brake piston assembly (15).

9. Remove bearing (9) and retainer (10) from axle (8). [*4]

WA500-6 50-259 ➁
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Brake tube: 84 – 132 N•m (61.96 – 97.36 lbf ft)

[*2]

Adjustment Procedure for Brake Disc Wear Indicator

1. Apply oil pressure of 5.39 – 5.88 MPa (781.75 – 852.82 psi) to the brake oil port.

2. Remove cap (11) and loosen nut (13).

3. Push in shaft (12) fully and rotate guide (14) to reduce its
projection distance (a) to 0.

4. Tighten nut (13).

Nut: 58.8 – 78.4 N•m (43.37 – 57.82 lbf ft)

5. Install cap (11).

Cap: 29.4 – 39.2 N•m (21.68 – 28.91 lbf ft)

[*3]

Mounting bolt (6): 548.8 ±58.8 N•m (404.77 ±43.37 lbf ft)

[*4]

Brake and wheel hub assembly

• When installing the bearing, drop 6 cc of the axle oil (AXO80) on it.

50-260 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM

Disassembly
Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

792T-422-1220 Plate ■ 1 N ❍
2 790-101-5421 Grip ■ 1
01010-81240 Bolt ■ 1
3 793T-622-2210 Fixture ■ 3 N ❍
792-520-2110 Installer ■ 1
791-580-1600 Push tool ■ 1
791-580-1610 Plate 1
791-580-1620 Arm 4
791-580-1640 Plate 1
4
791-580-1650 Plate 4
01010-51425 Bolt 8
H
01541-21670 Nut 4
01640-21426 Washer 4
792-530-1630 Stud ■ 4
792-520-2110 Installer ■ 1
793T-622-2310 Plate ■ 1 N ❍
793T-622-2320 Arm ■ 4 N ❍
791-580-1640 Plate ■ 1
5
792-530-1630 Stud ■ 4
01010-61425 Bolt ■ 4
01640-21426 Washer ■ 4
01580-01613 Nut ■ 4

1. Remove the brake assembly. For details, see the Brakes (Front and
Rear) removal procedure in this section.

2. Remove tool H3 (used to fix the wheel hub and brake housing)
installed for the above work.

WA500-6 50-261 ➁
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM
3. Cylinder assembly

A. Remove 24 mounting bolts (1).

B. Using forcing screws [1], disconnect cylinder assembly (2).

C. Using eyebolts [2], remove cylinder assembly (2).

D. Disassemble the cylinder assembly according to the following

procedure.

i. Install eyebolt [3]; push in the head of shaft (3) with

bar [4]; and remove pin (5) from the underside.

ii. Remove shaft (3) and spring (4).

iii. Reverse cylinder assembly (2) and remove piston (6).

iv. Remove nine mounting bolts (7) and inner cylinder (8).

50-262 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM
v. Remove seal ring (9) from piston (6).

vi. Remove seal ring (10) from inner cylinder (8).

4. Plate and disc

A. Remove eight discs (13), nine plates (14), and bottom plate
(15).

B. Before removing, make match marks between the inner gear

and discs and between the outer gear and plates.
★ Since the discs are made of soft material, be careful not to
scratch them.

C. Remove the discs and plates alternately.

5. Outer gear

A. Using sling [5], remove outer gear (16).

B. Remove oil seal (17) and floating seal (18) from outer
gear (16).

WA500-6 50-263 ➁
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM
6. Wheel hub

A. Remove bearing outer races (19) and (20).

B. Remove six mounting bolts (22) then remove seal cage (23)
and O-ring (25) from wheel hub (21).

C. Remove floating seal (24) from seal cage (23).

50-264 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM

Assembly

1. Wheel hub

A. Using push tool [6] (outside diameter: 313 mm [12.32 in]),

press-fit outer race (20) to wheel hub (21).

B. Using push tool [7] (outside diameter: 189 mm [7.44 in]),

press-fit outer race (19) to wheel hub (21).

C. Install O-ring (25) and seal cage (23) to wheel hub (21).

O-ring: Grease (G2-LI)

D. Tighten six mounting bolts (22).

Mounting bolt: 59 – 74 N•m (43.52 – 54.58 lbf ft)

E. Using tool H5, install floating seal (24) to wheel hub (21).

i. Fit the O-ring to the floating seal.

★ Be careful not to twist the O-ring of the floating seal.
Tighten tool H5 evenly.

ii. Use alcohol to remove all the white powder protecting the
surface of O-ring (24a).

iii. Thoroughly degrease the floating seal and O-ring contact

surface of the wheel hub.

iv. After press-fitting O-ring (24a) of the floating seal,

measure height (t) at four places on the periphery and
check that its dispersion is not larger than 1 mm (0.039
in).

v. Apply axle oil to the seal surface of floating seal (24b) to

prevent dirt from sticking.

WA500-6 50-265 ➁
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM
2. Outer gear

A. Using tool H2, install oil seal (17) to outer gear (16).

Seal lip surface: Grease (G2-LI)

B. Using tool H4, install floating seal (18) to outer gear (16).

i. Fit the O-ring to the floating seal.

★ Be careful not to twist the O-ring of the floating seal.
Tighten tool H4 evenly.

ii. Use alcohol to remove all of the white powder protecting

the surface of O-ring (18a).

iii. Thoroughly degrease the floating seal and O-ring contact

surface of the wheel hub.

iv. After press-fitting O-ring (18a) of the floating seal,

measure height (t) at four places on the periphery and
check that its dispersion is not larger than 1 mm (0.039
in).

v. Apply axle oil to the seal surface of floating seal (18b) to

prevent dirt from sticking.

C. Using sling [5], install outer gear (16).

50-266 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM
3. Plate and disc

A. Install bottom plate (15).

B. Install nine plates (14) and eight discs (13) alternately.

• Match the match marks made between the inner gear and
discs and between the outer gear and plates.
★ Since the discs are made of soft material, be careful not to
scratch them.

4. Cylinder assembly

A. Assemble the cylinder assembly according to the following

procedure.

i. Install seal rings (10) and (11) to inner cylinder (8).

Seal ring: Grease (G2-LI)

ii. Install seal ring (9) to piston (6).

Seal ring: Grease (G2-LI)

iii. Install inner cylinder (8).

iv. Tighten nine mounting bolts (7).

Mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

v. Install piston (6) to cylinder assembly (2).

WA500-6 50-267 ➁
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM
vi. Reverse cylinder assembly (2).

vii. Install shaft (3) and spring (4).

viii. Install eyebolt [3]; push in the head of shaft (3) with
bar [4]; and install pin (5) from underside.

B. Fit the O-ring and install cylinder assembly (2), using

eyebolts [2].

O-ring: Grease (G2-LI)

C. Tighten 24 mounting bolts (1).

Mounting bolt: 157 – 196 N•m (115.80 – 144.56 lbf ft)

5. Install tool H3 (to fix the wheel hub and brake housing).

6. Install the brake assembly. For details, see the Brakes (Front and
Rear) installation procedure in this section.

50-268 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM

Slack Adjuster
★ Only the precautions for assembling the slack adjuster are described in this section.

Assembly of Slack Adjuster Assembly

Valve and outside of spring (a): Grease (G2-LI)

Threaded part of plug (b): CEMEDINE 366 or equivalent

Threaded part of plug (b): CEMEDINE 366 or equivalent

Torque Values

Designation N•m lbf ft

A 60 – 75 44.25 – 55.32

C 10 – 20 7.38 – 14.75

D 50 – 65 36.88 – 47.94

Designation N•m lbf in

B 7–9 61.96 – 79.66

WA500-6 50-269 ➁
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM

Brake Accumulator Charge Valve

★ Only the precautions for assembling the brake accumulator charge valve assembly are described in this section.

Assembly of Brake Accumulator Charge Valve Assembly

Plug (1): THREEBOND 1305 or equivalent

Plug (2): Adhesive (LT-2)

Torque Values

Designation N•m lbf ft

AA 29.4 – 39.2 21.68 – 28.91

Designation N•m lbf in

BB 3.14 – 3.92 27.79 – 34.69

Plug (3): Adhesive (LT-2)

Plug (4): THREEBOND 1305 or equivalent

Torque Values

Designation N•m lbf ft

AA 30.4 – 37.3 22.42 – 27.51

BB 78.5 – 88.3 57.90 – 65.13

CC 53.9 – 68.6 39.75 – 50.60

Designation N•m lbf in

DD 9.8 – 11.8 86.74 – 104.44

50-270 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME

UNDERCARRIAGE AND FRAME

Center Hinge Pin

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

1 793-520-2630 Bar ■ 2
2 793-520-2640 Push tool ■ 1
3 793-520-2650 Guide ■ 1
4 790-101-2300 Push puller ■ 1
1 5 790-101-2102 • Block 1
6 02215-11622 • Nut 2
Puller 294 kN
7 790-101-2102 ■ 1
{30 ton}
K
8 790-101-1102 Pump ■ 1
1 793-520-2530 Guide ■ 1
2 01010-31480 Bolt ■ 2
3 01643-31445 Washer ■ 2
2 4 793-520-2640 Push puller ■ 1
Puller 294 kN
5 790-101-2102 ■ 1
{30 ton}
6 790-101-1102 Pump ■ 1

Removal
WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until
the coolant cools down then drain the coolant.

Disconnect the cable from the negative (-) battery terminal.

WA500-6 50-271 ➁
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
Precautions for Handling Refrigerant

WARNING! Collect refrigerant (R134a) beforehand.

★ Ask professional traders for collecting and filling the refrigerant (R134a).
★ Never release the refrigerant (R134a) to the atmosphere.

WARNING! If the refrigerant (R134a) gets into your eyes, it may cause blindness. You must wear protective
glasses when collecting or filling the refrigerant. Collecting and filling work must be done by a
qualified person.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant when
disconnecting the heater hoses and draining the coolant. Wait until the coolant has cooled and then
drain the coolant.

1. Drain the hydraulic oil.

Hydraulic oil: Approx. 337 l (89 gal)

2. Drain the coolant.

Coolant: Approx. 90 l (24 gal)

3. Remove the operator cab and floor frame assembly. For details, see
the Cab and Floor Frame removal and installation procedures in
this section.

4. Set jacks [1] under the right and left of the rear frame.

5. Set jack [2] under the front frame.

6. Set jack [3] under the rear counterweight.

50-272 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
7. Remove guard (1).

8. Sling center drive shaft (2); remove its mounting bolts; and lift it
off. [*1]
★ Before removing the drive shaft, make a match mark between
it and the coupling.

Center drive shaft: 49 kg (108 lb)

9. Unplug wiring harness connectors JF1 (3), JF2 (4), and JF3 (5);
remove wiring harness clamps (6) and (7).

10. Disconnect hoses (8), (9), (10), (11), and (12).

11. Disconnect hoses (13), (14), (15), (16), and (17).

WA500-6 50-273 ➁
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
12. Disconnect right and left steering hoses (18).

13. Remove right and left bolts (19) and pull out right and left cylinder
bottom pins (20). [*2]
• After removing the pins, retract the cylinder piston rods.
• Check the quantity and thickness of the shims on the frame.

14. Remove bolts (21) and (22) and retainer (22); pull out lower hinge
pin. [*3]
★ After removing the bolts, pull out the pin while adjusting the
height of the front frame and rear frame with the jacks.

15. Remove four bolts (24) and plate (25). [*4]

16. Remove six bolts (26), four bolts (27), and retainer (28); pull out
the hinge pin. [*5]
• After removing the bolts, pull out the pin while adjusting the
height of the front frame and rear frame with the jacks.
• Check the quantity and thickness of the shims between
retainer (28) and the frame.

17. Remove bushing (29) from the frame.

50-274 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
18. Pull front frame (30) forward slowly to disconnect it from rear
frame (31).
★ When disconnecting the front frame, balance it carefully.
• Check that all the pipings and wiring harnesses are
disconnected.
• Move the front frame about 100 mm (3.94 in) each time.

19. Remove bushing (32) and the collar from the rear frame.

20. Remove bolts (33) and retainer (34) from the front frame. [*6]
★ Check the quantity and thickness of the shims between the
retainer and frame.

21. Remove dust seal (35) from the retainer. [*7]

22. Remove dust seal (36) from the frame. [*8]

23. Remove bearing (37) from the frame. [*9]

24. Remove bolts (38) and retainer (39) from the front frame. [*10]
★ Check the quantity and thickness of the shims between the
retainer and frame.

25. Remove dust seal (40) from the retainer. [*11]

26. Remove bushing (41) and dust seal (42) from the front frame.
[*12]

27. Remove bearing (43) from the frame. [*13]

WA500-6 50-275 ➁
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Drive shaft mounting bolt: 98 – 123 N•m (72.28 – 90.72 lbf ft)

★ Tighten the drive shaft according to the following procedure.

1. Check that the seats of the mating yoke and drive shaft spider are free from rust, foreign matter (masking material),
damage, etc.

2. Set the keyway of the yoke vertically; place the drive shaft on the bottom of the yoke socket; and fit the key in the keyway.

3. Insert the four upper and lower bolts and finger tighten them until the seats of the spider and yoke are fitted.
★ At this time, if the keyway and socket of the yoke are tight and the spider is not fitted easily, drive in the spider with a
plastic or copper hammer. Do not use a steel hammer which can damage the cross bearing.
★ If the spider is not fitted perfectly at this time, it will float and its seat will be parted from the yoke when the other
parts are tightened. Tighten the spider securely.

4. Tighten the bolts in the diagonal order.

[*2]
Adjust the shim so that clearances (a) and (b) between the cylinder and
mounting face of the frame are 0.5 mm (0.02 in) or less.

[*3]
★ Install the lower hinge pin according to the following procedure.

1. Install bushing (32) and collar (44) to the frame.

2. Align the front frame and rear frame.

★ When aligning the pin holes, use a bar. Never insert your
fingers in the pin holes.

3. Fit retainer (23) to hinge pin (45); insert them in the pin hole; and
tighten bolts (22).
Periphery of hinge pin: Grease (G2-LI)

Threaded part of retainer mounting bolt:

Adhesive (LOCTITE 262)

Retainer mounting bolt:

245 – 309 N•m (180.70 – 227.91 lbf ft)

Threaded part of pin mounting bolt: Adhesive (LOCTITE 262)

Retainer mounting bolt: 343 – 426 N•m (252.98 – 314.20 lbf ft)

50-276 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
[*4], [*5]

★ Install the upper hinge pin according to the following procedure.

1. Measure the thickness of retainer (28) in advance at three places of

the Ø6.5 hole of the retainer.

2. Install bushing (29) to the upper hinge.

3. Temporarily install retainer (28) to hinge pin (46) with bolts (27)
and insert hinge pin (46) in the pin hole.

Periphery of hinge pin: Grease (G2-LI)

4. Tighten bolts (27) to the specified torque.

★ While tightening the bolts, check each one.

5. After tightening the bolts to the specified torque, measure the clearance between the retainer and rear frame at three places
of the Ø6.5 hole.

6. Select shims so that their total thickness is 0.08 – 0.18 mm (0.003 – 0.007 in) less than the measured clearance.

7. Remove the retainer; install shim (47); and tighten the retainer mounting bolts to the specified torque.

Threaded part of retainer (26) mounting bolt: Adhesive (LOCTITE 262)

Retainer (26) mounting bolt: 245 – 309 N•m (180.70 – 227.91 lbf ft)

Threaded part of pin mounting bolt (27): Adhesive (LOCTITE 262)

Pin mounting bolt (27): 343 – 426 N•m (252.98 – 314.20 lbf ft)

Threaded part of pin mounting bolt (24): Adhesive (LOCTITE 262)

Pin mounting bolt (24): 343 – 426 N•m (252.98 – 314.20 lbf ft)

WA500-6 50-277 ➁
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
[*6], [*7], [*8], [*9]

★ Assemble the lower hinge according to the following procedure.

1. Using push tool K2, press-fit bearing (37) to the frame.

★ Be careful that the bearing does not lean.
★ Since the clearance of the bearing is adjusted properly, do not
change the combination of it and the spacer. When the bearing
must be replaced, replace it and the spacer as a set.
• Fill the inside of the bearing with grease.

2. Press-fit dust seal (35) to retainer (34).

★ Press-fit the dust seal with the lip side out.

Lip of dust seal: Grease (G2-LI)

3. Evenly tighten the six mounting bolts of retainer (34) at intervals

of 60°.

Mounting bolt (when adjusting shim):

34.3 N•m (25.30 lbf ft) ±10%

4. Select shims so that their total thickness is 0.08 – 0.18 mm (0.003

– 0.007 in) less than clearance (a) between the retainer and hinge,
measured at four places on the periphery.

5. Tighten the mounting bolts to the specified torque.

Threaded part of retainer mounting bolt: Adhesive (LT-2)

Retainer mounting bolt:

245 – 309 N•m (180.70 – 227.91 lbf ft)

6. Press-fit dust seal (36).

★ Press-fit the dust seal with the lip side out.

Lip of dust seal: Grease (G2-LI)

50-278 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
[*10], [*11], [*12], [*13]

★ Assemble the upper hinge pin according to the following procedure.

1. Using push tool K1, press-fit bearing (43) to the frame.

★ Be careful that the bearing does not lean.
★ Since the clearance of the bearing is adjusted properly, do not
change the combination of it and the spacer. When the bearing
must be replaced, replace it and the spacer as a set.
• Fill the inside of the bearing with grease.

