Esque Ma

WENBM00171
BACKHOE LOADER
WB93R-8
SERIAL NUMBERS WB93R-8 F80004 and up
WB93R-8
BACKHOE LOADER
WB93R-8
Machine model Serial number

WB93R-8 F80004 and up
00 INDEX AND FOREWORD 0 -1
WB93R-8 00-1
00 INDEX AND FOREWORD
TABLE OF CONTENTS
TABLE OF CONTENTS 0 -2
TABLE OF CONTENTS .............................................................................................................................. 2
FOREWORD, SAFETY AND GENERAL INFORMATION.......................................................................... 9
IMPORTANT SAFETY NOTICE .............................................................................................................. 9
FIRE PREVENTION .............................................................................................................................. 14
DISPOSE OF WASTE MATERIALS ...................................................................................................... 15
HOW TO READ THE SHOP MANUAL .................................................................................................. 16
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.......................................................... 18
HANDLING EQUIPMENT OF FUEL SYSTEM DEVICES ..................................................................... 20
HANDLING OF INTAKE SYSTEM PARTS............................................................................................ 21
HANDLING OF HYDRAULIC EQUIPMENT .......................................................................................... 22
METHOD OF DISCONNECTING AND CONNECTING OF PUSH-PULL TYPE COUPLER................. 24
HANDLING OF ELECTRICAL EQUIPMENT ......................................................................................... 27
HOW TO READ ELECTRIC WIRE CODE............................................................................................. 35
PRECAUTIONS WHEN PERFORMING OPERATION ......................................................................... 38
PRACTICAL USE OF KOMTRAX.......................................................................................................... 43
STANDARD TIGHTENING TORQUE TABLE ....................................................................................... 44
ABBREVIATION .................................................................................................................................... 50
CONVERSION TABLE .......................................................................................................................... 57
01 SPECIFICATION
CONTENTS ................................................................................................................................................ 2
SPECIFICATIONS ...................................................................................................................................... 3
OVERALL DIMENSIONS......................................................................................................................... 3
WORKING RANGE DRAWINGS ............................................................................................................. 4
SPECIFICATIONS ................................................................................................................................... 6
WEIGHT TABLE .................................................................................................................................... 11
TABLE OF FUEL, COOLANT, AND LUBRICANTS............................................................................... 13
10 STRUCTURE AND FUNCTION

CONTENTS ................................................................................................................................................ 2
ABBREVIATION LIST ................................................................................................................................. 3
UREA SCR SYSTEM................................................................................................................................ 10
LAYOUT DRAWING OF UREA SCR SYSTEM ..................................................................................... 10
INDUCEMENT STRATEGY................................................................................................................... 17
COMPONENT PARTS OF UREA SCR SYSTEM ................................................................................. 24
DEF TANK ............................................................................................................................................. 28
DEF PUMP ............................................................................................................................................ 30
DEF INJECTOR ..................................................................................................................................... 31
DEF HOSE............................................................................................................................................. 32
DEF TANK HEATING VALVE................................................................................................................ 33
POWER TRAIN......................................................................................................................................... 34
00-2 WB93R-8
TABLE OF CONTENTS
POWER TRAIN DESCRIPTION ............................................................................................................ 34

UNDERCARRIAGE AND FRAME ............................................................................................................ 37
4WD TRANSMISION ............................................................................................................................. 37
FRONT AXLE ........................................................................................................................................ 47
REAR AXLE........................................................................................................................................... 51
HYDRAULIC SYSTEM ............................................................................................................................. 56
LAYOUT DRAWING OF HYDRAULIC SYSTEM................................................................................... 56
HYDRAULIC TANK ............................................................................................................................... 58
HYDRAULIC PUMP............................................................................................................................... 59
CONTROL VALVE - 9-spool loader and backhoe valves ...................................................................... 73
CONTROL VALVE - 11-spool loader and backhoe valves .................................................................... 84
CLSS ..................................................................................................................................................... 95
WORK EQUIPMENT SYSTEM............................................................................................................... 115
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM.................................................................... 115
LOADER WORK EQUIPMENT PPC VALVE....................................................................................... 118
OUTRIGGER PPC VALVE .................................................................................................................. 131
STEERING UNIT ................................................................................................................................. 136
BRAKE PUMP ..................................................................................................................................... 137
SOLENOID VALVE.............................................................................................................................. 138
ACCUMULATOR ................................................................................................................................. 140
HOLDING VALVE ................................................................................................................................ 141
WORK EQUIPMENT .............................................................................................................................. 146
LOADER WORK EQUIPMENT............................................................................................................ 146
BACKHOE WORK EQUIPMENT......................................................................................................... 147
20 STANDARD VALUE TABLES

CONTENTS ................................................................................................................................................ 2
ABBREVIATION LIST................................................................................................................................. 3
STANDARD SERVICE VALUE TABLE .................................................................................................... 10
STANDARD VALUE TABLE FOR ENGINE........................................................................................... 10
STANDARD VALUE TABLE FOR MACHINE........................................................................................ 15
30 TESTING AND ADJUSTING

CONTENTS ................................................................................................................................................ 2
ENGINE AND COOLING SYSTEM .......................................................................................................... 11
TEST ENGINE SPEED.......................................................................................................................... 11
TEST EXHAUST GAS COLOR ............................................................................................................. 14
CHECKING LEAKAGES IN THE STEERING CYLINDER .................................................................... 16
TESTING STEERING CIRCUIT OIL PRESSURE................................................................................. 17
TESTING THE BRAKING SYSTEM PRESSURE ................................................................................. 18
TESTING THE BRAKE SYSTEM LEAKAGE ........................................................................................ 20
WB93R-8 00-3
TABLE OF CONTENTS
BLEEDING AIR FROM THE BRAKE LINES ......................................................................................... 21