2. Press-fit dust seal (40) to retainer (39).

★ Press-fit the dust seal with the lip side out.

Lip of dust seal: Grease (G2-LI)

3. Evenly tighten the six mounting bolts of retainer (38) at intervals

of 60°.

Mounting bolt (when adjusting shim):

34.3 Nm (25.30 lbf ft) ± 10%

4. Select shims so that their total thickness is 0.08 – 0.18 mm (0.003

– 0.007 in) less than clearance (a) between the retainer and hinge,
measured at four places on the periphery.

5. Tighten the mounting bolts to the specified torque.

Threaded part of retainer mounting bolt: Adhesive (LT-2)

Retainer mounting bolt: 245 – 309 N•m (180.70 – 227.91 lbf ft)

6. Press fit dust seal (42).

★ Press fit the dust seal with the lip side out.

Lip of dust seal: Grease (G2-LI)

7. Install bushing (41).

WA500-6 50-279 ➁
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
Refilling with Coolant

1. Add coolant through the coolant filler to the specified level.

2. Run the engine to circulate the coolant through the system.

3. Check the coolant level again.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Bleeding Air

★ Bleed air from the brake circuit. For details, see Brake System: Bleeding Air from Wheel Brake Circuit in the Testing and
Adjusting section.

50-280 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

Hydraulic Tank
Removal
WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Operate the work equipment control lever two to three times to release the residual pressure in the
work equipment circuit.

Disconnect the cable from the negative (-) battery terminal.

Precautions for Handling Refrigerant

WARNING! Collect refrigerant (R134a) beforehand.

★ Ask professional traders for collecting and filling the refrigerant (R134a).
★ Never release the refrigerant (R134a) to the atmosphere.

WARNING! If the refrigerant (R134a) gets into your eyes, it may cause blindness. You must wear protective
glasses when collecting or filling the refrigerant. Collecting and filling work must be done by a
qualified person.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant when
disconnecting the heater hoses and draining the coolant. Wait until the coolant has cooled, and
then drain the coolant.

1. Drain the coolant.

Coolant: Approximately 90 l (24 gal)

2. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

3. Remove the hood. For details, see the Engine Hood removal and installation procedures in this section.

4. Remove the operator cab and floor frame. For details, see the Cab and Floor Frame removal and installation procedures
in this section.

WA500-6 50-281 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
5. Loosen hose clamps (1) between the air cleaner and turbocharger;
remove air cleaner fixing bands (2) and air cleaner assembly (3).
[*1]

6. Remove air cleaner bracket (4).

7. Disconnect heater hose (5).

8. Remove partition rubber plates (6) and (7).

★ Disconnect and move partition rubber plate (7).

9. Remove clamps (9) of transmission breather (8) and move the

breather aside. [*2]

10. Disconnect hose clamps (10) and (11) fixed together with the
hydraulic tank.

50-282 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
11. Disconnect all of air conditioner and reservoir tank hose
clamps (12) fixed together with the hydraulic tank.

12. Disconnect hoses (13), (14), (15), (16), (17), and (18) and all of the
hose clamps fixed together with the hydraulic tank.

13. Disconnect flange (19).

14. Disconnect hoses (20), (21), and (22).

★ Disconnect the hoses on the opposite side of the block from
the pump and motor.

15. Loosen hose clamps (23).

16. Disconnect hoses (24) and (25).

17. Remove tube (26).

18. Disconnect heater hose clamps (27).

★ Disconnect all of the heater hose clamps fixed together with
the hydraulic tank.

WA500-6 50-283 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
19. Remove eight hydraulic tank mounting bolts (29). [*3]

20. Lift off hydraulic tank (30).

★ Before lifting off the tank, check that all the pipings are
disconnected.

Hydraulic tank assembly: 480 kg (1,058 lb)

50-284 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Hose clamp: 10.5 N•m (92.93 lbf in)

[*2]

Threaded part of hose clamp mounting bolt: Adhesive (LT-2)

Hose clamp mounting bolt: 101 N•m (74.49 lbf ft)

[*3]

★ Adjust the clearance between the hydraulic tank and rear frame to 0.5 mm (0.02 in) or less with the shim.

Refilling with Coolant

1. Add coolant through the coolant filler to the specified level.

2. Run the engine to circulate the coolant through the system.

3. Check the coolant level again.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Charging Air Conditioner with Refrigerant

★ Charge the air conditioner circuit with refrigerant (R134a) through the compressor.

Bleeding Air

1. Bleed air from the brake circuit. For details, see Brake System: Bleeding Air from Wheel Brake Circuit in the Testing and
Adjusting section.

WA500-6 50-285 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Cooling Pump

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Operate the work equipment control lever two to three times to release the residual pressure in the
work equipment circuit.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the coolant.

Coolant: Approximately 90 l (24 gal)

2. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

3. Remove the hood. For details, see the Engine Hood removal and
installation procedures in this section.

4. Remove the operator cab and floor frame. For details, see the Cab
and Floor Frame removal and installation procedures in this
section.

5. Remove the hydraulic tank. For details, see the Hydraulic Tank
removal and installation procedures in this section.

6. Disconnect pump inlet tube (1) and outlet hose (2).

7. Remove the two mounting bolts and cooling pump assembly (3).
[*1]

50-286 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Pump mounting bolt: 235 – 285 N•m (173.33 – 210.20)

Refilling with Coolant

1. Add coolant through the coolant filler to the specified level.

2. Run the engine to circulate the coolant through the system.

3. Check the coolant level again.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Bleeding Air

★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section.
• Brake System: Bleeding Air from Wheel Brake Circuit
• Work Equipment: Bleeding Air from Work Equipment Circuit
• Steering System: Bleeding Air from Steering Cylinder Circuit
• Fuel System: Bleeding Air from Fuel Circuit

WA500-6 50-287 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Fan Pump

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Operate the work equipment control lever two to three times to release the residual pressure in the
work equipment circuit.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the coolant.

Coolant: Approximately 90 l (24 gal)

2. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

3. Remove the hood. For details, see the Engine Hood removal and
installation procedures in this section.

4. Remove the operator cab and floor frame. For details, see the Cab
and Floor Frame removal and installation procedures in this
section.

5. Remove the hydraulic tank. For details, see the Hydraulic Tank
removal and installation procedures in this section.

6. Disconnect wiring harness connector T02 (1) and remove the

wiring harness clamp.

7. Remove pump inlet tube (2).

8. Disconnect pump outlet hose (3).

9. Disconnect hose (4).

10. Remove three pump mounting bolts and lift off fan pump assembly (5). [*1]

Fan pump assembly: 25 kg (55 lb)

50-288 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Pump mounting bolt: 98 – 123 N•m (72.28 – 90.72)

★ Check that the clearance between the shroud and fan is even (standard clearance: 6 mm [0.24 in]). If it is uneven,
loosen the mounting bolts of the fan motor mounting bracket and adjust it.

Refilling with Coolant

1. Add coolant through the coolant filler to the specified level.

2. Run the engine to circulate the coolant through the system.

3. Check the coolant level again.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Bleeding Air

★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section.
• Brake System: Bleeding Air from Wheel Brake Circuit
• Work Equipment: Bleeding Air from Work Equipment Circuit
• Steering System: Bleeding Air from Steering Cylinder Circuit
• Fuel System: Bleeding Air from Fuel Circuit

WA500-6 50-289 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Work Equipment Pump

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Operate the work equipment control lever two to three times to release the residual pressure in the
work equipment circuit.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the coolant.

Coolant: Approximately 90 l (24 gal)

2. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

3. Remove the hood. For details, see the Engine Hood removal and
installation procedures in this section.

4. Remove the operator cab and floor frame. For details, see the Cab
and Floor Frame removal and installation procedures in this
section.

5. Remove the hydraulic tank. For details, see the Hydraulic Tank
removal and installation procedures in this section.

6. Remove side cover (1) on the right of the transmission.

7. Disconnect hose (2), (3), (4), and (5).

8. Disconnect pump inlet tube (6).

9. Remove the tube fixing U-bolt and pump outlet tube (7).

50-290 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
10. Remove the two pump mounting bolts and lift off work equipment
pump assembly (8). [*1]

Work equipment pump assembly: 110 kg (243 lb)

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Pump mounting bolt: 455 – 565 N•m (335.59 – 416.72)

Refilling with Coolant

1. Add coolant through the coolant filler to the specified level.

2. Run the engine to circulate the coolant through the system.

3. Check the coolant level again.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Bleeding Air

★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section.
• Brake System: Bleeding Air from Wheel Brake Circuit
• Work Equipment: Bleeding Air from Work Equipment Circuit
• Steering System: Bleeding Air from Steering Cylinder Circuit
• Fuel System: Bleeding Air from Fuel Circuit

WA500-6 50-291 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Steering, Torque Converter Charge, and EPC Pump Assembly

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Operate the work equipment control lever two to three times to release the residual pressure in the
work equipment circuit.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the coolant.

Coolant: Approximately 90 l (24 gal)

2. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

3. Remove the hood. For details, see the Engine Hood removal and
installation procedures in this section.

4. Remove the operator cab and floor frame. For details, see the Cab
and Floor Frame removal and installation procedures in this
section.

5. Remove the hydraulic tank. For details, see the Hydraulic Tank
removal and installation procedures in this section.

6. Disconnect pump inlet tubes (1), (2), and (3).

7. Disconnect pump outlet hoses (4), (5), and (6).

8. Disconnect hoses (7), (8), (9), and (10).

9. Remove the two pump mounting bolts and lift off steering-torque
converter charge-EPC pump assembly (11). [*1]

Steering-torque converter charge-EPC pump assembly:

60 kg (132 lb)

50-292 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Pump mounting bolt: 235 – 285 N•m (173.33 – 210.20)

Refilling with Coolant

1. Add coolant through the coolant filler to the specified level.

2. Run the engine to circulate the coolant through the system.

3. Check the coolant level again.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Bleeding Air

★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section.
• Brake System: Bleeding Air from Wheel Brake Circuit
• Work Equipment: Bleeding Air from Work Equipment Circuit
• Steering System: Bleeding Air from Steering Cylinder Circuit
• Fuel System: Bleeding Air from Fuel Circuit

WA500-6 50-293 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Work Equipment Valve

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Operate the work equipment control lever two to three times to release the residual pressure in the
work equipment circuit.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

2. Remove cover (1).

3. Remove right and left round covers (2).

4. Remove bracket (3).

5. Disconnect hose (4).

6. Remove accumulator fixing clamps (5) and (6).

50-294 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
7. Remove the two accumulator mounting bolts and lift off
accumulator assembly (7).

Accumulator assembly: 130 kg (287 lb)

8. Remove bracket (8).

9. Disconnect brake hose (9).

10. Disconnect hoses (10), (11), (12), and (13).

11. Disconnect wiring harness connectors F24 (14), F07 (15), and
F10 (16).

12. Remove bracket (17).

13. Disconnect wiring harness connectors F08 (18), F09 (19), and
F16 (20).

WA500-6 50-295 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
14. Remove hoses (21) and (22) and brackets (23) and (24).

15. Remove tubes (25) and (26).

16. Disconnect tubes (27) and (28).

17. Disconnect hoses (29), (30), (31), (32), and (33).

18. Remove four work equipment valve assembly mounting bolts (34).

19. Set a wooden block and steel plate [1] to the frame. Sling work
equipment valve assembly (35) and pull it out to this side to
remove it.

Work equipment valve assembly: 160 kg (353 lb)

50-296 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Bleeding Air

★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section.
• Brake System: Bleeding Air from Wheel Brake Circuit
• Work Equipment: Bleeding Air from Work Equipment Circuit
• Steering System: Bleeding Air from Steering Cylinder Circuit
• Fuel System: Bleeding Air from Fuel Circuit

WA500-6 50-297 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Work Equipment Control Valve Assembly

Disassembly and Assembly
★ Only the precautions for assembling the work equipment control valve assembly are described in this section.
Assembly

• When assembling, apply engine oil to the spool sliding surfaces.

• When slinging the work equipment control valve assembly, use tap
holes (a).

50-298 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
★ Valve mating face

Valve mating face (b): SEALEND 242 or equivalent

WA500-6 50-299 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
★ Plate mounting bolt (1) and cover mounting bolts (2)
Torque Values

Designation Description N•m lbf ft

Plate
A 156.8 – 196.0 115.65 – 144.56
mounting bolt (1)

Cover
B 156.8 – 176.5 115.65 – 130.18
mounting bolt (2)

• Tighten the mounting bolts in the order illustrated in the

figure.

★ Plugs
• Thoroughly degrease and dry the plugs and threaded parts of
the valve mounting holes with denatured alcohol, etc.
• Do not apply oil pressure for two hours after installing the
plugs.

Lift arm spool plug (3): LOCTITE No. 638

Bucket spool plug (4): LOCTITE No. 638

50-300 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
★ ECSS valve
• Loosen locknut (6) and tighten plug (5) to the specified
torque.
• Tighten locknut (6) to the specified torque.
• Check that no clearance is made at parts (c) on the seat surface
(to prevent oil from flowing in through the seat of plug (5)).
Torque Values

Designation Description N•m lbf ft

Plug (5) 19.6 – 27.5 14.46 – 20.28

B
Locknut (6) 19.6 – 27.5 14.46 – 20.28

★ O-ring on valve mounting face

• Before assembling the entire work equipment control valve
assembly, check that the O-ring of each valve is fitted to the
groove securely.
• Check O-ring (7) in particular since it is not circular.

WA500-6 50-301 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
★ Main relief valve assembly
• After installing main relief valve assembly (8) to the work
equipment control valve, adjust the main relief valve. For
details, see Work Equipment in the Testing and Adjusting
section.
Torque Value

Designation Description N•m lbf ft

A Locknut (9) 49 – 58.5 36.14 – 43.15

50-302 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Steering Cylinder
Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

790-502-1003
1 or Repair stand ■ 1
1 790-502-2000
2 790-101-1102 Pump 1
2 790-330-1100 Wrench assembly ■ 1
Socket
3 790-302-1290 (Width across flats: ■ 1
60 mm [2.36 in])
1 790-201-1500 Push tool kit ■ 1
2 790-201-1590 • Plate ■ 1
U 4
4 790-101-5021 • Grip 1
5 01010-50816 • Bolt 1
1 790-201-1702 Push tool kit ■ 1
2 790-201-1781 • Push tool ■ 1
5
4 790-101-5021 • Grip 1
5 01010-50816 • Bolt 1
1 790-720-1000 Expander ■ 1
6 2 796-720-1660 Ring ■ 1
3 07281-01159 Clamp ■ 1

Disassembly

1. Set cylinder assembly (1) to tool U1.

2. Using tool U2, remove cylinder head (2) from the cylinder.

WA500-6 50-303 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
3. Pull cylinder head and piston rod assembly (3) out of cylinder (4)
and lift it off.
★ Since oil flows out when the piston rod assembly is pulled out
of the cylinder, prepare a container to catch the oil.

4. Remove cylinder (4) from tool U1.

5. Set the cylinder head and piston rod assembly to tool U1 and
loosen nut (5) with torque multiplier [1] and socket U3.
Torque multiplier [1]:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16: 1
Width across flats of socket U3: . . . . . . . . . . . . . . . . . . 60 mm (2.36 in)

6. Remove nut (5) and then remove piston assembly (6) and cylinder
head assembly (7) from rod (8).

7. Disassembly of piston assembly

A. Remove wear ring (9).

B. Remove piston ring (10) from piston (11).

50-304 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
8. Disassembly of cylinder head assembly

A. Remove snap ring (16) and dust seal (17).

B. Remove rod packing (18).

C. Remove buffer ring (19).

D. Remove O-ring (20) and backup ring (21).

E. Remove O-ring (22).

F. Remove bushing (23) from cylinder head (24).

Assembly
★ When assembling, coat the sliding surfaces of each part with
engine oil and be careful not to damage the rod packings, dust
seals, and O-rings.

1. Assembly of cylinder head assembly

A. Using U5, press-fit bushing (23) to cylinder head (24).

★ When press-fitting, be extremely careful not to deform
the bushing.

B. Install buffer ring (19).

C. Install rod packing (18).

★ Pay attention to the installed directions of rod
packing (18) and buffer ring (19).

D. Using the push tool, install dust seal (17) to cylinder

head (24).

E. Install snap ring (16).

F. Install O-ring (22).

G. Install backup ring (21) and O-ring (20).

★ Do not insert the backup ring forcibly; warm it in water at
50 – 60°C (122 – 140°F) and then insert it.

WA500-6 50-305 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
2. Assembly of piston assembly

A. Using tool U6-1, expand piston ring (10).

Set the piston ring to the tool and rotate the handle of the tool
eight to ten turns to expand the piston ring.

B. Remove piston ring (10) from tool U6-1 and install it to

piston (11).

C. Install tool U6-2 to the piston ring and shrink the piston ring
with clamp U6-3.

D. Install wear ring (9).

3. Set piston rod (8) to tool U1.

4. Install cylinder head assembly (7) and piston assembly (6) to the
rod and install nut (5).

5. Using torque multiplier [1] and socket U3, tighten nut (5).

Piston nut
Power of torque multiplier [1] 16 times
Width across flats of nut (5) 60 mm (2.36 in)
1,764.0 ± 176.4 N•m
Tightening torque for nut
(1301.06 ±130.11 lbf ft)

50-306 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
6. Remove piston rod and head assembly (3) from tool U1.