METHOD FOR TESTING BRAKE PISTON STROKE ........................................................................... 22
METHOD FOR TESTING THE BRAKE PUMP BALANCING VALVE ................................................... 23
METHOD FOR TESTING THE BRAKE PEDAL STROKE .................................................................... 25
METHOD FOR ADJUSTING PEDAL BRAKING POSITION AND ALIGNMENT................................... 26
ADJUSTING TOE-IN-STEERING ANGLE WITH FRONT AXLE REMOVED FROM MACHINE........... 33
ADJUSTING TOE-IN-STEERING ANGLE WITH FRONT AXLE WITHOUT REMOVE THE AXLE FROM
MACHINE .............................................................................................................................................. 36
TESTING AND ADJUSTING THE PARKING BRAKE SYSTEM ........................................................... 40
CHECKING THE DISTANCE BETWEEN THE BRAKE PADS AND DISC............................................ 42
HYDRAULIC SYSTEM.............................................................................................................................. 44
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT ............................................... 44
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS.................................. 45
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT CIRCUITS............................. 47
TESTING OIL PRESSURE OF CONTROL CIRCUIT............................................................................ 53
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL OIL PRESSURE.................................. 55
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT .............................. 59
TESTING OUTLET PRESSURE OF SOLENOID VALVE ..................................................................... 61
TESTING PPC VALVE OUTLET PRESSURE ...................................................................................... 63
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVES ................................................................ 65
TESTING TRANSMISSION OIL PRESSURE CIRCUIT ........................................................................ 66
ISOLATING THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT............................. 68
BLEEDING AIR FROM HYDRAULIC CIRCUIT ..................................................................................... 71
CHECK OF OIL LEVEL AND OPERATION........................................................................................... 72
ELECTRICAL SYSTEM ............................................................................................................................ 74
SET AND ADJUST EACH EQUIPMENT ............................................................................................... 74
SET AND OPERATE MACHINE MONITOR.......................................................................................... 75
METHOD FOR STARTING UP KOMTRAX TERMINAL...................................................................... 102
ADJUST FRONT PANEL SETTINGS .................................................................................................. 110
HANDLING BATTERY DISCONNECT SWITCH ................................................................................. 112
TESTING DIODES............................................................................................................................... 113
WORK EQUIPMENT............................................................................................................................... 115
OUTRIGGER SENSOR AND SAFETY SYSTEM................................................................................ 115
RETURN TO DIG SENSOR ADJUSTMENT ....................................................................................... 118
TELESCOPIC ARM GUIDE SLACK ADJUSTMENT ........................................................................... 119
40 TROUBLESHOOTING
CONTENTS ................................................................................................................................................ 2
ABBREVIATION LIST ............................................................................................................................... 12
RELATED INFORMATION ON TROUBLESHOOTING............................................................................ 19
GENERAL TROUBLESHOOTING POINTS .......................................................................................... 19
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM ................................................................ 20
00-4 WB93R-8
TABLE OF CONTENTS
CHECKS BEFORE TROUBLESHOOTING .............................................................................................. 21

INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ............................................................... 23
WALK-AROUND CHECK ...................................................................................................................... 23
TESTING IN ACCORDANCE WITH TESTING PROCEDURE ................................................................ 25
CHECK OF FUEL LEVEL AND TYPE ................................................................................................... 25
METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDIMENT................ 26
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................ 28
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE ......................................................... 30
METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT ....................................................................... 31
METHOD FOR CHECKING DEF LEVEL AND TYPE ........................................................................... 32
METHOD FOR ADDING DEF................................................................................................................ 33
METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL ...................................... 36
METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT.................................................. 38
METHOD FOR CHECKING AIR CLEANER.......................................................................................... 39
METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT........................................................... 40
METHOD FOR CHANGING AIR CLEANER ELEMENT ....................................................................... 43
CHECK AND REPLACE VACUATOR VALVE ...................................................................................... 44
METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL .................................... 44
METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER45
BLEED AIR FROM HYDRAULIC SYSTEM ........................................................................................... 47
METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT ..................................................... 48
METHOD FOR CHECKING THE OIL LEVELS IN THE TRANSMISSION ............................................ 50
METHOD FOR CHECKING THE FRONT AXLE OIL LEVEL ................................................................ 51
METHOD FOR CHECKING THE REAR AXLE OIL LEVEL .................................................................. 52
FAILURE CODES TABLE......................................................................................................................... 52
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) ........................................................ 71
TROUBLESHOOTING OF ENGINE FAILURE...................................................................................... 71
50 DISASSEMBLY AND ASSEMBLY

CONTENTS ................................................................................................................................................ 2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ......................................................... 11
HOW TO READ THIS MANUAL ........................................................................................................... 11
COATING MATERIALS LIST.................................................................................................................... 13
Sketches of special tools ....................................................................................................................... 17
REMOVE AND INSTALL RADIATOR ASSEMBLY ............................................................................... 19
REMOVAL AND INSTALL OF FAN CLUTCH ASSEMBLY ................................................................... 25
REMOVE AND INSTALL ENGINE ........................................................................................................ 30
REMOVE AND INSTALL FUEL COOLER ASSEMBLY ........................................................................ 40
REMOVE AND INSTALL EXHAUST PIPE ............................................................................................ 41
REMOVAL AND INSTALL BELLOWS PIPE ASSEMBLY ..................................................................... 42
WB93R-8 00-5
TABLE OF CONTENTS
REMOVAL AND INSTALL KDOC ASSEMBLY ..................................................................................... 46

REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY ................................................ 52
REMOVE AND INSTALL DEF TANK SENSOR .................................................................................... 59
REMOVE AND INSTALL DEF TANK STRAINER ................................................................................. 61
REMOVE AND INSTALL DEF INJECTOR ............................................................................................ 62
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .......................................................................... 69
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY.......................................... 70
REMOVE AND INSTALL AIR CONDITIONER BELT ............................................................................ 72
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ........................................................... 74
REMOVE AND INSTALL ENGINE HOOD............................................................................................. 77
REMOVE AND INSTALL COUNTERWEIGHT ...................................................................................... 79
REMOVAL AND INSTALL FRONT AXLE.............................................................................................. 81
DISASSEMBLY AND ASSEMBLY FRONT AXLE ................................................................................. 84
REMOVAL AND INSTALL REAR AXLE .............................................................................................. 125
DISASSEMBLY AND ASSEMBLY REAR AXLE ................................................................................. 128
REMOVAL AND INSTALL TRANSMISSION ....................................................................................... 181
DISASSEMBLY AND ASSEMBLY TRANSMISSION .......................................................................... 189
HYDRAULIC SYSTEM............................................................................................................................ 285
REMOVAL AND INSTALL HYDRAULIC PUMP ASSEMBLY.............................................................. 285
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY..................... 289
WORK EQUIPMENT............................................................................................................................... 291
REMOVAL AND INSTALL LOADER WORK EQUIPMENT ASSEMBLY ............................................ 291
REMOVAL AND INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY.......................................... 295
REMOVAL AND INSTALL BACKHOE BOOM CYLINDER ................................................................. 299
REMOVAL AND INSTALL BACKHOE ARM CYLINDER .................................................................... 302
REMOVAL AND INSTALL BACKHOE TELESCOPIC ARM CYLINDER............................................. 305
REMOVAL AND INSTALL OUTRIGGER CYLINDER ......................................................................... 307
REMOVAL AND INSTALL BACKHOE BOOM SWING CYLINDERS .................................................. 309
REMOVAL AND INSTALL BACKHOE BUCKET CYLINDER .............................................................. 312
REMOVAL AND INSTALL BACKHOE BOOM LOCK CYLINDER....................................................... 314
REMOVAL AND INSTALL BACKHOE BOOM..................................................................................... 316
REMOVAL AND INSTALL BACKHOE ARM ASSEMBLY ................................................................... 318
REMOVAL AND INSTALL BACKHOE TELESCOPIC ARM ASSEMBLY ........................................... 320
REMOVAL AND INSTALL BACKHOE BOOM SWING BRACKET ..................................................... 322
REMOVAL AND INSTALL BACKHOE SLIDING BRACKET ............................................................... 324
REMOVAL AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON................................ 327
CAB AND ITS ATTACHMENTS.............................................................................................................. 329
REMOVAL AND INSTALL OPERATOR'S CAB ASSEMBLY .............................................................. 329
ELECTRICAL SYSTEM .......................................................................................................................... 338
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ........................................................ 338
00-6 WB93R-8
TABLE OF CONTENTS
REMOVE AND INSTALL FRONT PANEL ........................................................................................... 340

REMOVAL AND INSTALL STEERING COLUMN SWITCHES ........................................................... 342
REMOVAL AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................... 344
60 MAINTENANCE STANDARD
CONTENTS ................................................................................................................................................ 2
ENGINE MOUNT ................................................................................................................................... 10
COOLING SYSTEM .............................................................................................................................. 12
TRANSMISSION ................................................................................................................................... 13
FRONT AXLE ........................................................................................................................................ 16
REAR AXLE........................................................................................................................................... 21
HYDRAULIC SYSTEM ............................................................................................................................. 26
9-SPOOL CONTROL VALVE ................................................................................................................ 26
11-SPOOL CONTROL VALVE .............................................................................................................. 34
HYDRAULIC PUMP............................................................................................................................... 42
PPC VALVE ........................................................................................................................................... 44
WORK EQUIPMENT ................................................................................................................................ 50
FRONT WORKING EQUIPMENT.......................................................................................................... 50
BACKHOE WORKING EQUIPMENT .................................................................................................... 54
WORK EQUIPMENT CYLINDER .......................................................................................................... 56
90 DIAGRAMS AND DRAWINGS

CONTENTS ................................................................................................................................................ 2
HYDRAULIC CIRCUIT DIAGRAM............................................................................................................ 10
SYMBOLS IN HYDRAULIC CIRCUIT DIAGRAM.................................................................................. 10
HYDRAULIC CIRCUIT DIAGRAM 1/2................................................................................................... 13
ELECTRIC CIRCUIT DIAGRAM............................................................................................................... 19
SYMBOLS IN ELECTRIC CIRCUIT DIAGRAM..................................................................................... 19
ELECTRICAL CIRCUIT DIAGRAM (1/12) ............................................................................................. 23
WB93R-8 00-7
TABLE OF CONTENTS
ELECTRICAL CIRCUIT DIAGRAM (10/12) ........................................................................................... 41

00-8 WB93R-8
FOREWORD, SAFETY AND GENERAL INFORMATION
(ALL-0370-001-A-00-A)

(ALL-1120-012-A-01-A)
IMPORTANT SAFETY NOTICE

(Rev. 2012/10)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific pur-
The symbol mark k is used for such matters that require special cautions during the work. The work
pose.
•
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
General precautions knowledge of welding perform the work. When