7. Set cylinder (4) to tool U1.

8. Sling piston rod and head assembly (3) and install it to

cylinder (4).

9. Using tool U2, tighten cylinder head nut (2).

Cylinder head nut: 785 ±78.5 N•m (578.99 ±57.90 lbf ft)

10. Remove the cylinder assembly from tool U1.

WA500-6 50-307 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Lift Arm and Bucket Cylinder

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

1 790-502-1003 Repair stand ■ 1

1
2 790-101-1102 Pump 1
790-102-4300 Wrench assembly ■ 1
2
790-102-4310 Pin ■ 2
1 790-201-1500 Push tool kit ■ 1
3 790-201-1680 • Plate 1
4
4 790-101-5021 • Grip 1
5 01010-50816 • Bolt 1
U 1 790-201-1702 Push tool kit ❖ 1
3 790-201-1871 • Push tool 1
5
4 790-101-5021 • Grip 1
5 01010-50816 • Bolt 1
1 790-720-1000 Expander ■ 1
4 796-720-1680 Ring ■ 1
6 5 07281-01589 Clamp ■ 1
6 796-720-1690 Ring ■ 1
7 07281-01919 Clamp ■ 1

Disassembly

1. Set cylinder assembly (1) to tool U1.

2. Remove mounting bolt (2) of the cylinder head.

50-308 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
3. Set the cylinder to tool U1. Pull cylinder head and piston rod
assembly (3) out of cylinder (4) and lift it off.
★ Since oil flows out when the piston rod assembly is pulled out
of the cylinder, prepare a container to catch the oil.

4. Disassembly of piston rod assembly

A. Set piston rod assembly (3) to tool U1.

B. Remove piston assembly lock screw (5).

Screw size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 × Pitch 1.75

★ If screw (5) is caulked so that you cannot remove it,

tighten it temporarily and cut the threads on it with tap [1]
and then remove it.

WA500-6 50-309 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
C. Using tool U2, remove piston assembly (6).
★ When not using tool U2, loosen the piston assembly by
using the drilled holes (DH) (Ø10: two places).

D. Remove cylinder head assembly (7) from piston rod

assembly (9).

5. Disassembly of piston assembly

A. Remove guard rings (11).

B. Remove wear rings (12).

C. Remove piston ring (13).

D. Remove the O-ring and backup ring (14).

6. Disassembly of cylinder assembly

A. Remove O-ring (15) and backup ring (16).

B. Remove the snap ring and dust seal (17).

50-310 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
C. Remove rod packing (18).

D. Remove buffer ring (21).

E. Remove bushing (19).

Assembly
★ When assembling, coat the sliding surfaces of each part with
engine oil and be careful not to damage the U-packings, dust seals,
and O-rings.

1. Assemble the cylinder head assembly according to the following

procedure.

A. Using push tool U4, press-fit bushing (19) to cylinder

head (20).
★ When press-fitting, be extremely careful not to deform
the bushing.

B. Install rod packing (18).

★ Pay attention to the installed directions of the rod
packing.

C. Install buffer ring (21).

★ Pay attention to the installed directions of the buffer ring.

D. Install backup ring (16) and O-ring (15) in order.

★ Do not insert the backup ring forcibly; warm it in water at
50 – 60°C (122 – 140 °F) and then insert it.

WA500-6 50-311 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
E. Using push tool U5, install dust seal (17) to the cylinder head
and fix it with snap ring (22).

2. Assemble the piston assembly according to the following

procedure.

A. Using tool U6-1, expand piston ring (13).

★ Set the piston ring to the tool and rotate the handle of the
tool eight to ten turns to expand the piston ring.

B. Remove the piston ring from tool U6-1 and install it to

piston (10).

C. Install tool U6-4 and shrink the piston ring with clamp U6-5.

50-312 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
D. Install wear ring (12) to the piston.

E. Install guard ring (11) to the piston.

F. Install the O-ring and backup ring (14) to the piston.

3. Install cylinder head assembly (7) to piston rod (9).

4. Piston rod assembly

A. Set piston rod assembly (3) to tool U1.

B. Assemble piston assembly (6) according to the following

procedure.

i. When reusing piston rod assembly (3) and piston

assembly (6):
• Clean the piston rod and piston thoroughly and
remove chips, dirt, etc.
• Screw in piston assembly (6). Then, using tool U2,
tighten piston assembly (6) until the screw holes (H)
are aligned.
• Remove burrs from the threaded parts with a file, etc.

WA500-6 50-313 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
★ When either or both of the rod and piston are new:
• Screw in piston assembly (6) until it touches rod end
[part B]. Then using tool U2, tighten the piston
assembly to the specified torque.

ii. Make a screw hole to install screw (5).

★ Make a hole horizontally with a drill at the V-groove
of the threaded part of piston (6) and rod (3).
Threading dimensions (mm [in])
Diameter of Depth of Tap Tap to be Tapping
Tap Drill Hole Drill Hole Used Depth
10.3 27 12 × 7.5 20
[0.41] [1.06] [0.47 x 0.30] [0.79]

iii. After making the hole, remove all the chips and dirt and
clean thoroughly.

iv. Tighten screw (5).

Threaded part (b) of screw: Adhesive (LT-2)

Screw: 58.9 – 73.6 N•m (43.44 – 54.28 lbf ft)

v. Caulk four points (a) of the threaded part with a punch.

50-314 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
C. Remove piston rod assembly (3) from tool U1.

5. Set cylinder (4) to tool U1 and sling cylinder head and piston rod
assembly (3); install it to the cylinder.

A. Tighten cylinder head mounting bolt (2).

Cylinder head mounting bolt (2):

Lift arm: 529.7 ±78.5 N•m(390.69 ±57.90 lbf ft)
Bucket: 892 ±137 N•m (657.90 ±101.05 lbf ft)

B. Remove cylinder assembly (1) from tool U1.

WA500-6 50-315 ➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Steering Valve

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Operate the work equipment control lever two to three times to release the residual pressure in the
work equipment circuit.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Drain the hydraulic oil.

Hydraulic oil: Approximately 337 l (89 gal)

2. Remove guard and seat (1).

3. Remove plate (2).

4. Remove toolbox (3).

5. Remove covers (4), (5), and (6).

6. Disconnect hoses (7), (8), (9), (10), (11), (12), and (13).

7. Disconnect tube (14).

8. Sling steering valve assembly (15); remove its four mounting

bolts; and lift it off.

Steering valve assembly: 35 kg (77 lb)

50-316 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Installation
★ Carry out installation in the reverse order of removal.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

WA500-6 50-317 ➁
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

WORK EQUIPMENT

Work Equipment
Removal
WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

1. Sling the bucket link and remove pin (1). [*1]

• Using a lever block, fix the bucket link to the bell crank.
★ If any shim is inserted, check the quantity and thickness.

2. Remove right and left bucket hinge pins (2). [*2]

★ If any shim is inserted, check the quantity and thickness.

3. Disconnect the bucket from the lift arm by moving the machine in
reverse or sling the bucket with a crane.

Bucket: 3,150 kg (6,945 lb)

4. Disconnect grease hose (4).

5. Sling bucket cylinder (5); pull out pin (6); and disconnect the
bucket cylinder from the bell crank.
★ After disconnecting the bucket cylinder, start the engine and
retract the piston rod.

50-318 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
6. Fix bucket cylinder (5) to the frame with a nylon sling, etc.

7. Set stand [1] under the lift arm end and release the residual
pressure in the hydraulic piping.

8. Sling lift arm cylinder (7) and remove pin (8).

• Remove the other lift arm cylinder pin in the same manner.
• After disconnecting the lift arm cylinder, start the engine and
retract the piston rod.

9. Remove coves (9) and (10).

10. Disconnect wiring harness connector F13 (11) and remove the
three wiring harness clamps.

11. Remove lift arm angle sensor assembly (12). [*3]

WA500-6 50-319 ➁
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12. Disconnect right and left grease tubes (13).

13. Sling lift arm, bell crank, and bucket link assembly (14); pull out
right and left pins (15); and lift off the assembly. [*4]
★ When slinging the assembly, insert block [2] in the bell crank.
★ If any shim is inserted, check the quantity and thickness.

Lift arm, bell crank and bucket link assembly:

3,250 kg (7,165 lb)

14. Sling bucket link assembly (16); pull out pin (17); and remove the
assembly from the bell crank.

Bucket link: 160 kg (353 lb)

15. Sling bell crank (18); pull out pin (19); and remove the bell crank
from the lift arm.

Bell crank: 800 kg (1,764 lb)

50-320 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
16. Remove dust seal (21) and bushing (22) from lift arm (20). [*5]

17. Remove dust seal (23) and bushing (24) from bell crank (18).

18. Remove dust seal (25) and bushing (26) from bucket link (16).

WA500-6 50-321 ➁
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

Installation
★ Carry out installation in the reverse order of removal.

WARNING! When aligning the pin holes, use a bar. Never insert your fingers in the pin holes.

When starting the engine, check that the directional lever is in neutral and the parking brake is
applied.

[*1]

1. Sling bucket link (16) and install cord rings (27) while aligning the
holes for pin (1).

2. Insert a shim so that clearances (a) on the right and left sides are
the same.

3. Install pin (1) and lock it with the bolt.

★ Be careful that the cord ring does not get caught.
Clearance (a): . . . . . . . . . . . . . . . . . . . . . . . Maximum 1.5 mm (0.06 in)

[*2]

1. Operate the control lever to align the holes for bucket mounting
pin (2) and install cord rings (28).

2. Insert a shim so that clearances (b) on the right and left sides are
the same.

3. Install mounting pin (2) and lock it with the bolt.

★ Be careful that the cord ring does not get caught.
Clearance (b): . . . . . . . . . . . . . . . . . . . . . . . Maximum 1.5 mm (0.06 in)

[*3]

★ Adjust the lift arm angle sensor assembly. For details, see Work Equipment in the Testing and Adjusting section.

[*4]

1. Sling the assembly of the lift arm, bell crank, and bucket link and
set it to the lift arm mounting hole of the front frame.

2. Insert a shim so that clearances (c) on the right and left sides are
the same.

3. Install pin (15) and lock it with the bolt.

★ Be careful that the cord ring does not get caught.
Clearance (c): . . . . . . . . . . . . . . . . . . . . . . . Maximum 1.0 mm (0.04 in)
★ After installing the pin, set a stand under the lift arm end.

50-322 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
[*5]

1. Press-fit the respective bushings to the bucket link, bell crank, and
lift arm with puller [3] and install the dust seals.

Bushing: Grease (G2-LI)

★ The figure to the right shows the lift arm.

2. Supply grease to each pin.

WA500-6 50-323 ➁
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

Counterweight (Large)

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Operate the work equipment control lever two to three times to release the residual pressure in the
work equipment circuit.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove the radiator guard assembly. For details, see the Engine
and Cooling System: Radiator Guard and Cooling Fan removal
and installation procedures in this section.

2. Disconnect wiring harness connector R18 (1) (when removing

only the left-hand battery).

3. Disconnect right and left battery cables (2) and (3).

4. Remove right and left battery holders (4).

5. Lift off right and left batteries (5).

Battery: 65 kg (143 lb)

6. Remove right and left battery box covers (6) and (7).

50-324 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
7. Sling counterweight assembly (8); remove its four mounting bolts;
and lift it off. [*1]

Counterweight: 2,550 kg (5,622 lb)

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Counterweight mounting bolt:

1,372 – 1,764 N•m (1,011.93 – 1,301.06 lbf ft)

WA500-6 50-325 ➁
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

Counterweight (Small)

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Operate the work equipment control lever two to three times to release the residual pressure in the
work equipment circuit.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove the right and left batteries and right and left battery
covers. For details, see the Work Equipment: Counterweight
(Large) removal and installation procedures in this section.

2. Sling counterweight assembly (2); remove its four mounting

bolts ); and lift it off. [*1]

Counterweight: 900 kg (1,984 lb)

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Counterweight mounting bolt: 785 – 980 N•m (578.99 – 722.81 lbf ft)

50-326 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

CAB AND ITS ATTACHMENTS

Cab (Separate Cab and Floor)

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove floor skirt cover (1) and right and left covers (2).

2. Open the external air filter cover and remove filter (3) and filter
box (4).

3. Remove brake combination box front cover (5).

WA500-6 50-327 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
4. Remove upper cover (6) of the steering valve cover.

5. Remove right and left covers (7) under the hydraulic tank.

6. Disconnect tipping protection wire (8).

7. Disconnect heater hose clamp (9).

50-328 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
8. Disconnect reservoir tank and subtank hose clamps (10).

9. Remove front step (11).

10. Remove air conditioner pipe and heater hose fixing plate (12).

11. Remove the floor mat.

12. Remove rear wiper motor cover (13).

13. Remove rear cover (14).

14. Remove lunchbox (15).

WA500-6 50-329 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
15. Disconnect rear windshield wiper wiring harness connector
C15 (16).

16. Disconnect rear window washer hose (17).

17. Disconnect KOMTRAX wiring harnesses (18).

18. Remove the five mounting bolts and disconnect rear controller
box (19) from the rear side of the cab.

19. Remove the four mounting bolts and disconnect right console (20).

20. Remove right and left pillar covers (21) and (22).

21. Disconnect internal temperature sensor connector (23).

22. Disconnect parking brake switch (24).

23. Disconnect switch connectors (25) L59, (26) L65, L66, L69, L70,
(27) L67, L68, L72 (if equipped), and (28) C10.

24. Remove the ten mounting bolts and monitor dashboard cover (29).

50-330 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
25. Remove right and left covers (30) and (31) on the front side of the
cab.

26. Disconnect six wiring harness clamps (32).

27. Remove wiring harness protection cover (33).

28. Unplug wiring harness connectors (34) AL1, (35) CL1, (36) CL2,
and (37) CL15.

29. Remove four bolts (38) marked with ★.

30. Remove two screws (39) marked with ●.

31. Disconnect wiper motor wiring harness connector (40) C12.

WA500-6 50-331 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
32. Disconnect window washer hose (41).

33. Disconnect hose (42) of the cooler and heater hoses from the air
conditioner unit.

34. Remove the four mounting bolts and disconnect air conditioner
unit assembly (43) from the cab.

35. Disconnect internal air filter (44) from the floor.

50-332 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
36. Remove the cab mounting bolts. [*1]
★ Remove the bolts marked with ★ and ● from the underside of
the floor.
★ Remove the bolts marked with ▲ from the top of the floor.

37. Lift off cab (45).

★ When removing the cab, check that all the wiring harnesses
and pipings are disconnected. Be extremely careful that the
cab does not interfere with another part. [*2]

Cab assembly: 750 kg (1,654 lb)

WA500-6 50-333 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Installation
★ Carry out installation in the reverse order of removal.

[*1]

Cab mounting bolt:

(M20): 490 – 608 N•m (361.40 – 448.44 lbf ft)
(M12): 98 – 123 N•m (72.28 – 90.72 lbf ft)

[*2]

1. Replace seal (46) between the cab and floor frame.

A. Stick the seal along the periphery of the floor frame top.

B. Remove oil, grease, dust, etc. from the sticking surface.

C. Do not cut the bent parts of the seal but stick them as they are.
Bend each part by 10 – 20 mm (0.40 – 0.79 in).

2. If the cab is not sealed perfectly, the pressurized performance of

the cab drops and the noise in the cab increases.

50-334 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Cab and Frame (Cab-Floor Unit)

★ The cab of this machine forms one unit with the floor frame.

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Loosen the hydraulic tank cap gradually to release the internal pressure of the hydraulic tank.

Removal
Precautions for Handling Refrigerant

WARNING! Collect refrigerant (R134a) beforehand.

★ Ask professional traders for collecting and filling the refrigerant (R134a).
★ Never release the refrigerant (R134a) to the atmosphere.

WARNING! If the refrigerant (R134a) gets in your eyes, it may cause blindness. You must wear protective
glasses when collecting or filling the refrigerant. Collecting and filling work must be conducted by a
qualified person.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant when
disconnecting the heater hoses and draining the coolant. Wait until the coolant has cooled and then
drain the coolant.

1. Drain the coolant.

Coolant: Approximately 90 l (24 gal)

2. Remove right and left side panels (1).

3. Remove cover (2).

4. Remove box (3).

WA500-6 50-335 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
5. Remove the bolts from the rear part of cover (4).

6. Remove the bolts from the front part of cover (5).

7. Remove cover (6).

8. Remove toolbox (7).

9. Disconnect air conditioner hoses (8) and (9). [*1]

10. Disconnect hose bracket (10).

11. Disconnect brake hoses (11) and (12).

12. Disconnect steering hose (13).

50-336 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
13. Unplug wiring harness connectors LR1 (14), LR4 (15), LS2 (16),
LR3 (17), LR2 (18), LR6 (19), and LR5 (20).

14. Disconnect wiring harness connector bracket (21) from the frame.

15. Disconnect wiring harness clamps (22) and (23).

16. Disconnect wiring harness connectors FL1 (24) and RT1 (25).

17. Disconnect wiring harness clamps (26) and (27) from the bracket.

18. Disconnect heater hoses (28) and (29).

WA500-6 50-337 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
19. Disconnect hoses (30) and (31).