k Inappropriate handling causes an extreme
performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
d an ger. Read and un derstand what is
• Before starting work, warm up your body thor-
described in the operation and maintenance
oughly to start work under good condition.
manual before operating the machine. Read
• Avoid continuing work for long hours and take
and understand what is described in this
rests with proper intervals to keep your body in
manual before starting the work.
good condition. Take a rest in a specified safe
• Before performing any greasing or repairs, read place.
all the safety labels stuck to the machine. For
the locations of the safety labels and detailed Safety points
explanation of precautions, see the operation
and maintenance manual. 1 Good arrangement
• Locate a place in the repair workshop to keep 2 Correct work clothes
the tools and removed parts. Always keep the 3 Observance of work standard
tools and parts in their correct places. Always 4 Practice of making and checking signals
keep the work area clean and make sure that Prohibition of operation and handling by unlicensed
there is no dirt, water or oil on the floor. Smoke 5
workers
only in the areas provided for smoking. Never 6 Safety check before starting work
smoke while working. Wearing protective goggles (for cleaning or grinding
• When performing any work, always wear the 7
work)
safety shoes and helmet. Do not wear loose Wearing shielding goggles and protectors (for weld-
work cloths, or clothes with buttons missing. 8
ing work)
1. Always wear the protective eyeglasses 9 Good physical condition and preparation
when hitting parts with a hammer. Precautions against work which you are not used to
2. Always wear the protective eyeglasses 10
or you are used to too much
when grinding parts with a grinder, etc.
• When performing any work with two or more Preparation
workers, always agree on the working proce- • Before adding oil or making any repairs, place
dure before starting. While working, always the machine on a firm and level ground, and
keep conversations of the work between your apply the parking brake and chock the wheels
fellow workers and your self on any step of the or tracks to prevent the machine from moving.
work. During the work, hang the warning tag of • Before starting work, lower the work equipment
"UNDER WORKING" in the operator's com- (blade, ripper, bucket, etc.) to the ground. If it is
partment. not possible to lower the equipment to the
• Only qualified workers must perform the work ground, insert the lock pin or use blocks to pre-
and operation which require license or qualifi- vent the work equipment from falling. And be
cation. sure to lock all the work equipment control
• Keep the tools in good condition. And learn the levers and hang a warning tag on them.
correct way to use the tools, and use the proper • When performing the disassembling or assem-
ones among them. Before starting the work, bling work, support the machine securely with
thoroughly check the tools, lift truck, service blocks, jacks, or stands before starting the
vehicle, etc. work.
• If welding repairs is required, always have a • Remove all of mud and oil from the steps or
trained and experienced welder with good other places used to get on and off the machine
WB93R-8 00-9
completely. Always use the handrails, ladders • When removing piping, prevent the fuel or oil
of steps when getting on or off the machine. from spilling out. If any fuel or oil drips onto the
Never jump on or off the machine. When the floor, wipe it off immediately. Fuel or oil on the
scaffold is not provided, use steps or steplad- floor can cause you to slip and can even cause
der to secure your footing. fires.
• As a general rule, do not use gasoline to wash
Precautions during work parts. Do not use gasoline to clean the electri-
• For the machine equipped with the battery dis- cal parts, in particular.
connect switch, check that the system operat- • Reinstall the parts removed to their original
ing lamp is turned off before starting the work. places. Replace the damaged parts and the
Then, turn the battery disconnect switch to OFF parts which must not be used with new ones.
(Q) position and remove the switch key. For the When installing the hoses and wiring har-
machine not equipped with the battery discon- nesses, be careful that they are not damaged
nect switch, remove the cable from the battery by contacting with other par ts when the
before starting the work. Be sure to remove the machine is operated.
negative end (-) of the battery cable first. • When connecting the high pressure hoses and
• Release the remaining pressure in the circuits tubes, make sure that they are not twisted. The
completely before the work when the parts in damaged high pressure hoses and tubes are
the circuits of oil, fuel, coolant and air are dis- very dangerous when they are installed. So, be
connected or removed. When the cap of the oil extremely careful when connecting the high
filter, drain plug or oil pressure pickup plug is pressure pipings. In addition, check that their
removed, loose them slowly to prevent the oil connections are correct.
from spurting out. • When assembling or installing the parts, be
• When removing or installing the checking plug sure to tighten the bolts to the specified torque.
or the piping in the fuel circuit, wait 30 seconds When installing the protective parts such as
or longer after the engine is shut down and guards, or the parts which vibrate violently or
start the work after the remaining pressure is rotate at high speeds, be sure to check that
released from the fuel circuit. they are installed correctly.
• Immediately after the engine is shut down, the • When aligning 2 holes, never insert your fin-
coolant and oil in the circuits are hot. Be careful gers or hand into the holes. Align the holes with
not to get scalded by the hot coolant and oil. care so that your fingers are not caught in the
Start the work after checking that the coolant hole.
and oil are cooled down sufficiently. • When measuring hydraulic pressure, check
• Start the work after the engine is shut down. Be that the measuring tools are correctly installed.
sure to shut down the engine when working on • If the engine is operated for a long time in a
or around the rotating parts in particular. When closed place which is not ventilated well, you
checking the machine without shutting down may suffer from gas poisoning. Accordingly,
the engine (measuring oil pressure, rotational open the windows and doors to ventilate the
speed, oil or coolant temperature), take place well.
extreme care not to get caught in the rotating
parts or the working equipment. Precautions for slinging work and making sig-
• The hoist or crane must be used to sling the nals
components weighing 25 kg or heavier. Check • Only one appointed worker must make signals
the slings (wire rope, nylon sling, chain and and co-worker must communicate with each
hook) for damage before the work. Use the other frequently. The appointed signaler must
slings with ample capacity and install them to make specified signals clearly at the place
the proper places. Operate the hoist or crane where the signaler is well seen from the opera-
slowly to prevent the component from hitting tor's seat and where the signaler can see the
any other part. Do not work with any part still working condition easily. The signaler must
raised by the hoist or crane. always stand in front of the load and guide the
• When removing the part which is under internal operator safely.
pressure or reaction force of the spring, always 1. Do not stand under the load.
leave 2 bolts in diagonal positions. Loosen 2. Do not step on the load.
those 2 bolts gradually and alternately and • Check the slings before starting sling work.
release the pressure, then, remove the part. • Keep putting on the gloves during sling work.
• When removing the part, be careful not to (Put on the leather gloves, if available.)
break or damage the electrical wiring. The • Measure the weight of the load by the eye and
damaged wiring may cause electrical fires. check its center of gravity.
00-10 WB93R-8
• Use the proper sling according to the weight of The strength of the hook is maximum at its
the load and method of slinging. If too thick wire central part.
ropes are used to sling a light load, the load
may slip and fall.
• Do not sling a load with 1 wire rope only. If do
so, the load may rotate or the sling gets loose
and the sling may slip off. Install 2 or more wire
ropes symmetrically.
k Slinging with one rope may cause turning of
the load during hoisting, untwisting of the
rope, or slipping of the rope from its original
slinging position on the load, which can
result in a dangerous accident.
• Hanging angle must be 60 degrees or smaller
as a rule.
• When hanging a heavy load (25kg or heavier), • Do not use twisted or kinked wire ropes.
the hanging angle of the rope must be narrower • When slinging up a load, observe the following.
than that of the hook. 1. Wind up the rope slowly until the wire rope
a When slinging a load with 2 ropes or more, tensions. When putting your hands on the
the larger the hanging angle is, the larger wire ropes, do not grasp them but press
the tension of each rope. The figure bellow them down from above. If you grasp them,
shows the variation of allowable load in kN your fingers may be caught.
{kg} when hoisting is made with 2 ropes, 2. After the wire ropes are stretched, stop the
each of which is allowed to sling up to 9.8 crane and check the condition of the slung
kN {1000kg} a load vertically, at various load, wire ropes, and pads.
hanging angles. When the 2 ropes sling a 3. If the load is unstable or the wire rope or
load vertically, up to19.6 kN {2000 kg} of chains are twisted, lower the load and lift it
total weight can be suspended. This weight up again.
is reduced to 9.8 kN {1000 kg} when the 2 4. Do not lift up the load at an angle.
r op e s m ak e a h an g i n g a n gl e o f 1 2 0 • When lowering a load, pay attention to the fol-
degrees. If the two ropes sling a 19.6 kN lowing.
{2000 kg} load at a hanging angle of 150 1. When lifting down a load, stop it temporar-
degrees, each rope is subjected to a force ily at 30 cm above the floor, and then lower
as large as 39.2 kN {4000 kg}. it slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane

a Read the Operation and Maintenance Manual
of the crane carefully in advance and operate
the crane safely.
• When installing wire ropes to an angular load,

apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.
• Use the specified eye bolts and fix wire ropes,
chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
a Slinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
WB93R-8 00-11
Precautions for using overhead traveling crane Selecting wire ropes

k The hoist or crane must be used to sling the
• Select adequate ropes depending on the
weight of the parts to be hoisted, referring to
components weighing 25 kg or heavier. A
the table below
part weighing 25 kg or heavier in "disas-
Wire rope (JIS G3525, 6 x 37 - Type A)
sembly and assembly" section is indicated
with the symbol of 4.
(Standard Z twist wire ropes without galvanizing)
• Before starting work, check the wire ropes, Nominal diameter