20. Disconnect window washer hoses (32).

21. Disconnect steering hoses (33) and (34).

22. Disconnect brake booster hoses (35), (36), (37), and (38).

23. Remove rear windshield wiper motor cover (39).

24. Remove cover (40).

25. Remove lunchbox (41).

50-338 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
26. Disconnect ground wire (42) from the floor frame.

27. Remove four front and rear rubber caps (43).

28. Remove four front and rear nuts (44). [*2]

29. Lift off cab and floor frame assembly (45).

★ Before removing the assembly, check that all the wiring
harnesses and pipings are disconnected.

Cab and floor frame assembly: 1,200 kg (2,646 lb)

WA500-6 50-339 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Installation
★ Carry out installation in the reverse order of removal.

[*1]

★ When installing the air conditioner circuit hoses, be careful that dirt, dust, or water does not enter them.

1. Before connecting each air conditioner hose, check that the O-rings are fitted to the joints.

2. Check that each O-ring is not damaged or deteriorated.

3. Tighten each nut with two spanners.

Threaded part of refrigerant piping: ND-OIL8

Threaded part of hose (M16 x 1.5): 12 – 15 N•m (8.85 – 11.06 lbf ft)

Threaded part of hose (M24 x 1.5): 30 – 35 N•m (22.13 – 25.81 lbf ft)

Filling with Air Conditioner Gas

★ Fill the air conditioner circuit with refrigerant (R134a).

[*2]

Floor frame mounting nut: 1,177 – 1,471 N•m (868.11 – 1,084.95 lbf ft)

Refilling with Coolant

1. Add coolant through the coolant filler to the specified level.

2. Run the engine to circulate the coolant through the system.

3. Check the coolant level again.

Refilling with Oil (Hydraulic Tank)

1. Add oil through the oil filler to the specified level.

2. Run the engine to circulate the oil through the system.

3. Check the oil level again.

Bleeding Air

★ Bleed air from the brake circuit. For details, see Brake System: Bleeding Air from Wheel Brake Circuit in the Testing and
Adjusting section.

50-340 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Cab Glass (Stuck Glass)

1. Front glass

2. Right door glass

3. Right window glass

4. Rear window glass

5. Left window glass

WA500-6 50-341 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Special Tools

New/Remodel
Necessity

Sketch
Qty
Symbol Part No. Part Name

1 793-498-1120 Clear plate ■ 2

2 2 793-498-1130 Plate ■ 2
X
3 793-498-1110 Magnet ■ 2
3 793-498-1210 Lifter (Suction cup) ■ 2

Removal
★ All sides of each glass of the cab of this machine are stuck.
★ Remove the window glass to be replaced according to the following procedure.

1. Using seal cutter [1], cut the adhesive between broken window
glass (1) and cab (2).

★ If the glass is narrow, you can cut the adhesive by inserting a

fine wire [2] (piano wire, etc.) in the adhesive and gripping
both of its ends with pliers [3] (or holding the ends by winding
them onto something) and cutting the adhesive with the wire.

★ If the window glass is finely broken, you can remove the glass
with a knife [4] and a screwdriver. (If the screwdriver is
applied directly to the normal window glass, the glass will
break.)
★ When using a knife [4], insert a screwdriver in the cut to
widen it and move the knife forward.

2. Remove the window glass.

50-342 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Installation

1. Using scraper [5], remove the remaining adhesive.

★ Do not scratch the paint.

2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (2)
and window glass (3) with white gasoline.
★ If the sticking surfaces are not cleaned well, the glass may not
stick correctly.
★ Clean all the black part on the back side of the window glass.
★ After cleaning the sticking surfaces, leave them to dry for at
least five minutes.

3. If paint was flaked off when the adhesive was removed with the
scraper, coat the bare part with paint.
★ If the glass is installed without repairing the bare part, that part
will rust.
★ Do not apply paint to a part which will be coated with primer.

4. Stick double-sided adhesive tape (4) along the inside edge of the
glass-sticking section.
Size of double-sided adhesive tape: . . . . . . 7 × 4.8 mm (0.28 x 0.19 in)
★ When sticking the double-sided adhesive tape, do not touch
the cleaned surface for as long as possible.
★ Do not remove the release tape of the double-sided adhesive
tape on the glass-sticking side before sticking the glass.

WA500-6 50-343 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
★ Be careful that the corner (part (b)) of the double-sided
adhesive tape does not float.

★ When sticking the double-sided adhesive tape around a side or

a rear window glass, start at the center of the top and make a
clearance of about 5 mm (0.20 in) at end joint (c).

5. Position the replacement glass.

A. Stick X2-2 (thin steel sheet) to tool X2-1 (spacer) with

adhesive.
Spacer thickness (t): . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.20 in)

B. Set tool X2-3 (magnet) to tools X2-1 and X2-2 and set them to
the two lower places of the window glass-sticking part of
cab (2).

50-344 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
C. Using tool X3 (suction cup), place window glass (3) on tool
X2-1 (5 mm (0.20 in) spacer) and match it to the cab.

D. Check the clearance between window glass (3) and cab (2) on
both sides and adjust it evenly.

E. Stick tape [6] between window glass (3) and cab (2) and draw
positioning line (a) on the tape.

F. Cut the tape between window glass (3) and cab (2) with a
knife and then remove the window glass.
★ Do not remove the tapes left on the window glass and cab
before installing the window glass.

6. Apply primer.
★ The using limit of primer (5) is four months after the date of
manufacture. Do not use primer (5) after this limit.
★ Use the primer within two hours after unpacking it.
★ Even if the primer is packed again just after it is unpacked, use
it within 24 hours after it is unpacked for the first time.
(Discard the primer 24 hours after it is packed.)

A. Stir the primers for paint and glass sufficiently before using
them.
★ If the primer has been stored in a refrigerator, leave it at
room temperature for at least half a day before stirring it.
(If the primer is unpacked just after being taken out of the
refrigerator, water will condense. Leave the primer at
room temperature for a sufficient time.)

B. When reusing primer brush (6), wash it in white gasoline.

★ After washing the brush, check it again for dirt and foreign matter.
★ Prepare respective brushes for the paint primer and glass primer.

WA500-6 50-345 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
C. Evenly apply paint primer (7) to the parts on the outside of the
double-sided adhesive tape, on cab (2), which will be coated
with the adhesive.

Paint primer: SUNSTAR PAINT PRIMER 580 SUPER

★ Do not apply the primer more than two times.

(If it is applied more than two times, its performance is
reduced.)

★ Parts to be coated with primer: Apply the primer all over

dimension (d) on the outside of the double-sided adhesive
tape.
Dimension to apply primer (d): . . . . . . . . . . . . . . . . . . . 23 mm (0.91 in)
★ After applying the primer, leave it for at least five minutes
(within eight hours) to dry.
★ If the glass primer is applied by mistake, wipe it off with
white gasoline.
(If the wrong primer is applied, the glass will not stick.)

D. Evenly apply glass primer (8) to the black part of window

glass (3) to be stuck.

Glass primer: SUNSTAR GLASS PRIMER 580 SUPER

★ Do not apply the primer more than two times.

(If it is applied more than two times, its performance is
reduced.)
★ Parts to be coated with primer: Apply the primer to the
sticking surface of window glass (3) and all over
dimension (d) on double-sided adhesive tape (4) and
cab (2).
Dimension to apply primer (d):. . . . . . . . . . . . . . . . . . . . 23 mm (0.91 in)
★ Do not apply the primer to the border, about 5 mm
(0.20 in) wide, between the black part and transparent
part of the glass.
★ After applying the primer, leave it for at least five minutes
(within eight hours) to dry.
★ If the paint primer is applied by mistake, wipe it off with
white gasoline.
(If the wrong primer is applied, the glass will not stick.)

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
7. Apply adhesive.
★ Use either of the two types of adhesive.

Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER “S”

Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER “W”

★ The using limit of the adhesive is four months after the date of manufacture. Do not use the adhesive after this limit.
★ Keep the adhesive in a dark place where the temperature is below 25°C (77°F).
★ Never heat the adhesive higher than 30°C (86°F).
★ When reusing the adhesive, remove all the hardened parts from the nozzle tip.

A. Break aluminum seal (10) of the outlet of adhesive

cartridge (9) and install the nozzle.

B. Cut the tip of the adhesive nozzle (11) so that dimensions (f)
and (g) are as follows.
Dimension (f):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (0.39 in)
Dimension (g): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.47 in)

C. Put the adhesive cartridge (9) in caulking gun [7].

★ An electric caulking gun is more efficient.

WA500-6 50-347 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
D. Remove release tape (13) of the double-sided adhesive tape on
the glass side.

E. Apply adhesive (12) to the outside of double-sided adhesive

tape (4) of the cab.
★ Before applying the adhesive, check that the primer is
applied to the surface to which the adhesive will be
applied.

★ Apply adhesive (12) to dimensions (h) and (j) of double-

sided adhesive tape (4) of cab (2).
Dimension (h): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (0.39 in)
★ Apply adhesive (12) wider than double-sided adhesive
tape (4).
★ Apply the adhesive evenly.

8. Install window glass (3).

★ If the glass is positioned incorrectly, the adhesive must be
removed and cleaned and then the primer and adhesive must
be applied again. Position the glass carefully when sticking it.

A. Similarly to Step 5, match tools X2-1, X2-2, and X2-3 and set
them to the two lower places of the window glass-sticking part
of cab (2).

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
B. Using tool X3, raise and place window glass (3) on tool X2-1
(5-mm spacer) and stick it to the cab.
★ Match the lines of the match tapes stuck in Step 5.
★ Stick the glass within ten minutes after applying the
adhesive.
★ Before sticking the glass, check that the primer is applied
to the surface to which the glass will be stuck.

★ Check that clearance (k) between the front side of the

front glass and right and left side glasses is even.
Clearance (k): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.20 in)

C. After sticking window glass (3), press it evenly.

★ Press all over the window glass just enough so that the
window glass sticks to the double-sided adhesive tape.
★ Do not press too hard on the window glass.

9. Cure the stuck window glass for a certain time.

Curing time before removing tool X2-1 (5 mm (0.20 in) spacer) (at
temperature of 20°C (68°F) and humidity of 60%): . . . . . . . . . . 10 hours
Curing time before operating machine: . . . . . . . . . . . . . . . . . . . . . 1 day

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
10. If the front glass and both front side glasses are replaced, seal
them.

A. Stick masking tapes (14) along the parts to be sealed as shown

in the figures.
★ Stick the masking tapes to both the inside and outside of
the cab.

B. Fill the glass joints with caulking material (15).

★ The usable period of the following caulking material is
four months after the date of manufacture. Do not use the
caulking material after its usable period.

Caulking material: SUNSTAR PENGUINE SEAL NO. 2505

C. Use cardboard [8], etc. to remove the caulking material

projecting from the joint.

D. Remove the masking tapes from the window glass.

11. Remove the primer and adhesive from the cab and window glass.
★ Using white gasoline, wipe off the adhesive before it dries.
★ When cleaning the glass, do not hit it or push on it.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Operator Seat (Upper Seat)

★ Manufactured by Grammer.

Remark
Although the machine with joystick steering is not equipped with the left armrest, its operator seat is also
disassembled and assembled according to the following procedure.

Storage Box
Removal

1. Open the storage box (1).

2. Remove the hook (3).

3. Undo the screws (2) and remove the storage box (1).

Installation

1. Set the storage box (1) and fix it with the screws (2).

2. Install the hook (3).

Seat Pad and Backrest Upholstery

Removal

1. Remove the storage box. See the Operator Seat (Upper Seat):
Storage Box removal procedure on this page.

2. Undo the four screws (1) and remove the backrest upholstery (2).

3. Undo the five screws (4) and remove the seat pad (5).

4. Unplug the connectors (3) and (6).

Installation

1. Plug in the connectors (3) and (6).

2. Install the seat pad (5) and fix it with the five screws (4).

3. Install the backrest upholstery (2) and fix it with the four screws (1).

4. Install the storage box. See the Operator Seat (Upper Seat): Storage Box installation procedure on this page.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Mechanical Lumbar Support

Removal

1. Remove the storage box. See the Operator Seat (Upper Seat):
Storage Box removal procedure in this section.

2. Remove the backrest upholstery. See the Operator Seat (Upper

Seat): Seat Pad and Backrest Upholstery removal procedure in this
section.

3. Drill off the rivets (1); loosen the spring steel sheets (2) from the
L-bar (3); and remove them.

4. Unhook the L-bars (3) from the catch element (4).

5. Undo the hexagon socket screw (5) and remove the adjusting
knob (6) with the toothed wheel (7).

6. Drill off the rivet (8); remove the wrap spring brake element (9) and the catch element (4).

Installation

1. Install the wrap spring brake element (9) and the catch element (4); fix them with the rivets (8).

2. Install the adjusting knob (6) and the toothed wheel (7); tighten the hexagon socket screw (5).

3. Install the catch element (4) to the L-bars (3); fix with the rivets (1).

4. Install the two spring steel sheets (2) to the L-bar (3); fix with the rivets (1).

5. Install the backrest upholstery. See the Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery installation
procedure in this section.

6. Install the storage box. See the Operator Seat (Upper Seat): Storage Box installation procedure in this section.

Armrests (if equipped)

Removal

1. Remove the cover (1).

2. Unscrew the hexagon nuts (2) and remove the nuts and
washers (3).

3. Remove the armrests (4).

Installation

1. Set the armrests (4).

2. Put the washers (3) and tighten hexagon nuts (2).

Hexagon nuts: 25 N•m (18.44 lbf ft)

3. Install the cover (1).

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Backrest

Removal

1. Detach the storage box. See the Operator Seat (Upper Seat): Storage Box removal procedure in this section.

2. Remove the backrest upholstery. See the Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery removal
procedure in this section.

3. Remove the armrests. See the Operator Seat (Upper Seat): Armrests (if equipped) removal procedure in this section.

4. Disassemble the backrest. See the Operator Seat (Upper Seat): Backrest Adjustment disassembly procedure in this
section.

5. Unscrew the hexagon nut (5); remove the washers (6) and (7).

6. Remove the hexagon bolt (11) and the washer (10).

7. Press the backrest (1) slightly to the left and move it upwards to take it off.

8. Remove the bearing (8) and the torsion spring (9) from the backrest (1).

WA500-6 50-353 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Installation

1. Install the bearing (8) and the torsion spring (9) to the backrest (1).
★ Oil the bearing point (Q) on the backrest (1) for the bearing (8) with acid-free multiple-purpose lubricant.
★ Insert the bearing (B/8) into the upper hole on the backrest support on the right side (figure B/4).

2. Press the backrest (1) slightly to the left and install it.
★ The big cylindrical stamping on the backrest adjustment (figure C/2) must engage into the big positional bore hole on
the backrest support on the left side (figure C/3).
★ The integral catch on the backrest (figure A/1) must engage into the torsion spring (figure A/9).

3. Put the washer (10) and tighten the hexagon bolt (11).

4. Put the washers (6) and (7) and tighten the hexagon nut.

Hexagon nuts: 25 N•m (18.44 lbf ft)

5. Assemble the backrest adjustment. See the Operator Seat (Upper Seat): Backrest Adjustment assembly procedure in this
section.

6. Install the armrests. See the Operator Seat (Upper Seat): Armrests (if equipped) installation procedure in this section.

7. Install the backrest upholstery. See the Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery installation
procedure in this section.

8. Install the storage box. See the Operator Seat (Upper Seat): Storage Box installation procedure in this section.

Backrest Adjustment
Disassembly

1. Remove the storage box. See the Operator Seat (Upper Seat):
Storage Box removal procedure in this section.

2. Remove the backrest upholstery. See the Operator Seat (Upper

Seat): Seat Pad and Backrest Upholstery removal procedure in this
section.

3. Remove the armrests. See the Operator Seat (Upper Seat):

Armrests (if equipped) removal procedure in this section.

4. Fold the backrest (1) forwards.

5. Unscrew three flat-headed screws (2); remove the adaptor plate (3)
and the flat-headed screw (4).

6. Remove the lever (5) and handle (6).

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Assembly

1. Fold the backrest (1) forwards.

2. Install the handle (6) and the lever (5).

3. Tighten the three flat-headed screws (4); install the adaptor plate (3); and tighten the flat-headed screw (2).
★ The lifter of the flat-headed screw (4) must engage into the nut of the adaptor plate (3).

Flat-headed screw: 12 N•m (106.21 lbf in)

4. Install the armrests. See the Operator Seat (Upper Seat): Armrests (if equipped) installation procedure in this section.

5. Install the backrest upholstery. See the Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery installation
procedure in this section.

6. Install the storage box. See the Operator Seat (Upper Seat): Storage Box installation procedure in this section.

Seat Angle and Seat Depth Adjuster

Disassembly

1. Remove the seat pad. See the Operator Seat (Upper Seat): Seat
Pad and Backrest Upholstery removal procedure in this section.

2. Remove the switch (if equipped).

A. Disconnect the spring (1).

B. Tilt the switch-plate (2) forwards and remove it.

C. Drill off the rivet (3) and remove the seat switch (4).

3. Remove the flexible support plate (7).

A. Press the spring plate (5) (P position) inwards (arrow), operate

the lever for seat angle adjustment (6).

B. Pull the flexible support plate (7) backwards and remove it.

WA500-6 50-355 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
4. Remove the plate (15).