Allowable load
brake, clutch, controller, rails, over winding pre- of rope
vention device, ground fault circuit interrupter mm kN ton
for electric shock prevention, crane collision 10 8.8 0.9
prevention device, and energizing warning 12 12.7 1.3
lamp, and check the following safety items. 14 17.3 1.7
• Observe the signals for sling work. 16 22.6 2.3
• Operate the hoist at a safe place.
18 28.6 2.9
• Be sure to check the directions of the direction
20 35.3 3.6
indication plate (north, south, east and west)
25 55.3 5.6
and the operating button.
• Do not sling a load at an angle. Do not move 30 79.6 8.1
the crane while the slung load is swinging. 40 141.6 14.4
• Do not raise or lower a load while the crane is 50 221.6 22.6
moving longitudinally or laterally. 60 318.3 32.4
• Do not drag a sling.
a The allowable load is calculated as one sixth of
• When lifting up a load, stop it just after it leaves
the breaking load of the rope to be used (safety
the ground and check safety, and then lift it up.
coefficient: 6).
• Consider the travel route in advance and lift up
a load to a safe height. Precautions for disconnecting and connecting
• Place the control switch in a position where it hoses and tubes in air conditioner circuit
will not be an obstacle to work and passage.
• After operating the hoist, do not swing the con- Disconnection
k When replacing the air conditioner unit, air
trol switch.
• Remember the position of the main switch so
that you can turn off the power immediately in conditioner compressor, condenser or
an emergency. receiver drier, etc., collect the refrigerant
• Shut down the main switch when the hoist (air conditioner gas: R134a) from the air
stops because of a blackout. When turning on a conditioner circuit before disconnecting the
switch which is turned OFF by the ground fault air conditioner hoses.
circuit interrupter for electric shock prevention, a Ask a qualified person for collecting, adding
check that the devices related to that switch are and filling operations of the refrigerant (air con-
not in operating condition. ditioner gas: R134a). (Only registered persons
• If you find an obstacle around the hoist, stop can work.)
the operation. a Never release the refrigerant (air conditioner
• After finishing the work, stop the hoist at the gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas:
specified position and raise the hook to at least
2 meters above the floor. Do not leave the sling
attached to the hook. R134a) gets in your eyes, you may lose your
sight. And if it touches your skin, you may
suffer from frostbite. Put on protective eye-
glasses, gloves and working clothes with
long sleeves while collecting the refrigerant
or filling the air conditioner circuit with the
refrigerant.
• When loosening the nuts fixing air conditioner
hoses and tubes, be sure to use 2 wrenches;
use one wrench to fix and use the other one to
loosen the nut.
00-12 WB93R-8
Connection
• When installing the hose for the air conditioner
circuit, take care not to allow invasion of dirt,
dusts and water into the hose.
• Check that the O-rings are fitted to the joints
when connecting the air conditioner piping.
• Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
• When removing the O-rings, use a soft tool so
that the piping is not damaged.
• Check that the O-ring is not damaged or deteri-
orated.
• Apply compressor oil for refrigerant (R134a) to
the O-ring.
a However, do not apply oil to the threaded
portion of a bolt, nut or union.
Manufacturer Part name

DENSO ND-OIL8
VALEO THERMAL ZXL100PG (equivalent to
SYSTEMS PAG46)
SANDEN SP-10
• When tightening nuts of the air conditioner

hoses and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of the air
conditioner piping.
WB93R-8 00-13
• When performing grinding or welding work

(ALL-0000-001-K-27-A)
FIRE PREVENTION
(ALL-0000-17A-K-01-A)
on the machine, move any flammable
Action if fire occurs
materials to a safe place before starting.
• Turn the starting switch to OFF position to stop
the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
,&
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is recom-
mended is polychloroprene (Neoprene) or poly-
v inyl c hl oride (i n the l ower temper atur e
environment).
When wearing cotton-work-gloves, wear rubber
gloves under them.
(ALL-0000-17B-K-03-A)
Prevent fire
• Fire caused by fuel, oil, coolant or window
washer fluid
,&
Do not bring any flame or fire close to flamma-
ble substances such as fuel, oil, coolant or win-
dow washer fluid.There is danger that they may • Fire caused by accumulation or attachment
catch fire. Always observe the following. of flammable material
• Do not smoke or use any flame near fuel or • Remove any dry leaves, chips, pieces of
other flammable substances. paper, coal dust, or any other flammable
• Shut down the engine before adding fuel. materials accumulated or attached to or
• Do not leave the machine when adding fuel around the engine exhaust manifold, muf-
or oil. fler, or battery, or on the undercovers.
• Tighten all the fuel and oil caps securely. • To prevent fires from being caught, remove
• Be careful not to spill fuel on overheated any flammable materials such as dry
surfaces or on parts of the electrical sys- leaves, chips, pieces of paper, coal dust, or
tem. any other flammable materials accumu-
• After adding fuel or oil, wipe up any spilled lated around the cooling system (radiator,
fuel or oil. oil cooler) or on the undercover.
• Put greasy rags and other flammable mate- • Fire coming from electric wiring
rials into a safe container to maintain safety Short circuits in the electrical system can cause
at the workplace. fire. Always observe the following.
• When washing parts with oil, use a non- • Keep all the electric wiring connections
flammable oil. Do not use diesel oil or gas- clean and securely tightened.
oline.There is danger that they may catch • Check the wiring every day for looseness
fire. or damage. Reconnect any loose connec-
• Do not weld or use a cutting torch to cut tors or refasten wiring clamps. Repair or
any pipes or tubes that contain flammable replace any damaged wiring.
liquids. • Fire caused by piping
• Determine well-ventilated areas for storing Check that all the clamps for the hoses and
oil and fuel. Keep the oil and fuel in the tubes, guards, and cushions are securely fixed
specified place and do not allow unauthor- in position.
ized persons to enter. If they are loose, they may vibrate during oper-
ation and rub against other parts.There is
00-14 WB93R-8
danger that this may lead to damage to the DISPOSE OF WASTE MATERIALS
hoses and cause high-pressure oil to spurt out,
leading to fire and serious personal injury or To prevent pollution, pay full attention to the way to
death. dispose of waste materials.
• Fire around the machine due to highly • Always put the oil and coolant drained from the
heated exhaust gas machine in containers. Never drain the oil and
This machine is equipped with KDPF (Komatsu coolant directly onto the ground or dump into
Diesel Particulate Filter). the sewage system, rivers, the sea, or lakes.
KDPF is a system for purifying soot in exhaust • Observe the related laws and regulations when
gas.Its exhaust gas discharged during purifica- disposing of harmful objects such as oil, fuel,
tion process (regeneration) can be at higher coolant, solvent, filters, and batteries.
temperature than that from existing models. Do
not bring any flammable material close to the
outlet of the exhaust pipe.
• When there are thatched houses, dry
leaves or pieces of paper near the work
site, set the system to disable the regener-
ation before starting work to prevent fire
hazards due to highly heated exhaust gas.
See the operation and maintenance man-
ual for the setting procedure.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications. Some kinds of rubber and plastics may produce
• When taking the electrical power for the poisonous gas harmful to human body when they
lighting equipment from the machine itself, are burned.
follow the instructions in the operation and • As for rubber, plastics, or parts (hoses, cables,
maintenance manual. and wiring harnesses, etc.) which contain those
(ALL-0000-99A-K- 02-A)
materials, ask the industrial waste treatment

firms for their disposals in accordance with the
local regulations.
WB93R-8 00-15
(ALL-0320-010-A-01-A)
HOW TO READ THE SHOP MANUAL

(Rev. 2012/10)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop man-
ual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual

• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as reference
material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the
standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the crite-
rion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Reading the symbols

Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
00-16 WB93R-8
Symbol Item Remark
k
This signal indicates an extremely hazardous situation which will
Danger
result in death or serious injury if it is not avoided.
k
This signal indicates a potentially hazardous situation which will
Warning
k
Caution result in injury or property damage around the machine if it is not
avoided.
4
This signal indicates the weight of parts and components, and items
Weight which requires great attention to a selection of wires and working
posture for slinging work.
3
This signal indicates the tightening torque for portions which
Tightening torque
requires special care in assembling work.
2
This signal indicates a place to be coated with adhesive, grease, etc.
Coat
in assembling work.
5
This signal indicates a place to supply oil, coolant, etc. and the
Oil and coolant
quantity. (*1)
6
This signal indicates a place to drain oil, coolant, etc. and the quan-
Draining
tity.
*1:For places to supply oil, coolant, etc. and their quantities, see SPECIFICATIONS “TABLE OF FUEL,
COOLANT, AND LUBRICANTS”.
Reading the signal word

Signal word for notice and remark describes the following.
Symbol Item Remark

If the precaution of this signal word is not observed, the machine
NOTICE NOTICE
damage or shortening of service life may occur.
REMARK
Remarks This signals contains useful information to know.
a
Reading the unit

International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.
WB93R-8 00-17
(ALL-0330-006-A-01-A)
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

(Rev. 2012/10)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance • When some parts are repaired, the value of
• To be accurate, the finished dimension of a part performance/function is set to the standard
is slightly different from one to another. value.
• The finished dimension of a part specifies the
allowable difference from the standard dimen-
sion which is set first.
• The dimension set as the standard is called the
standard dimension and the range of difference
from this standard dimension is called the "tol-
erance".
• An indication example of a standard dimension
and tolerance is shown in the following table.
(The standard dimension is entered on the left
side and the tolerance is entered with a positive
or negative symbol on the right side)
Example:
Standard dimension Tolerance

-0.022
120
-0.126
• The tolerance may be indicated in the text and

a table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)"
Example: 120(-0.022/-0.126)
• Usually, the dimension of a hole and the dimen-
sion of a shaft to be inserted into the hole are
indicated by the same standard dimension and
different tolerances of the hole and shaft. The
tightness of fit is decided by the tolerance.
• An indication example of a shaft and hole is
Standard interference
shown in the following table.
• When the diameter of a hole of a part shown in
(The standard dimension is entered on the left
the given standard dimension and tolerance
side and the tolerance of the shaft is entered
table is smaller than that of the shaft to be
with a positive or negative symbol at the center
inserted, the difference between those diame-
and that of the hole on the right side)
ters is called the "interference".
• Subtract the maximum dimension of the hole
Standard dimen- Tolerance
from the minimum dimension of the shaft and
sion Shaft Hole
call it (A). Subtract the minimum dimension of
-0.030 +0.046 the hole from the maximum dimension of the
60
-0.076 0
shaft and call it (B). The range between (A) and
(B) is the "standard interference".
Standard clearance and standard value
• After repairing or replacing some parts, meas-
• The clearance made when new parts are
ure the dimension of their hole and shaft and
assembled is called the standard clearance,
check that the interference is in the standard
which is indicated by the range from the mini-
range.
mum clearance to the maximum clearance.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance.
• The values indicating performance and function
of new products or equivalent are called the
"standard value", which is indicated by a range
or a target value.
00-18 WB93R-8
Repair limit and allowable value or allowable di-

mension
• The dimensions of parts change because of the
wear or deformation while they are used. When
the dimension changes exceeding certain
value, the parts can not be used any longer.
This value is called "repair limit".
• If a part is worn to the repair limit, it must be
replaced or repaired.
• The performance and function of the products
lower while they are used. When the value of
the performance and function lowers exceeding
a certain limit and it influences the operation
etc., this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the allow-
able value, must be repaired. However, since
the allowable values are generally estimated
through various tests or experiences in most
cases, the judgement must be made in consid-
eration of the operating condition and cus-
tomer's requirement.
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part
to be assembled is called the "allowable inter-
ference".
• The allowable interference shows the repair
limit of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.
WB93R-8 00-19
(PC-AD00-2A4-K-00-A)
HANDLING EQUIPMENT OF FUEL SYSTEM DEVICES

(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump
and nozzle. If foreign material enters this sys-
tem, it may cause a failure. Use special care to
prevent entry of the foreign material when ser-
vicing the fuel system.
Use care for working environment

• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the compo-
nents which are removed with the caps, tapes,
vinyl bags, etc. to prevent foreign material from
entering. Never perform repair works under the
condition that the openings are left as they are
or plugged with cloths as foreign material may
enter or environment may be polluted by the oil
leaked. Do not discard the waste oil some-
where or other. Hand it over to your customer
for disposal, or dispose it by yourself.
How to clean parts when dirt is stuck

• If any dirt or dust sticks the parts of the fuel sys-
tem, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge

• Be sure to use the Komatsu genuine fuel filter
cartridge.
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump
and nozzle. In order to prevent foreign material
from entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is
used, the fuel system may have a failure.
Accordingly, never use such a filter element.
00-20 WB93R-8
(PC220-A900-2A4-K-00-A)
HANDLING OF INTAKE SYSTEM PARTS

(Rev.2013/10)
• The Komatsu Variable Geometry Turbocharger
consists of more precise parts (variable mecha-
nism) than the parts used in the conventional
turbocharger. If foreign material enters this sys-
tem, it may cause a failure. Use special care to
prevent entry of the foreign material when ser-
vicing the air intake system.
Be careful of working environment

• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
nents which are removed, with the caps, tapes,
vinyl bags, etc. to prevent foreign material from
entering. Never perform repair works under the
condition that the openings are left open or
plugged with rag since foreign material may
enter.
WB93R-8 00-21
(ALL-C000-2A4-P-01-A)
HANDLING OF HYDRAULIC EQUIPMENT

(Rev. 2012/10)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Be careful of working environment

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

• When disassembly or maintenance work of the
hydraulic is performed in the field, there is dan-
ger of dust entering the components. It is also
difficult to check the performance of the compo-
nents after repairs, so it is desirable to use the
component exchange service. The disassem-
bly and assembly of the hydraulic components
must be performed in the specially arranged
dustproof workshop and the performance test Preventing intrusion of foreign materials during
of the components must be performed with the refilling operations.
special testing equipment. • Care must be taken when adding hydraulic oil
so that foreign material does not enter. Keep
the oil filler port and the area around it, oil sup-
ply pump and oil container clean. If an oil clean-
ing device is used, it is possible to remove the
dirt that is collected during storage. It is a surer
means.
Plugging of opening (prevention of flowing out

of oil)
nents which are removed (when plugs are not
prepared, seal with caps, tapes, vinyl bags,
etc.) to prevent entry of foreign material and
flowing out of oil. Never leave the openings of Replacing hydraulic oil while its temperature is
the pipes and hoses without being covered or high
plugged with cloth as foreign material may • When the hydraulic oil is warm, it flows easily.
enter them or environment may be polluted by In addition, sludge can also be drained from the
the oil leaked. Do not discard the waste oil circuit together with the oil. So, it is better to
somewhere or other. Hand it over to your cus- change the hydraulic oil while it is warm. When
tomer for disposal, or dispose it by yourself. changing the hydraulic oil, the old oil must be
drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the cir-
cuit.) If the old oil is left in the system, the con-
taminant and sludge in the oil mix with the new
oil and shorten the life of the new hydraulic oil.
00-22 WB93R-8
Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil cir-
cuit. The oil cleaning equipment can remove
the ultra fine (approximately 3 μm) particles
that the filter built in the hydraulic equipment
can not remove. So, it is an extremely effective
device.
WB93R-8 00-23
(ALL- C930-001-P-00-A)
METHOD OF DISCONNECTING AND CONNECTING OF PUSH-PULL

TYPE COUPLER
(Rev. 2012/01)
k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
(ALL-C930-925-P-01-A)
Type 1
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it
mating adapter (3). (Fig. 1) in mating adapter (3) aligning them with each
a It can be pushed in by approximately other. (Fig. 4)
3.5mm. a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4). 2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3), the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until connecting condition. (Fig. 4)
"click" is heard. (Fig. 2) a When the hose fitting is pulled back, the
3. Hold hose adapter (1) or hose (5) and pull it rubber cap will move toward the hose,
out. (Fig. 3) however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.
00-24 WB93R-8
(ALL-C930-925-P-02-A)
Type 2
1. While holding the fitting, push body (7) in 1. While holding the fitting, push body (7) in
straight until sliding prevention ring (6) hits con- straight until sliding prevention ring (6) hits con-
tact surface (a) at the hexagonal part on the tact surface (a) at the hexagonal part on the
male side. (Fig. 6) male side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn
lever (8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)
WB93R-8 00-25
(ALL-C930-925-P-03-A)
Type 3
1. While holding the fitting, push body (9) in 1. While holding the fitting, push body (9) in
straight until sliding prevention ring (8) hits con- straight until sliding prevention ring (8) hits con-
tact surface (b) at the hexagonal portion on the tact surface (a) at the hexagonal portion on the
male side. (Fig. 10) male side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface
(b) of the hexagonal portion on the male side.
(Fig. 11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig.
12)
00-26 WB93R-8
(ALL-E000-2A4-P-01-A)
HANDLING OF ELECTRICAL EQUIPMENT

(Rev. 2012/10)
• To maintain the performance of the machine over a long period, and to prevent failures or troubles
before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs"
must be performed. This section deals particularly with correct repair procedures for mechatronics com-
ponents and is aimed at improving the quality of repairs. For this purpose, it describes the working pro-
cedures in "Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
• Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For Defective crimping or soldering of connectors
this reason, it is necessary to be extremely • The pins of the male and female connectors
careful when handling the wiring harnesses. are attached to wires by crimping or soldering.
If excessive force is applied to the wire, the
joining area may become loose, which may
result in a defective connection or breakage.
Main failures occurring in wiring harness Defec-

tive contact of connectors (defective contact be-
tween male and female connectors)
• Problems with defective contact are likely to Disconnections in wiring
occur because the male connector is not prop- • If the wiring harness is pulled to disconnect the
erly inserted into the female connector, or connector, or the components are lifted with a
b e c au s e o n e o r bo th of c on n ec t or s a r e crane while the wiring harness is still con-
deformed or the position is not correctly nected, or a heavy object hits the wiring har-
aligned, or because there is corrosion or oxidi- ness, the crimping of the connector may
zation of the contact surfaces. The corroded or separate, or the soldering may be damaged, or
oxidized contact surfaces may become shiny the wiring harness may be broken.
again (and contact may become normal) by
connecting and disconnecting the connectors
approximately 10 times.
WB93R-8 00-27
dry cloth or blow it with compressed air and