A. Drill off the rivet and remove the spring steel sheet (5).

B. Unscrew the hexagon socket screws (8); remove the cover (9), the levers for seat angle and seat depth adjustment (6)
and (10), the linkage rod (11), and the locking lever (12).

C. Remove the spring (13).

D. Turn the lever (14) clockwise until it snaps in; pull the plate (15) to the very front and remove it.

5. Remove the covers on the right and left side. See the Operator Seat (Upper Seat): Covers removal procedure in this
section.

6. Unscrew the nut (16); remove the lever (14) and the screw (17).

7. Drill off the rivet (18); remove the spring steel sheets (19).

8. Drill off the rivet (20); remove the locating element (21).

Assembly

1. Install the locating element (21); fix it with the rivet (20).

2. Install the spring steel sheets (19); fix it with the rivet (18).

3. Set the lever (14) and the screw (17); fix with nut (16).

4. Install the covers on the right and left side. See the Operator Seat
(Upper Seat): Covers installation procedure in this section.

5. Assemble the plate (15).

A. Turn the lever (14) clockwise until it snaps in; install the
plate (15).

B. Install the spring (13) to hook (a) of the lever (14) and
hook (b) of the plate (15).

C. Install the cover (9), the levers for seat angle and seat depth
adjustment (6) and (10), the linkage rod (11), and the locking
lever (12); tighten the hexagon socket screws (8).

D. Install the spring steel sheet (5) and fix it with the rivet.

6. Install the flexible support plate.

A. Press the spring plate (5) (P position) inwards (arrow); operate

the lever for seat angle adjustment (6).

B. Swivel the flexible support plate (7) upwards and install it.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
7. Install the end hook of the linkage rod (11) to position (c) of the
lever (10) and the other side of the hook of the linkage rod (11) to
the port (d) of the lever (14).

8. Install the switch (4) (if equipped).

A. Install the seat switch (4) and fix it with rivet (3).

B. Tilt switch-plate (2) forwards and install it.

C. Install the spring (1).

9. Install the seat pad. See the Operator Seat (Upper Seat): Seat Pad
and Backrest Upholstery installation procedure in this section.

Covers
Removal

1. Remove the seat pad. See the Operator Seat (Upper Seat): Seat
Pad and Backrest Upholstery removal procedure in this section.

2. Remove spring (1) and switch-plate (2) (if equipped).

3. Remove the flexible support plate.

A. Press the spring sheet inwards (arrow) and operate the lever
for seat angle adjustment (3).

B. Pull the flexible support plate (4) backwards and remove it.

4. Remove the spring (5).

5. Turn the lever (6) clockwise until it snaps in; pull the plate (7) to
the extreme front and remove it.

6. Drill off the rivet (8) and remove the washers (9).

7. Unhook the covers (10) by pulling them forwards; remove them in

an upward direction.

WA500-6 50-357 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Installation

1. Install the covers (10) on right and left side.

2. Install the washers (9) and fix them with the rivet (8).

3. Turn the lever (6) clockwise until it snaps in, then install the plate (7).

4. Remove the spring (5). See the Operator Seat (Upper Seat): Seat Angle and Seat Depth Adjuster disassembly procedure
in this section.

5. Install the flexible support plate (4). See the Operator Seat (Upper Seat): Seat Angle and Seat Depth Adjuster assembly
procedure in this section.

6. Install spring (1) and switch-plate (2). See the Operator Seat (Upper Seat): Seat Angle and Seat Depth Adjuster assembly
procedure in this section.

7. Install the seat pad. See the Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery installation procedure in this
section

Slide Rails
Removal

1. Remove the seat pad. See the Operator Seat (Upper Seat): Seat
Pad and Backrest Upholstery removal procedure in this section.

2. Push the seat top assembly (1) as far back as possible.

3. Unscrew the hexagon socket screws (2) and remove the nuts (3).

4. Push the seat top assembly (1) as far forward as possible.

5. Unscrew the hexagon socket screws (4); remove the washers (5)
and nuts (6).

6. Remove the seat top assembly (1) and remove the washers (7).

7. Disconnect the bellows from the upper part of the suspension

system and lay it down.

8. Unscrew the hexagon socket screws (8) and remove the nuts (9).

9. Remove the slide rails (10).

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Installation

1. Install the slide rails (10).

2. Put the nuts (9) and tighten the hexagon socket screws (8).
★ Replace the hexagon socket screws (8) with new ones.

Hexagon socket screws: 25 N•m (18.44 lbf ft)

3. Install the bellows to the upper part of the suspension system.

4. Put the washers (7) and install the seat top assembly (1).

5. Put the washers (5) and nuts (6), then tighten the hexagon socket screws (4).
★ Replace the hexagon socket screws (4) with new ones.

Hexagon socket screws: 25 N•m (18.44 lbf ft)

6. Push the seat top assembly (1) as far forward as possible.

7. Put the nuts (3) and tighten the hexagon socket screws (2).
★ Replace the hexagon socket screws (2) with new ones.

Hexagon socket screws: 25 N•m (18.44 lbf ft)

8. Push the seat top assembly (1) as far back as possible.

9. Install the seat pad. See the Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery installation procedure in this
section.

WA500-6 50-359 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Operator Seat (Suspension)

Top Cover
Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper
Seat) in this section.

2. Pull the connecting cable (3) inwards through the upper cover (2).

3. Remove the two bellows pins (1) and take the upper cover (2) off.

Installation

1. Install the connecting cable (3) inwards through the upper

cover (2).

2. Install the upper cover (2) and fix it with the two bellows pins (1).

3. Install the upper part of the seat. Refer to Operator Seat (Upper
Seat) in this section.

Front Cover
Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper
Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension):

Top Cover removal procedure in this section.

3. Bore out two rivet heads and drive out blind rivets (1); remove the
front cover (2).

Installation

1. Install the front cover (2) and fix it with the two rivets (1).

2. Install the top cover. Refer to the Operator Seat (Suspension): Top
Cover installation procedure in this section.

3. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Bellows
Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper
Seat) in this section.

2. Remove the bellows (2) from the upper part of the suspension (1).

A. Take bellows pins (4) off on the front.

B. Take bellows pins (3) off on the left side of the top.

C. Remove two bellows pins (4) on the back; take two bellows
pins (3) off the upper part of the suspension system (1).

D. Take three bellows pins (3) on the right side off the upper part
of the suspension (1); pull the bellows (2) over the handle for
vertical shock absorber adjustment (9).

3. Remove the bellows (2) from the lower part of the suspension (6).

A. Take three bellows pins (3) on the front side off the lower part
of the suspension (6).

B. Release two bellows pins (3) on the left side from the lower
part of the suspension (6).

C. Release four bellows pins (3) on the back side from the lower
part of the suspension (6).

D. Remove a cable tie (10) on the right side from the connecting
cable; take two bellows pins (3) off the lower part of the
suspension (6) (if equipped).

4. Lift the bellows (2) over the lower part of the suspension (6) and
remove the bellows (2) in a downward direction.

5. Remove the wire insert (5) from the bellows (2).

Installation

1. Install the wire insert (5) to the bellows (2).

2. Install the bellows (2).

3. Fix the bellows (2) with pins (3) to the lower part of the suspension (6) in the reverse order of their removal.

4. Fix the connecting cable with the cable tie (10) (if equipped).

5. Fix the bellows (2) with pins (3) to the upper part of the suspension (1) in the reverse order of their removal.

6. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

WA500-6 50-361 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Bidden Pull Wires and Handle (Vertical Shock Absorber Adjustment)

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

5. Screw out Torx screw (2).

6. Pull the handle for vertical shock absorber adjustment (1) off the upper part of the suspension (4).

7. Remove the Bidden pull wire (5) from the handle for vertical shock absorber adjustment (1).

8. Push the Bowden pull wire (5) off the bearing for Bowden pull wire (6).

9. Bore out the rivet head and drive out the blind rivet (7); remove the bearing for Bowden pull wire (6).

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
10. Mark the points where the Bowden pull wire (5) is fastened with the swinging structure (14) with the cable tie (8); take the
cable tie (8) off.

11. Pull the fixation (12) off the vertical shock absorber (13).

12. Take the Bowden pull wire (5) off the bearing (9).

13. Remove the fixation (12) from the fork (11).

14. Take the Bowden pull wire (5) off the fork (11); remove the fork (11) and compression spring (10).

15. Mark the location of the mounting hole for the Bowden pull wire (5) in the upper part of the suspension (4); pull the
Bowden pull wire (5) out of the upper part of the suspension (4); and then remove it.

Installation

1. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

2. Put the Bowden pull wire (5) to the upper part of the suspension (4) through the location of the mounting hole marked
before removing the Bowden pull wire (5).

3. Install the fork (11) and compression spring (10) and take the Bowden pull wire (5) to the fork (11).

4. Install the fixation (12) to the fork (11).

5. Take the Bowden pull wire (5) to the bearing (9).

6. Put the fixation (12) to the vertical shock absorber (13).

7. Install the Bowden pull wire (5) and fix it with the cable tie (8) at the marked points.
★ Install the Bowden pull wire according to the marking.

8. Install the bearing for Bowden pull wire (6) and fix it with the rivet (7).

9. Install the Bowden pull wire (5) to the bearing for Bowden pull wire (6).

10. Install the Bowden pull wire (5) to the handle for vertical shock absorber adjustment (1).

11. Install the handle for vertical shock absorber adjustment (1) to the upper part of the suspension (4).

12. Tighten Torx screw (2).

Torx screw: 2.25 N•m (19.91 lbf in)

13. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

14. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

15. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

WA500-6 50-363 ➁
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Vertical Shock Absorber

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper
Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension):

Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension):

Bellows removal procedure in this section.

4. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension

between the swinging structure and lower part
of the suspension system with suitable
spacers.

5. Remove circlip (8) from stud (6).

6. Pull the stud (6) out of swinging structure (7) and vertical shock
absorber (4).

7. Take fixation (2) and bearing (1) off vertical shock absorber (4).

8. Remove circlip (5) from stud (3).

9. Pull stud (3) out of swinging structure (7) and vertical shock
absorber (4).

10. Remove vertical shock absorber (4) in an upward direction.

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Installation

1. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

2. Install vertical shock absorber (4).

★ When re-installing vertical shock absorber (4), make sure the labeling is on top.

3. Assemble vertical shock absorber (4) to swinging structure (7) and put stud (3).

4. Install circlip (5) to stud (3).

★ Apply acid-free multi-purpose lubricant to the entire external surface (F) of stud (3).

5. Install fixation (2) and bearing (1) to vertical shock absorber (4).

6. Assemble vertical shock absorber (4) to swinging structure (7) and put stud (6).
★ Apply acid-free multi-purpose lubricant to the entire external surface (F) of stud (6).

7. Install circlip (8) to stud (6).

8. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

9. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

10. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Compressor

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

5. Mark the points where compressor cable (5) is fastened with six cable ties (6); remove cable ties (6).

6. Disconnect right-angle plug (10) from height level control unit (1).

7. Disconnect the electric connector of flat plug (11).

8. Mark the points where compressed-air hose (7) is fastened with cable tie (12); remove cable tie (12).

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
9. Mark the points where compressor (3) is fastened with two cable ties (4); remove cable ties (4).

10. Pull fitting (8) out of the spike of compressor (3) and push it backwards off compressed-air hose (7).

11. Pull compressed-air hose (7) off compressor (3).

★ Do not use a screwdriver to lift compressed-air hose (7) off the spike of compressor (3).
★ Heat compressed-air hose (7) at the head of compressor (3) (for example, using a hot-air blower) and then pull it off
in one move.

12. Pull out compressor cable (5) in a downward direction and remove compressor (3) to the front.

13. Remove support (9) from the lower part of suspension (2).

Installation

1. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

2. Install support (9) to the lower part of suspension (2).

3. Install compressor (3) to support (9).

4. Install compressed-air hose (7) and fix it with cable tie (4) at the marked points.
★ Loosely apply cable tie (4) until the locking head of cable tie (4) is located slightly over the front curve of
compressor (3) and while compressor (3) can be still moved.
★ Align the compressor (3) and use the pliers to tighten the locking head of the cable tie (4) to 310 N•m (228.64 lbf ft)
in the direction shown (arrow).

5. Put fitting (8) to compressed-air hose (7).

6. Install them to the spike of compressor (3).

7. Fix compressor (3) with cable ties (4) at marked points.

★ Fix the cable tie according to the marking.

8. Fix compressed-air hose (7) with cable tie (12) at the marked points.

9. Connect the electric connector of flat plug (11).

10. Connect right-angle plug (10) to height level control unit (1).

11. Install compressor cable (5) and fix it with cable tie (6) at the marked points.
★ Tie back any excess length of compressor cable (5).

12. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

13. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

14. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Height Level Controller

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

5. Loosen up two circlips (17) from stud (18) and then remove them.

6. Knock out stud (18) from the lower part of suspension (15) and then remove it.
★ Firmly hold webbing (5) and let it carefully roll back to the rewinder on the height level controller (1).

7. Remove two buffers (16) from the loop of webbing (5).

8. Mark the points where air input hoses (10) and (11) are fastened with five cable ties (12); remove cable ties (12).

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
9. Pull air input hoses (10) and (11) off the pneumatic spring. Refer to the Operator Seat (Suspension): Compressed-Air
Hoses removal procedure in this section.

10. Mark the place where the cable is fastened with right-angle plugs (13) and (14) and the cable tie; remove the cable tie.

11. Mark the place where Bowden pull wire (19) is fastened with the cable tie; remove the cable tie.

12. Unhook Bowden pull wires (3) and (19) from height level control (1).

13. Mark and then unplug the right-angle plugs (13) and (14) from height level control unit (1).

14. Remove two hexagon nuts (4) from the thread of height level control (1).

15. Remove plate (7), loop of webbing (5), and edge protection strip (6).

16. Remove height level control (1) from the upper part of suspension (8).

17. Undo Torx screw (9); take the attachment for Bowden pull wire (2) off the height level valve (1).
★ To do this, first release the two catchers on the backside of the attachment for Bowden pull wire (2) and take the
attachment for Bowden pull wire (2) off the height level valve (1).

18. Pull Bowden pull wire (3) out of the attachment for Bowden pull wire (2).

19. Remove the height level controller in an upward direction.

Installation

1. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

2. Install the height level controller.

3. Install Bowden pull wire (3) to the attachment for Bowden pull wire (2).

4. Install the attachment for Bowden pull wire (2) to height level controller (1).

5. Tighten Torx screw (9) to height level controller (1).

★ Finger-tighten Torx screw (9).

6. Install height level control (1) to the upper part of suspension (8).

7. Install plate (7), loop of webbing (5), and edge protection strip (6).

8. Install two hexagon nuts (4) to the thread of height level controller (1).

9. Connect right-angle plugs (13) and (14) to height level controller (1) at the marked point.

10. Install Bowden pull wires (3) and (19) to height level controller (1).

11. Install Bowden pull wire (19) and fix it with the cable tie at the marked points.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
12. Install right-angle plugs (13) and (14) and fix them with the cable tie at the marked points.

13. Install air input hoses (10) and (11) to the pneumatic spring. Refer to the Operator Seat (Suspension): Compressed-Air
Hoses installation procedure in this section.

14. Fix air input hoses (10) and (11) with five cable ties (12) at the marked points.

15. Install two buffers (16) to the loop of webbing (5).

16. Install stud (18) to the lower part of suspension (15).

17. Install two circlips (17) to stud (18); then remove them.

18. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

19. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

20. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

Adjustment

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

4. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

5. Loosen self-tapping screw (9) a half turn.

6. Adjust micro switch (3).

A. Adjust the clearance between cam switch (5) and cam disc (7) by turning the crosshead screw (8).
Specified clearance (A) = . . . . . . . . . . . . . . . . . . . . . . .0.5 mm (0.02 in)

B. Turn the crosshead screw (8) to the left; cam switch (5) is moving towards the cam disc (7).

C. Turn the crosshead screw (8) to the right; cam switch (5) is moving away from the cam disc (7).
★ When cam switch (5) seats on cam disc (7) under pressure, compressor (11) turns too early and runs during the
compression and expansion of the seat suspension.

7. Adjust the output level (2).

A. Adjust the clearance between valve lever (6) and cam disc (7) by turning crosshead screw (10).
★ Specified value: The valve lever (6) must seat on the cam disc without pressure (7).

B. Turn crosshead screw (10) to the left; valve lever (6) is moving towards cam disc (7). This increases the pressure on
valve tappets (4) at output valve (2) and the air escapes output valve (2) earlier.

C. Turn crosshead screw (10) to the right; valve lever (6) is moving away from cam disc (7). This decreases the pressure
on valve tappets (4) at output valve (2) and the air escapes output valve (2) later.

8. Tighten self-tapping screw (9) after the adjustment has been completed.

9. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

10. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

11. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Compressed-Air Hoses
★ Do not disconnect the hose more than one or two times. Check the hose for damage before connecting it.

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

5. Mark the points where compressed-air hose (11) is fastened with cable tie (12); remove cable tie (12).

6. Pull compressed-air hose (11) off pneumatic spring (9).

★ When pulling the hoses out, the retaining ring of quick coupling (13) must first be completely pressed back (for
example, using flat pliers) to avoid marks.

7. Pull compressed-air hose (11) off compressor (5) and remove it. Refer to the Operator Seat (Suspension): Compressor
removal procedure in this section.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
8. Pull the compressed-air hose with angle (8) off pneumatic spring (9) and then off air tank (10).
★ When pulling the hoses out, the retaining ring of quick coupling (13) must first be completely pressed back (for
example, using flat pliers) to avoid marks.

9. Mark the points where the compressed-air hose with angle (8) is fastened with cable ties (6), (7), and (12); remove cable
ties (6), (7), and (12).

10. Remove the air hose with angle (8).

11. Mark the points where air input hoses (3) and (4) are fastened with cable ties (2) and (6); remove cable ties (2) and (6).

12. Pull air input hoses (3) and (4) out of pneumatic spring (9).

13. Remove height level controller (1) with air input hoses (3) and (4).
★ To ensure tightness, air input hoses (3) and (4) cannot be removed from height level control (1).

Installation

★ Always replace a damaged hose with a new one. It is possible to cut the damaged part off (about 12 mm [0.50 in]) using
special tools (14) only once. After cutting off this piece, the blue marking should be (arrow) set back by the length of the
cutoff piece.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

1. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

2. Install height level controller (1) with air input hoses (3) and (4).
★ Cut air input hose (3) or (4) off at the leaky area and connect new air input hose (3) or (4) to an appropriate adapter.
Subsequently, cut the excess length off.

3. Install air input hoses (3) and (4) to pneumatic spring (9).

4. Fix air input hoses (3) and (4) with cable ties (2) and (6) at the marked points.

5. Install the compressed-air hose with angle (8) to pneumatic spring (9) and then off air tank (10).
★ To avoid kinking, always install the compressed-air hose with angle (8) first on pneumatic spring (9).
★ Apply pressure to insert the air hose with angle (8) into pneumatic spring (9) and air tank (10) up to the blue marking.

6. Fix the compressed air hose with angle (8) with cable ties (6), (7), and (12) at the marked points.
★ Do not fix cable tie (12) at the angle.

7. Install the compressed-air hose (11) to the compressor (5). Refer to the Operator Seat (Suspension): Compressor
installation procedure in this section.

8. Install compressed-air hose (11) to pneumatic spring (9).

9. Fix the compressed-air hose with cable tie (12) at the marked points.

10. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

11. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

12. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

Hydrostatic test

★ After the installation of a compressed-air hose, the hydraulic test of the suspension should be performed.
• Apply a 60 kg (132 lb) load to the suspension for 24 hours.
• The lowering within this time may not exceed 15 mm (0.59 in).
★ The compressed-air hoses are locked after they are connected.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Bowden Pull Wires and Handle (Height Adjustment)

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper
Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension):

Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension):

Bellows removal procedure in this section.

4. Mark the points where Bowden pull wire (1) is fastened with two
cable ties (3); remove cable ties (3).

5. Mark the points where Bowden pull wire (6) is fastened with two
cable ties (8); remove cable ties (8).

6. Take Bowden pull wire (1) off the height level controller and pull
it out of the holder for the Bowden pull wire. Refer to the Operator
Seat (Suspension): Height Level Controller removal procedure in
this section.)
★ To release the tension of Bowden pull wire (1), press the
handle for height adjustment (5) upwards.

7. Take Bowden pull wire (6) off the height level controller. Refer to
the Operator Seat (Suspension): Height Level Controller removal
procedure in this section.
★ To release the tension of Bowden pull wire (6), press the
handle for height adjustment (5) upwards.

8. Undo the three crosshead screws (7).

9. Take Bowden pull wires (1) and (6) off the holder for Bowden pull wire (4); pull the wires out of the upper part of
suspension (2).

10. Remove holder (4) for the Bowden pull wire.

11. Replace handle (5), if required.

A. Handle (5) and the holder for Bowden pull wire (4) are wedged into the two latching noses (arrow) at the lower part
of the holder for Bowden pull wire (4). Carefully separate the parts.

B. To remove the handle, use a screwdriver to bend open handle (5) between handle (5) and the holder for Bowden pull
wire (4) so that the two latching noses are released from handle (5).

C. Take handle (5) off the holder for Bowden pull wire (4).

WA500-6 50-375 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Installation

1. Install handle (5) to holder (4), if removed.

★ When handle (5) is deformed, replace it.

2. Install Bowden pull wires (1) and (6) to the holder for Bowden wire (4).
★ Adjust the new Bowden pull wire to the length of the old one (excess length of the wire).

3. Install holder (4) to the upper part of suspension (2) and tighten three crosshead screws (7).

4. Install Bowden pull wire (6) to the height level controller. Refer to the Operator Seat (Suspension): Height Level
Controller installation procedure in this section.

5. Install Bowden pull wire (1) to the height level controller. Refer to the Operator Seat (Suspension): Height Level
Controller installation procedure in this section.

6. Fix Bowden pull wire (6) with two cable ties (8) at the marked points.
★ Loosely fix the Bowden pull wire with the cable ties at the marked points and make sure it is not distorted.

7. Fix Bowden pull wire (1) with two cable ties (3) at the marked points.
★ Loosely fix the Bowden pull wire with the cable ties at the marked points and make sure it is not distorted.

8. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

9. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

10. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Checking and Adjusting

★ When checking and adjustment is performed during removal and installation, skip Steps 1 and 2 in the Checking
procedure.
Checking

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Operate the handle for height adjustment (2) several times in both directions and check the following:
• Bowden pull wires (1) and (3) for easy-running
• Bowden wire lever (10), valve lever (14), and valve tappets (13) at the output valve (12) for smoothness of running

4. Check the neutral position of the handle for seat height adjustment (2) and the tensile force of the retracting spring (11) on
height level valve (4):
• The retracting spring (11) must fix the handle for seat height adjustment (2) in the neutral position.
• The retracting spring (11) must tightly pull Bowden pull wires (1 and 3) and keep Bowden wire lever (10) in the
neutral position.

5. Check the clearance between Bowden wire lever (10) and the holder for Bowden wire end cap (9).
Specified value: . Distance (A) between 1 and 3.5 mm (0.039 – 0.14 in)
. . . . . . . . . (with the handle for height adjustment (2) in the up position)
★ When the specified value exceeds 3.5 mm (0.14 in), the suspension cannot be lifted above the middle position.

WA500-6 50-377 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Adjustment

1. Adjustment of the Bowden pull wire (3):

A. Loosen counternut (6) and adjust the clearance between Bowden wire lever (10) and the holder for Bowden wire end
cap (9) using locknut (5).
★ Turn the locknut (5) inwards; the Bowden pull wire gets longer.
★ Turn the locknut (5) outwards; the Bowden pull wire gets shorter.
Specified value: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . Clearance (A) between 1 and 3.5 mm (0.039 – 0.14 in)

B. Secure locknut (5) with counternut (6) and make sure not to distort Bowden pull wire (3).

C. Operate the handle for seat height adjustment (2) several times and check the specified value. Repeat the adjustment
if necessary.

2. Adjustment of Bowden pull wire (1):

A. Loosen counternut (7) and adjust the tension of Bowden pull wire (1) on height valve (4) using locknut (8).
★ Turn the locknut (8) inwards; the Bowden pull wire gets longer.
★ Turn the locknut (8) outwards; the Bowden pull wire gets shorter.
★ Specified value: Bowden wire (8) must be tightened, but not distorted, on the suspension device on height level
valve (4).

B. Secure locknut (8) with counternut (7) and make sure not to distort Bowden pull wire (1).

C. Operate the handle for seat height adjustment (2) several times and check the specified value. Repeat the adjustment
if necessary.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Pneumatic Spring

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Remove the two air input hoses, compressed-air hose, and air input hose with angle from the pneumatic spring (6). Refer
to the Operator Seat (Suspension): Compressed-Air Hoses removal procedure in this section.

5. Undo countersunk screw (3) from pneumatic spring (6) and remove it together with washer (4).

6. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

7. Turn the spring system by 180° and place it onto the upper part (1).

8. Undo countersunk screw (7) from pneumatic spring (6).

9. Slightly compress pneumatic spring (6) and remove it from swinging structure (5) and lower part of suspension (2).

WA500-6 50-379 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Installation

1. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

2. Turn the spring system by 180° and place it onto upper part (1).

3. Slightly compress pneumatic spring (6) and install pneumatic spring (6) to swinging structure (5) and lower part of
suspension (2).

4. Tighten countersunk screw (7) to pneumatic spring (6).

Countersunk screw (6): 6 N•m (53.10 lbf in)

5. Turn the spring system by 180° and place it onto upper part (1).

6. Put washer (4) to pneumatic spring (6) and tighten countersunk screw (3).

Countersunk screw (6): 6 N•m (53.10 lbf in)

7. Install the two air input hoses, compressed-air hose, and air input hose with angle to the pneumatic spring (6). Refer to the
Operator Seat (Suspension): Compressed-Air Hoses installation procedure in this section.

8. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

9. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

10. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Air Tank for Additional Air Supply

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

5. Remove the air hose with angle (4) from air tank (3). Refer to the Operator Seat (Suspension): Compressed-Air Hoses
removal procedure in this section.

6. Remove air tank (3) from bracket (2) and clamp (5).

7. Take clamp (5) off bracket (6) in a downward direction, if required.

★ To do this, use a screwdriver to press through the hole (arrow) in the bracket against the catchers (arrow) of clamp (5)
and pull clamp (5) out in a downward direction.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Installation

1. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

2. Install clamp (5) to bracket (6), if removed.

★ Replace the clamp with a new one, if required.

3. Install air tank (3) to bracket (2) and clamp (5).

4. Install the air hose with angle (4) to air tank (3). Refer to the Operator Seat (Suspension): Compressed-Air Hoses
installation procedure in this section.

5. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

6. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

7. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

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DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Cable Harness

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

5. Mark the points where the cable of machine power connector (3) is fastened with cable tie (8) on the upper part of
suspension (7); remove cable tie (8).

6. Mark places where the cable harness of connector plug (2) and the cable harness of machine power connector (3) are
fastened with cable ties (5); remove cable ties (5).

7. Unplug the electric connection (flat plug) of compressor cable (4) to the cable harness of connector plug (2) and the cable
harness of machine power connector (3).

8. Disconnect right-angle plug (6) from height level control unit (1).

WA500-6 50-383 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
Installation

1. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

2. Connect right-angle plug (6) to height level control unit (1).

3. Plug the electric connection (flat plug) of compressor cable (4) to the cable harness of connector plug (2) and the cable
harness of machine power connector (3).

4. Fix the cable harness of connector plug (2) and the cable harness of machine power connector (3) with cable ties (5) at the
marked points.
★ Run cable harnesses (2) and (3) and fix them with cable ties (5) so that they are neither squeezed nor otherwise
damaged.

5. Fix the cable of machine power connector (3) with cable tie (8) on the upper part of suspension (7) at the marked points.

6. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

7. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

8. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

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Suspension System (Upper Part)

Disassembly

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Take the Bowden pull wire and handle off the upper part of suspension (1). Refer to the Operator Seat (Suspension):
Bowden Pull Wires and Handle (Vertical Shock Absorber Adjustment) removal procedure in this section.
★ The Bowden pull wire does not need to be taken off the vertical shock absorber.

5. Remove the vertical shock absorber from the upper part of suspension (1). Refer to the Operator Seat (Suspension):
Vertical Shock Absorber removal procedure in this section.

6. Remove the height level controller from the upper part of suspension (1). Refer to the Operator Seat (Suspension): Height
Level Controller removal procedure in this section.
★ Air input hoses do not need to be taken off the pneumatic spring.

7. Remove Bowden pull wires and handle for height adjustment. Refer to the Operator Seat (Suspension): Bowden Pull
Wires and Handle (Height Adjustment) removal procedure in this section.

WA500-6 50-385 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

8. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

9. Bore out two rivet heads and drive out blind rivets (10); remove stops (9).

10. Push the upper part of suspension (1) forwards until the cutouts (arrow) on the left and right sides at guiding rails (2) are
located at the same height with front rollers (8) of swinging structure (7).

11. Remove the upper part of suspension (1) on the front side over rollers (8) and back rollers (6) of swinging structure (7).

Assembly

1. Move the suspension system to the highest position.

WARNING! Risk of crushing! Secure the suspension between the swinging structure and lower part of the
suspension system with suitable spacers.

2. Push the upper part of suspension (1) forwards until the cutouts (arrow) on the left and right sides at guiding rails (2) are
located at the same height with front rollers (8) of swinging structure (7).

3. Install the upper part of suspension (1) on back rollers (6) and front rollers (8) of swinging structure (7).
★ Apply acid-free multi-purpose lubricant to side surfaces (F) of two guiding rails (2) of rollers (6).

4. Install stops (9) and fix with two rivets (10).

5. Install Bowden pull wires and handle for height adjustment. Refer to the Operator Seat (Suspension): Bowden Pull Wires
and Handle (Height Adjustment) installation procedure in this section.

6. Install the height level controller to the upper part of suspension (1). Refer to the Operator Seat (Suspension): Height
Level Controller installation procedure in this section.

7. Install the vertical shock absorber to the upper part of suspension (1). Refer to the Operator Seat (Suspension): Vertical
Shock Absorber installation procedure in this section.

8. Install the Bowden pull wire and handle to the upper part of the suspension (1). Refer to the Operator Seat (Suspension):
Bowden Pull Wires and Handle (Vertical Shock Absorber Adjustment) installation procedure in this section.

9. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section.

10. Install the top cover. Refer to the Operator Seat (Suspension): Top Cover installation procedure in this section.

11. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

50-386 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Suspension System (Lower Part)

Disassembly

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Remove the compressor from the lower part of suspension (7). Refer to the Operator Seat (Suspension): Compressor
removal procedure in this section
★ Compressor cable and compressed-air hose do not need to be removed.
★ Protect the compressor against shocks (impacts) by fixing it on the swinging structure with adhesive tape.

5. Remove the webbing from the lower part of suspension (7). Refer to the Operator Seat (Suspension): Height Level
Controller removal procedure in this section.

6. Undo the countersunk screw from the pneumatic spring. Refer to the Operator Seat (Suspension): Pneumatic Spring
removal procedure in this section.

7. Remove the two cable ties for the vehicle power connector cable on the lower part of suspension (7). Refer to the
Operator Seat (Suspension): Cable Harness removal procedure in this section.

8. Unscrew the two hexagon nuts (11); remove washers (10) and countersunk screws (9).

WA500-6 50-387 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
9. Undo the two corrugated-head screws (5) and take the U-shaped profiles (6) off guiding rail (8).

10. Push the upper part of suspension (1) with swinging structure (3) backwards until the two fixed bearings (4) on swinging
structure (3) can be taken out through the cutouts (arrows) of guiding rails (8) on the upper part of suspension (1).

11. Lift the upper part of suspension (1) with swinging structure (3) out and pull it out together with the two rollers (2) from
guiding rails (8) by turning it sideways.

Assembly

1. Install the upper part of suspension (1) with swinging structure (3) together with the two rollers (2) to guiding rails (8).
★ Apply acid-free multi-purpose lubricant to the bearing surface at side (F) of the two guiding rails (8) of rollers (2).

2. Install the U-shaped profile (6) to guiding rail (8) and tighten the two corrugated-head screws (5).

3. Put the countersunk screws (9) and washers (10); tighten the two hexagon nuts (11).

4. Install the two cable ties for the machine power connector cable on the lower part of suspension (7). Refer to the Operator
Seat (Suspension): Cable Harness installation procedure in this section.

5. Tighten the countersunk screw to the pneumatic spring. Refer to the Operator Seat (Suspension): Pneumatic Spring
installation procedure in this section.

6. Install the webbing to the lower part of suspension (7). Refer to the Operator Seat (Suspension): Height Level Controller
installation procedure in this section.

7. Install the compressor to the lower part of suspension (7). Refer to the Operator Seat (Suspension): Compressor
installation procedure in this section

8. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section

9. Install the top cover. Refer to the Operator Seat (Suspension): Cover installation procedure in this section

10. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

50-388 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS

Swinging Structure

Removal

1. Remove the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

2. Remove the top cover. Refer to the Operator Seat (Suspension): Top Cover removal procedure in this section.

3. Take the bellows off. Refer to the Operator Seat (Suspension): Bellows removal procedure in this section.

4. Take the Bowden pull wire for vertical shock absorber adjustment off the vertical shock absorber. Refer to the Operator
Seat (Suspension): Bowden Pull Wires and Handle (Vertical Shock Absorber Adjustment) removal procedure in this
section.

5. Take the vertical shock absorber off the swinging structure. Refer to the Operator Seat (Suspension): Vertical Shock
Absorber removal procedure in this section.

6. Remove the compressor. Refer to the Operator Seat (Suspension): Compressor removal procedure in this section.

7. Take the webbing off the lower part of the suspension. Refer to the Operator Seat (Suspension): Height Level Controller
removal procedure in this section.

8. Remove the cable tie for the air input hoses of the height level control and pull the air input hoses off the pneumatic
spring. Refer to the Operator Seat (Suspension): Compressed-Air Hoses removal procedure in this section.

9. Take the Bowden pull wires for height level adjustment off the height level valve. Refer to the Operator Seat
(Suspension): Bowden Pull Wires and Handle (Height Adjustment) removal procedure in this section.

WA500-6 50-389 ➁
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
10. Remove the pneumatic spring. Refer to the Operator Seat (Suspension): Pneumatic Spring removal procedure in this
section.

11. Remove the air tank for additional air supply. Refer to the Operator Seat (Suspension): Air Tank for Additional Air Supply
removal procedure in this section.

12. Remove the cable harness. Refer to the Operator Seat (Suspension): Cable Harness removal procedure in this section.

13. Take the upper part of the suspension off the swinging structure. Refer to the Operator Seat (Suspension): Suspension
System (Upper Part) removal procedure in this section.

14. Take the lower part of the suspension off the swinging structure. Refer to the Operator Seat (Suspension): Suspension
System (Lower Part) removal procedure in this section.

15. Take four rollers (5), two rollers (6), two fixed bearings (9), and four felt rings (4) off the swinging structure (1).

16. Pull the tube piece (8) out of the fixed bearing (9).

17. Remove the two buffers (7) from the swinging structure (1).

18. Remove the edge protection strip (2) from the swinging structure (1).

Installation

1. Check: maximum clearance (A) or (B) between rollers (5) and guiding rails of the lower part of suspension (11) or upper
part of suspension (10) over the complete adjustment length.

2. Place the washer compensating for clearance (2) between roller (5 or 6) and axle of swinging structure (1), if necessary.
★ Clearance spacers (with thickness of 0.2 mm and 0.5 mm) are included in the wear parts set.

3. Install edge protection strip (2) to swinging structure (1).

4. Install the two buffers (7) to swinging structure (1).

5. Put tube piece (8) to fixed bearing (9).

6. Install four rollers (5), two rollers (6), two fixed bearings (9), and four felt rings (4) to swinging structure (1).

7. Install the lower part of the suspension to the swinging structure. Refer to the Operator Seat (Suspension): Suspension
System (Lower Part) installation procedure in this section.

8. Install the upper part of the suspension to the swinging structure. Refer to the Operator Seat (Suspension): Suspension
System (Upper Part) installation procedure in this section.

9. Install the cable harness. Refer to the Operator Seat (Suspension): Cable Harness installation procedure in this section.

10. Install the air tank for additional air supply. Refer to the Operator Seat (Suspension): Air Tank for Additional Air Supply
installation procedure in this section.

11. Install the pneumatic spring. Refer to the Operator Seat (Suspension): Pneumatic Spring installation procedure in this
section.

12. Install the Bowden pull wires for height level adjustment to the height level valve. Refer to the Operator Seat
(Suspension): Bowden Pull Wires and Handle (Height Adjustment) installation procedure in this section.

50-390 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY CAB AND ITS ATTACHMENTS
13. Install the cable tie for the air input hoses of the height level controller and pull the air input hoses to the pneumatic spring.
Refer to the Operator Seat (Suspension): Compressed-Air Hoses removal procedure in this section.

14. Install the webbing to the lower part of the suspension. Refer to the Operator Seat (Suspension): Height Level Controller
installation procedure in this section.

15. Install the compressor. Refer to the Operator Seat (Suspension): Compressor installation procedure in this section.

16. Install the vertical shock absorber to the swinging structure. Refer to the Operator Seat (Suspension): Vertical Shock
Absorber installation procedure in this section.

17. Install the Bowden pull wire for vertical shock absorber adjustment to the vertical shock absorber. Refer to the Operator
Seat (Suspension): Bowden Pull Wires and Handle (Vertical Shock Absorber Adjustment) installation procedure in this
section.

18. Install the bellows. Refer to the Operator Seat (Suspension): Bellows installation procedure in this section

19. Install the top cover. Refer to the Operator Seat (Suspension): Cover installation procedure in this section

20. Install the upper part of the seat. Refer to Operator Seat (Upper Seat) in this section.

WA500-6 50-391 ➁
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

Engine Controller

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove the right side panel.

2. Open the right side door.

3. Remove cover (1).

4. Disconnect wiring harness connectors E18 (2), (3) and E19 (4).
[*1]

5. Remove engine controller assembly (5).

Installation
★ Carry out installation in the reverse order of removal.

[*1]

★ When installing each heavy-duty wire connector, check that it is locked.

Connectors (2) and (3): 2.54 – 3.01 N•m (22.48 – 26.64 lbf in)

50-392 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM

Transmission Controller

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove the cover under the operator seat.

2. Disconnect wiring harness clamps (1) and (2).

3. Disconnect wiring harness connectors L04 (3), L03 (4), and

L02 (5). [*1]

4. Remove transmission controller assembly (6).

Installation
★ Carry out installation in the reverse order of removal.

[*1]

★ Before plugging each connector, check that its inside is free from dirt, dust, and water.
★ When installing each heavy-duty wire connector, check that it is locked. (When it is locked, it clicks.)

Connectors (3), (4) and (5): 2.54 – 3.01 Nm (22.48 – 26.64 lbf in)

WA500-6 50-393 ➁
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM

Work Equipment Controller

WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Removal

1. Remove the cover under the operator seat.

2. Disconnect wiring harness clamps (1) and (2).

3. Disconnect wiring harness connectors L05 (3), L06 (4), and

L07 (5). [*1]

4. Remove work equipment controller assembly (6).

Installation
★ Carry out installation in the reverse order of removal.

[*1]

★ Before connecting each connector, check that its inside is free from dirt, dust, and water.
★ When installing each heavy-duty wire connector, check that it is locked. (When it is locked, it clicks.)

Connectors (3), (4), and (5): 2.54 – 3.01 N•m ((22.48 – 26.64 lbf in)

50-394 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM

Air Conditioner Unit

Removal
WARNING! Stop the machine on level ground and set the lock bar to the frame to lock the front and rear
frames.

Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks
under the tires.

Disconnect the cable from the negative (-) battery terminal.

Precautions for Handling Refrigerant

WARNING! Collect refrigerant (R134a) beforehand.

★ Ask professional traders for collecting and filling the refrigerant (R134a).
★ Never release the refrigerant (R134a) to the atmosphere.

WARNING! If the refrigerant (R134a) gets in your eyes, it may cause blindness. You must wear protective
glasses when collecting or filling the refrigerant. Collecting and filling work must be conducted by a
qualified person.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant when
disconnecting the heater hoses and draining the coolant. Wait until the coolant has cooled and then
drain the coolant.

1. Remove covers (1) and (2).

2. Remove filter (3) and filter cover (4).

WA500-6 50-395 ➁
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
3. Unplug wiring harness connector (5).

4. Remove blower assembly (6).

5. Remove front windshield wiper (7).

6. Remove left side cover (8).

7. Remove door lock (9), ashtray (10), holder (11), and right side
cover (12).

8. Remove cover (13).

9. Unplug the cigarette lighter wiring harness connector.

50-396 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
10. Unplug the seven wiring harness connectors and remove monitor
assembly (14).

11. Unplug wiring harness connector C12 (15) and remove wiper
motor (16).

12. Disconnect wiper washer hose (17).

13. Remove ducts (18) and (19).

14. Remove four mounting bolts (20) and disconnect steering wheel
stand (21) from the bracket.

15. Disconnect two wiring harness clamps (22).

16. Remove bracket (23).

WA500-6 50-397 ➁
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
17. Remove covers (24) and (25).

18. Disconnect heater hose (26).

19. Unplug wiring harness connector (27).

20. Disconnect drain hose (28).

21. Disconnect air conditioner pipes (29) and (30) and clamps (31) and
(32). [*1]

22. Disconnect drain hose (33).

23. Unplug wiring harness connectors L17 (34), C50 (35), C49 (36),
and AL1 (37).

24. Remove the mounting bolts and disconnect fuse (38).

50-398 ➁ WA500-6
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
25. Remove air conditioner unit assembly (39). [*2]

Installation
★ Carry out installation in the reverse order of removal.

[*1]

• When installing the air conditioner circuit hoses, be careful that dirt, dust, water, etc. does not enter them.
• Before connecting each air conditioner hose, check that the
O-rings are fitted to its joints.
• Check that each O-ring is not damaged or deteriorated.

O-ring: ND-OIL8 or equivalent

Filling Air Conditioner Gas

★ Fill the air conditioner circuit with refrigerant (R134a).

[*2]

Air conditioner unit mounting bolt: 8 – 12 N•m (70.81 – 106.21 lbf in)

WA500-6 50-399 ➁
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM

MEMORANDUM

50-400 ➁ WA500-6
 90 OTHERS

CONNECTOR ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2
CONNECTOR ARRANGEMENT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
1 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
2 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
3 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
1 OF 7 (SECTION A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
1 OF 7 (SECTION B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
1 OF 7 (SECTION C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
2 OF 7 (SECTION A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
2 OF 7 (SECTION B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33
2 OF 7 (SECTION C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-35
3 OF 7 (SECTION A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
3 OF 7 (SECTION B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-39
3 OF 7 (SECTION C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-41
4 OF 7 (SECTION A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-43
4 OF 7 (SECTION B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45
5 OF 7 (SECTION A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47
5 OF 7 (SECTION B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-49
5 OF 7 (SECTION C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-51
6 OF 7 (SECTION A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-53
6 OF 7 (SECTION B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-55
6 OF 7 (SECTION C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-57
7 OF 7 (SECTION A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-59
7 OF 7 (SECTION B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-61
7 OF 7 (SECTION C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-63
HYDRAULIC DIAGRAMS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-65
POWER TRAIN CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-65
(WITH LOCKUP CLUTCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-67
BRAKE HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-69
(FORCED BRAKE COOLING SYSTEM ATTACHED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-71
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-73

WA500-6 90-1 1
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

CONNECTOR ARRANGEMENT DIAGRAM

12

INDEX

Connector Number Address of

Model Component name
No. of pins stereogram
1.PS DT2 2 1st ECMV solenoid AI-3
1.SW DT 2 1st ECMV fill switch AI-3
2.PS DT2 2 2nd ECMV solenoid AK-1
2.SW DT 2 2nd ECMV fill switch AL-2
3.PS DT2 2 3rd ECMV solenoid AM-5
3.SW DT 2 3rd ECMV fill switch AM-5
4.PS DT2 2 4th ECMV solenoid AL-2
4.SW DT 2 4th ECMV fill switch AM-3
AL1 DT2 6 Intermediate connector (Air conditioner unit) R-1
B01 DT2 2 Left brake oil pressure sensor N-4
B02 DT2 2 Lift arm EPC cut-off solenoid N-4
B03 DT2 2 Diode N-3
B04 DT2 2 Brake accumulator low pressure switch (Rear) L-2
B05 DT2 2 Brake accumulator low pressure switch (Front) K-3
B06 DT2 2 Rear emergency brake switch L-2
B07 DT2 2 Front emergency brake switch K-3
B09 KES0 2 Front windshield washer N-5
B10 Terminal 1 GND (Rear frame) K-5
B11 KES0 2 Rear windshield washer N-6
B12 DT2 2 Diode K-4
B13 DT2 2 Diode K-5
BL1 DT2(B) 12 Intermediate connector (Brake component box) N-5
BP DT-T 2 Bypass valve AE-4
C01 YAZAKI 9 AM/FM radio D-8
C02 M 2 Speaker (Right) F-9
C03 M 2 Speaker (Left) F-9
C04 M 2 Front working lamp (Right) C-7
C05 M 2 Front working lamp (Left) B-7
C07 KES1 2 Room lamp F-9
C08 M 1 Right door switch (Room lamp) C-8
C09 M 1 Left door switch (Room lamp) B-7
C10 YAZAKI 2 Cigarette lighter B-7

90-2 1 WA500-6
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

Connector Number Address of

Model Component name
No. of pins stereogram
C12 M 6 Front wiper motor A-6
C15 M 4 Rear wiper motor G-9
C17 SWP 6 Auto grease switch (If equipped) E-9
C18 DT 2 Warning lamp (If equipped) B-7
C18A M 1 Auto grease (If equipped) A-7
C19 SWP 6 Rear glass heater switch E-9
C22 DT 3 Rotary lamp (If equipped)
C25 X 4 Intermediate connector (Warning lamp, rotary lamp) C-8
C29 M 1 Glass heater (If equipped) D-8
C33 Terminal 1 Rear glass heater E-9
C35 Terminal 1 Rear glass heater G-9
C39 Terminal 1 Radio GND D-8
C40 Terminal 1 Cab GND E-9
C47 Terminal 1 Beacon GND (If equipped) C-7
C47 JAE IL-AG5 22 Manual air conditioner controller D-8
C48 JAE IL-AG5 14 Manual air conditioner controller D-8
C49 DT2(B) 12 Intermediate connector (Air conditioner) G-1
C50 DT2(Gr) 12 Intermediate connector (Air conditioner) G-1
C52 S 3 Multi-coupler switch E-9
C60 AMP 2 Daylight sensor I-3
C65 DT 3 Alarm buzzer (If equipped)
C91 M 1 Intermediate connector (Alarm buzzer) C-8
CAN1 DT2 3 CAN terminal resistance O-3
CHK0 X 1 Intermediate connector (KOMTRAX) Z-6
CHK1 X 1 Intermediate connector (KOMTRAX) Y-7
CL1 SWP 8 Intermediate connector (Floor – cab wiring harness) O-3
CL2 SWP 12 Intermediate connector (Floor – cab wiring harness) O-3
CL24 X 2 Intermediate connector (Multi-coupler solenoid) (If equipped) A-6
CL26 X 2 Auto grease (If equipped) A-6
CN1 DT 2 No. 1 injector AD-3
CN2 DT 2 No. 2 injector AD-4
CN3 DT 2 No. 3 injector AF-5
CN4 DT 2 No. 4 injector AF-5
CN5 DT 2 No. 5 injector AH-5
CN6 DT 2 No. 6 injector AH-5
COMBI M 3 Right front combination lamp A-6
COMBI M 3 Left front combination lamp F-1

WA500-6 90-3 1
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

Connector Number Address of

Model Component name
No. of pins stereogram
D01 YAZAKI 3 Diode X-3
D01 Terminal 1 Right battery relay L-7
D02 YAZAKI 3 Diode X-4
D02 Terminal 1 Left battery relay M-7
D03 YAZAKI 2 Diode X-4
D03 Terminal 1 Left battery relay L-8
D04 YAZAKI 2 Diode X-4
D04 Terminal 1 Right battery relay L-8
D11 Terminal 1 Disconnecting switch
DIODE1 DT2 2 Diode AI-5
E01 DT2 2 Starting motor AC-5
E03 Terminal 1 Alternator terminal R AF-7
E04 Terminal 1 Alternator terminal B AF-7
E05 Terminal 1 Alternator terminal E AF-7
E06 Terminal 1 Alternator GND AF-6
E08 Terminal 1 Starting motor AC-6
E11 DT2 2 Diode AE-5
E15 DT2 2 Dust indicator AD-9
E16 DT2 2 Air conditioner compressor AD-1
E17 DT2 2 Diode AE-5
E18 DRC26 50 Engine controller AH-2
E19 DTP 4 Engine controller AG-1
E21 DT2 3 CAN terminal resistance AH-2
E22 Terminal 1 GND (Engine unit) AD-2
E31 Terminal 1 Heater AD-3
E32 Terminal 1 Heater relay L-9
EGR DT-T 2 EGR valve solenoid AE-5
ENG DRC 60 Engine controller AG-1
ER1 DT2(B) 12 Intermediate connector (Engine) J-3,AE-5
ER2 DT2 12 Intermediate connector (Engine controller) J-4,AD-5
ER3 L 2 Intermediate connector (Engine controller) J-5,AD-5
F.PS DT2 2 F (Forward) ECMV solenoid AM-4
F.SW DT1 2 F (forward) ECMV fill switch AM-4
F01 DT2 6 Intermediate connector (Right combination lamp, headlamp) A-5
F02 DT2 6 Intermediate connector (Left combination lamp, headlamp) A-3
F03 AMP 090 2 Horn Lo A-4
F05 AMP 090 2 Horn Hi A-5

90-4 1 WA500-6
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

Connector Number Address of

Model Component name
No. of pins stereogram
F07 DT2 2 Lift arm raise EPC solenoid B-2
F08 DT2 2 Lift arm lower EPC solenoid C-1
F09 DT2 2 Bucket tilt EPC solenoid C-1
F10 DT2 2 Bucket dump EPC solenoid B-1
F11 DT2 3 Bucket level positioner proximity switch A-4
F12 DT2 3 Bucket tilt sensor proximity switch A-3
F13 DT2 3 Lift arm angle sensor E-1
F14 DT2 3 Lift arm bottom pressure sensor (Load meter specification) D-1
F15 DT2 3 Lift arm rod pressure sensor (Load meter specification) D-1
F16 DT2 3 Loader pump pressure sensor B-1
F20 [q 1 Ground (Front frame) A-3
F21 DT2 4 3-spool valve (Attachment) EXT EPC solenoid (If equipped)
F22 DT2 2 3-spool valve (Attachment) RET EPC solenoid (If equipped)
F24 DT2 2 E.C.C.S. solenoid A-2
F31 DT-T 2 Multi-coupler extension solenoid (If equipped)
F32 DT-T 2 Diode (If equipped)
F33 DT-T 2 Multi-coupler retraction solenoid (If equipped)
F34 DT-T 2 Diode (If equipped)
FL1 DRC16 40 Intermediate connector (Floor – front frame) X-3
FL4 DT2 4 Intermediate connector (Attachment EPC solenoid)
G SUMITOMO 3 Bkup speed sensor AD-1
G01 DT2 6 Right rear combination lamp H-9
G02 DT2 6 Left rear combination lamp J-7
G03 DT2 2 Right rear working lamp G-9
G04 DT2 2 Left rear working lamp J-8
G06 DT2 2 Backup buzzer H-9
G09 DT2 2 Fan reverse solenoid H-9
GR1 DT2(Gr) 12 Intermediate connector (Radiator guard wiring harness) J-6
HEAD DT2 3 Right headlamp A-5
HEAD DT2 3 Left headlamp F-1
J1939 DT 3 CAN connector AG-6
JB1 DT2(B) 6 Junction connector K-4
JB2 DT2 6 Junction connector L-5
JB3 DT2 6 Junction connector N-3
JB4 DT2 6 Junction connector M-2
JE1 — 6 Junction connector AE-5
JE2 — 6 Junction connector AE-5

WA500-6 90-5 1
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

Connector Number Address of

Model Component name
No. of pins stereogram
JF1 DT2 6 Junction connector D-1
JF2 DT2(B) 6 Junction connector E-1
JF3 DT2(B) 6 Junction connector E-1
JF4 DT2 6 Junction connector A-4
JG1 DT2(B) 12 Junction connector J-7
JG2 DT2 6 Junction connector J-7
JG3 DT2 8 Junction connector J-8
JL1 DT2(Gr) 8 Intermediate connector (Joystick steering) AB-2
JL2 DTM 12 Joystick lever switch AB-3
JL3 DT2 4 Intermediate connector (Joystick EPC solenoid) W-2
JM01 — 6 Junction connector (Engine) AH-3
JM02 — 6 Junction connector (Engine) AH-2
JM03 — 4 Junction connector (Engine) AH-2
JM04 — 4 Junction connector (Engine) AG-1
JM05 — 3 Junction connector (Engine) AH-3
JM06 — 3 Junction connector (Engine) AH-3
JM07 — 4 Junction connector (Engine) AG-6
JM08 — 6 Junction connector (Engine) AG-6
JR1 — 6 Junction connector N-7
JR2 — 6 Junction connector M-7
JS1 SWP 6 Joystick ON/OFF switch (Joystick steering specification) AA-4
JS2 SWP 6 Steering speed mode switch (Joystick steering specification) Z-4
JS3 DT2 4 Joystick lever potentiometer (Joystick steering specification) Y-4
JS4 DT2 2 Joystick neutral lock switch (Joystick steering specification) AA-2
JS5 DT2 2 Joystick EPC solenoid (Joystick steering specification) Q-1
JS6 DT2 2 Joystick EPC solenoid (Joystick steering specification) Q-1
JT1 DT2(B) 8 Junction connector AM-5
JT2 DT2 6 Junction connector AI-6
JT3 DT2 6 Junction connector AN-7
KOM DT2A 12 Intermediate connector (KOMTRAX) Y-7
L01 Terminal 1 GND (Floor frame) X-4
L02 DRC26 24 Transmission controller W-7
L03 DRC26 40 Transmission controller X-7
L04 DRC26 40 Transmission controller X-7
L05 DRC26 24 Work equipment controller V-8
L06 DRC26 40 Work equipment controller W-8
L07 DRC26 40 Work equipment controller W-7

90-6 1 WA500-6
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

Connector Number Address of

Model Component name
No. of pins stereogram
L08 DT2(Gr) 12 Intermediate connector (VHMS wiring harness) X-5
L10 M 6 Intermediate connector (Printer wiring harness) W-8
L11 DT2 2 Pneumatic suspension seat W-7
L14 DT2 2 Spare O-2
L15 DT2 8 Accelerator pedal O-2
L16 DT2 2 Stop lamp switch U-1
L17 M 4 DC24V/DC12V converter V-8
L19 KES1 4 Flasher unit X-4
L20 M 2 Caution buzzer X-6
L21 KES1 6 Interval wiper timer X-5
L22 S 10 Front/Rear wiper switch R-1
L25 X 1 Optional connector X-5
L26 DT1 1 Optional connector U-8
L26 DT2(B) 8 Intermediate connector (3rd EPC)
L27 SWP 6 Spare (Wiper)
L31 Terminal 1 Emergency parking release switch X-6
L32 Terminal 1 Emergency parking release switch X-6
L34 Terminal 1 Emergency parking release switch X-6
L35 Terminal 1 Emergency parking release switch X-6
L36 YAZAKI 2 12V DC outlet V-8
L45 D-sub 25 Printer (If equipped)
L46 HOSHIDEN 4 Printer (If equipped)
L51 AMP 20 Machine monitor P-1
L52 AMP 18 Machine monitor P-2
L53 AMP 12 Machine monitor O-2
L54 AMP 18 Machine monitor O-4
L55 AMP 12 Machine monitor O-5
L56 AMP 12 Machine monitor P-2
L57 AMP 14 Machine monitor O-5
L58 SWP 6 Parking brake switch O-5
L59 SWP 6 E.C.S.S. switch S-1
L61 SWP 6 Light switch/Dimmer switch Q-1
L62 SWP 6 Turn and hazard switch P-6
L63 SWP 14 Gearshift switch Q-1
L64 DT2 2 Steering wheel horn switch O-6
L65 SWP 6 Character display item selector switch S-1
L66 SWP 6 Character display mode selector switch S-1

WA500-6 90-7 1
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

Connector Number Address of

Model Component name
No. of pins stereogram
L69 SWP 6 Load meter mode switch (If equipped) T-1
L70 SWP 6 Load meter display selector switch (If equipped) T-1
L72 SWP 6 Beacon lamp switch (If equipped) O-5
L73 SWP 6 Left brake pedal switch R-1
L80 DRC 40 KOMTRAX Z-6
L101 SHINAGAWA 5 Relay No. 1 Backup lamp AB-7
L102 SHINAGAWA 6 Relay No. 2 Stop lamp AA-6
L103 SHINAGAWA 5 Relay No. 3 Neutral safety AB-7
L104 SHINAGAWA 5 Relay No. 4 Lever AA-6
L105 SHINAGAWA 5 Relay No. 5 Parking brake safety AB-8
L106 SHINAGAWA 5 Relay No. 6 Preheating AA-6
L107 SHINAGAWA 5 Relay No. 7 Dust indicator AA-8
L108 SHINAGAWA 6 Relay No. 8 Horn Z-6
L109 SHINAGAWA 6 Relay No. 9 Front working lamp AA-8
L110 SHINAGAWA 6 Relay No. 10 Rear working lamp Y-6
L111 SHINAGAWA 5 Relay No. 11 Rear glass heater AA-8
L113 SHINAGAWA 5 Relay No. 13 Hazard AA-8
L114 SHINAGAWA 6 Relay No. 14 Fan motor Y-7
L115 SHINAGAWA 5 Relay No. 15 Headlamp Z-9
L116 SHINAGAWA 5 Relay No. 16 Coolant level Y-8
L117 SHINAGAWA 5 Relay No. 17 Engine control cut 1 Z-9
L118 SHINAGAWA 5 Relay No. 18 Joystick cut-off Y-8
L119 SHINAGAWA 6 Relay No. 17 Engine control cut 2 Z-9
L120 SHINAGAWA 5 KOMTRAX engine cut relay Y-8
L141 SHINAGAWA 5 Printer power supply relay (If equipped)
L142 DT2 2 Diode (If equipped)
L143 DT2 2 Diode (If equipped)
L144 DT2 2 Diode (If equipped)
L145 DT2 2 Diode (If equipped)
LC.PS DT2 2 Torque converter lockup ECMV solenoid AJ-2
LR1 DTHD4 1 Intermediate connector (Slow blow fuse) W-3
LR2 DT 2 Intermediate connector (Multi-coupler solenoid) (If equipped)
LR2 L 2 Intermediate connector (Slow blow fuse) V-2
LR3 L 2 Intermediate connector (Slow blow fuse) V-2
LR4 L 2 Intermediate connector (Rear frame GND) X-3
LR5 DRC12 70 Intermediate connector (Floor – rear frame) W-3
LR6 L 2 Intermediate connector (Engine controller) W-2

90-8 1 WA500-6
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

Connector Number Address of

Model Component name
No. of pins stereogram
LS1 DT2(B) 12 Intermediate connector (Floor – right console) U-1
LS2 DT2(Gr) 12 Intermediate connector (Floor – right console) U-2
LS3 DT2(Br) 12 Intermediate connector (Floor – right console) V-2
LS4 DT2(G) 12 Intermediate connector (Floor – right console) V-2
LS8 DT2 4 Intermediate connector (3-spool valve EPC lever)
LT1 HD30 31 Intermediate connector (Floor – transmission) AI-6
NE FRAMATONE 3 Ne speed sensor AH-2
PAMB FRAMATONE 3 Ambient pressure sensor AH-2
PB.PS DT2 2 Parking brake solenoid AN-6
PB.SW DT2 2 Parking brake indicator switch AJ-2
PCV1 SUMITOMO 2 Supply pump AD-2
PCV2 SUMITOMO 2 Supply pump AD-2
PEVA FRAMATONE 3 EGR valve inlet pressure sensor AD-3
PFUEL AMP 3 Common rail pressure sensor AG-1
PIM SUMITOMO 4 Charge pressure (Boost pressure) sensor AH-4
POIL SUMITOMO 3 Engine oil pressure sensor AG-1
R.PS DT2 2 R (Reverse) ECMV solenoid AM-3
R.SW DT 2 R (Reverse) ECMV fill switch AM-4
R01 Terminal 1 Circuit breaker SBF1 L-9
R02 Terminal 1 Circuit breaker SBF1 L-9
R03 Terminal 1 Circuit breaker SBF2 N-9
R04 Terminal 1 Circuit breaker SBF2 N-9
R05 Terminal 1 Circuit breaker SBF2 N-8
R06 Terminal 1 Circuit breaker SBF3 N-8
R07 Terminal 1 Slow blow fuse SBF3
R08 Terminal 1 Slow blow fuse SBF2
R09 Terminal 1 GND (Rear frame) J-6
R10 Terminal 1 GND (Rear frame) I-8
R11 Terminal 1 Disconnecting switch
R11 DT2 2 Parking brake emergency release solenoid H-2
R12 X 2 Transmission oil filter clogging sensor H-2
R13 DT2 2 Coolant level sensor H-2
R14 Terminal 1 Heater relay L-8
R15 Terminal 1 Heater relay L-9
R16 DT2 2 Fuel level sensor J-4
R17 DT2 12 Rear brake oil temperature sensor J-3
R18 DT2 2 Battery electrolyte level sensor J-6

WA500-6 90-9 1
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

Connector Number Address of

Model Component name
No. of pins stereogram
R38 DT2 6 Auto grease controller (If equipped)
R87 DT 2 Intermediate connector (Front frame GND)
RES DT 2 Resistor AH-3
REV OUT1 DT2 2 Speed sensor 1 AK-8
REV OUT2 DT2 2 Speed sensor 2 AI-4
RG1 DT2 6 Intermediate connector (Auto grease (If equipped)) G-2
RS1 DT2 2 Left side working lamp (If equipped) I-3
RS2 DT2 2 Right side working lamp (If equipped) I-3
RT1 DT2(Gr) 12 Intermediate connector (Rear frame – radiator guard) AI-4
S01 DT2 2 Lift arm neutral lock switch P-6
S02 DT2 4 Lift arm and bucket EPC lever Q-8
S03 DT2 4 Lift arm and bucket EPC lever Q-8
S04 DT2 2 Lift arm and bucket EPC lever Q-8
S05 DT2 2 Lift arm and bucket EPC lever Q-9
S06 DT2 2 Lift arm and bucket EPC lever P-7
S07 DT2 4 Lift arm kick-down switch and hold switch Q-8
S08 DT2 4 Bucket control lever (Load meter specification) Q-8
S09 DT2 4 Right gearshift switch (Steering wheel specification (If equipped)) Q-7
S10 SWP 6 Transmission cut-off ON/OFF switch R-7
S11 SWP 6 RPM set ON/OFF switch S-8
S12 SWP 6 RPM set idle up/down selector switch S-8
S13 SWP 6 Lift arm position set switch R-7
S14 SWP 6 Bucket position set switch R-8
S15 SWP 6 Hydraulic fan reverse switch S-8
S16 DT2 4 Auto-shift mode switch Q-7
S17 SWP 6 Engine power mode selector switch Q-7
S18 SWP 6 Torque converter lockup switch Q-7
S19 SWP 6 Transmission cut-off set switch R-7
S20 SWP 6 Semi auto-digging selector switch S-8
Right gearshift ON/OFF switch (Steering wheel specification
S21 SWP 6 R-8
(If equipped))
S25 DT2 4 3-spool valve (Attachment) EPC lever (If equipped)
S67 SWP 6 Front working lamp switch O-4
S68 SWP 6 Rear working lamp switch O-4
SBP DT 4 Bypass valve AE-5
SEGR DT 4 EGR valve lift sensor AF-5
T01 DT2 2 Pump EPC solenoid AN-7

90-10 1 WA500-6
OTHERS CONNECTOR ARRANGEMENT DIAGRAM

Connector Number Address of

Model Component name
No. of pins stereogram
T02 DT2 2 Fan pump EPC solenoid AL-9
T03 DT2 2 Hydraulic oil temperature sensor AI-7
T04 DT2 2 Emergency steering drive switch AJ-7
T05 DT2 2 Torque converter oil temperature sensor AK-8
TFUEL PACKARD 2 Fuel temperature sensor AH-4
TGN Terminal 1 Transmission body GND AN-6
TIM PACKARD 2 Charge temperature (Boost temperature) sensor AH-4
TM.T DT2(B) 2 Transmission oil temperature sensor AI-5
TWTR PACKARD 2 Coolant temperature sensor AC-7

WA500-6 90-11 1
OTHERS CONNECTOR ARRANGEMENT DIAGRAM
12

MEMORANDUM

90-12 1 WA500-6
OTHERS CONNECTOR ARRANGEMENT DIAGRAMS

CONNECTOR ARRANGEMENT DIAGRAMS

1 OF 3

WA500-6 90-13 1
OTHERS CONNECTOR ARRANGEMENT DIAGRAMS

90-14 1 WA500-6
OTHERS CONNECTOR ARRANGEMENT DIAGRAMS

CONNECTOR ARRANGEMENT DIAGRAMS

2 OF 3

WA500-6 90-15 1
OTHERS CONNECTOR ARRANGEMENT DIAGRAMS

90-16 1 WA500-6
OTHERS CONNECTOR ARRANGEMENT DIAGRAMS

CONNECTOR ARRANGEMENT DIAGRAMS

3 OF 3

WA500-6 90-17 1
OTHERS CONNECTOR ARRANGEMENT DIAGRAMS

90-18 1 WA500-6
OTHERS AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM

AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM

SECTION A

WA500-6 90-19 1
OTHERS AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM

90-20 1 WA500-6
OTHERS AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM

AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM

SECTION B

WA500-6 90-21 1
OTHERS AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM

90-22 1 WA500-6
OTHERS AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM

AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM

SECTION C

WA500-6 90-23 1
OTHERS AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM

90-24 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

1 OF 7 (SECTION A)

WA500-6 90-25 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-26 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

1 OF 7 (SECTION B)

WA500-6 90-27 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-28 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

1 OF 7 (SECTION C)

WA500-6 90-29 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-30 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

2 OF 7 (SECTION A)

WA500-6 90-31 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-32 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

2 OF 7 (SECTION B)

WA500-6 90-33 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-34 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

2 OF 7 (SECTION C)

WA500-6 90-35 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-36 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

3 OF 7 (SECTION A)

WA500-6 90-37 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-38 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

3 OF 7 (SECTION B)

WA500-6 90-39 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-40 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

3 OF 7 (SECTION C)

WA500-6 90-41 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-42 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

4 OF 7 (SECTION A)

WA500-6 90-43 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-44 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

4 OF 7 (SECTION B)

WA500-6 90-45 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-46 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

5 OF 7 (SECTION A)

WA500-6 90-47 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-48 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

5 OF 7 (SECTION B)

WA500-6 90-49 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-50 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

5 OF 7 (SECTION C)

WA500-6 90-51 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-52 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

6 OF 7 (SECTION A)

WA500-6 90-53 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-54 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

6 OF 7 (SECTION B)

WA500-6 90-55 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-56 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

6 OF 7 (SECTION C)

WA500-6 90-57 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-58 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

7 OF 7 (SECTION A)

WA500-6 90-59 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-60 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

7 OF 7 (SECTION B)

WA500-6 90-61 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-62 1 WA500-6
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

7 OF 7 (SECTION C)

WA500-6 90-63 1
OTHERS ELECTRICAL CIRCUIT DIAGRAM

90-64 1 WA500-6
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS

HYDRAULIC DIAGRAMS AND DRAWINGS

POWER TRAIN CIRCUIT DIAGRAM

WA500-6 90-65 1
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS
12

90-66 1 WA500-6
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS

(WITH LOCKUP CLUTCH)

WA500-6 90-67 1
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS
12

90-68 1 WA500-6
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS
12
BRAKE HYDRAULIC CIRCUIT DIAGRAM

WA500-6 90-69 1
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS
12

90-70 1 WA500-6
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS
12
(FORCED BRAKE COOLING SYSTEM ATTACHED)

WA500-6 90-71 1
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS
12

90-72 1 WA500-6
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS
12
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

WA500-6 90-73 1
OTHERS HYDRAULIC DIAGRAMS AND DRAWINGS
12

90-74 1 WA500-6