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

• The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high- pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water
from entering, but once water does enter, it is
difficult to drain it. If water should get into the Removing, installing, and drying connectors
connector, the pins will be short-circuited by the and wiring harnesses
water. So if any water gets in, immediately dry Disconnecting connectors
the connector or take other appropriate action 1. Hold the connectors when disconnecting.
before passing electricity through it. • Disconnect connectors by holding the con-
nector bodies. For the connectors held by a
screw, loosen the screw fully, then hold the
male and female connectors with each
hand respectively and pull them apart hori-
zontally. For the connectors with lock stop-
per, press down the stopper with your
thumb and pull the connectors apart.
a Never pull the connector with one hand.
Entry of water, mud or dirt when disconnecting

a connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off
any stuck water or dirt by using a piece of dry
cloth or blow it with compressed air.
2. When removing from clips
Oil, mud or dirt stuck to connector • Both of the connector and clip have stop-
• If any oil or grease is stuck to the connector pers, which are engaged with each other
and an oil film is formed on the mating surface when the connector is connected.
of the male and female pins, the oil prevents
electricity from passing through, resulting in
defective contact. If any oil or grease, mud or
dirt is stuck to the connector, wipe it off with a
00-28 WB93R-8
• Check that there is no oil, dirt or water stick

to the connector pins (joint portion).
• Check that the connector pins are free from
deformation, defective contact, corrosion,
or damage.
• Check that external surfaces of the con-
nectors are free from damage or breakage.
a If any oil, water or dirt is stuck to the con-
nector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring har-
ness with a dryer. But be careful not to
make it too hot as it causes short circuit.
• When removing a connector from a clip, a If there is any damage or breakage,
pull the connector in a parallel direction to replace the connector.
the clip for removing stoppers. 2. Fix the connector securely.
a If the connector is pried up and down or to • Align the connectors correctly, and fit them
the right and left, the housing may break. securely. For the connectors with the lock
stopper, push in the connectors until "click"
is heard.
3. Action to take after removing connectors

• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt, 3. Correct the protrusion of the boot and misalign-
oil or water in the contact portion. ment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for improper any extrusion of the boot. In addition, if the
contact to occur, so always cover the con- wiring harness or the clamp is out of the
nector. position, put it in its original position.
a If the connector cannot be corrected easily,
remove the clamp and adjust the position.
Connecting connectors
1. Check the connector visually.
WB93R-8 00-29
• If the connector clamp is removed, be sure Drying wiring harness

to return it to its original position. And • If there is any oil or dirt on the wiring harness,
check that it is securely installed. wipe it off with a dry cloth. Avoid washing by
using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as fol-
lows.
1. Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the con-
ditioner, remove oil and water in the air
before starting air blow.
Handling of Deutsch connector (DT8-pin, DT12-

pin)
Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
2. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
a Hot air from the dryer can be used, but reg-
ulate the time to use hot air in order to pre-
vent the connector or related parts from
becoming too hot, as it causes deformation
Connection or damage to the connector.
1. Push in female connector (2) horizontally until
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set com-
pletely, push in female connector (2) with curv-
ing movement until the locks are set normally.
(Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness discon-
nected and perform a continuity test to check
for any short circuits between pins caused by
water.
a After the connector is completely dried,
blow the contact restorer and reassemble
them.
00-30 WB93R-8
Handling of connectors used on engine 2. While pressing lock (L2), pull out connector (1).
Slide, lock type

(FRAMATOME-3, FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connec-

tor (1).
Connection
1. Insert the connector securely until a click is
heard.
Connection
(FRAMATOME-24) 1. Insert the connector securely until a click is
Disconnection heard.
1. Slide down lock (red) (L1).
Pull lock type
(PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.
WB93R-8 00-31
Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
(AMP-3)
Push lock type
Disconnection
(BOSCH-3)
1. While pressing lock (E), pull out connector (5)
Disconnection
in the direction of the arrow.
1. While pressing lock (C), pull out connector (3)
• 114 series
Connection
heard.
• 107 series
(SUMITOMO-2)
Disconnection
a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector
with flat-head screwdriver [1], pull out con- Connection
nector (3) in the direction of the arrow. 1. Insert the connector securely until a click is
heard.
00-32 WB93R-8
(SUMITOMO-2)
Disconnection
a Pull the connector straight up.
Connection
1. Insert the connector to the end while aligning
its grove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".
Connection
heard.
(SUMITOMO-4)
Disconnection
1. While pressing lock (D), pull out connector (4)
Handling controller
• The electronic circuits for control including the
microcomputers are assembled in the control-
ler. These electronic circuits in the controller
must be handled with care as they control the
machine.
• Do not place objects on top of the controller.
Connection
heard.
Turn-housing type (Round green connector)

(CANNON-4)
Disconnection
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing
(H1). When the lock is release the housing
is felt tight to turn.
2. Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side. • Cover the control connectors with tape or a
vinyl bag. Never touch the connector contacts.
• During rainy weather, do not leave the control-
ler in a place where it is exposed to rain.
WB93R-8 00-33
• Do not place the controller on oil, water, or soil,

or in a place that can be heated to a high tem-
perature even for a short period of time. (Place
it on a suitable dry stand.)
• Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all the wiring harness connec-
tors connected to the controller. Put the arc
welding ground to the place close to the weld-
ing point.
Precautions for troubleshooting electrical cir-

cuits
• Be sure to turn the starting switch to the "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all
the related connectors for loose connection.
a Check the related connectors for their per-
formance by disconnecting and connect-
ing them several times.
• Be sure to connect all the disconnected con-
nectors before proceeding to the next step.
a If the starting switch is turned to the "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wir-
ing harnesses and connectors several times
and check that the multimeter reading does not
change.
a If there is any value change on the multim-
eter, there may be a defective contact in
the circuit.
00-34 WB93R-8
(ALL-E500-030-P-00-A)
HOW TO READ ELECTRIC WIRE CODE

(Rev. 2012/10)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by sym-
bols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the
diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material

• AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the
coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Temperature
Sym- Conductor mate-
Type Insulator material range (°C) in Example of use
bol rial
use
Low-voltage
For large current wiring (nomi-
wire for auto- AV
nal No. 5 and above)
mobile
Thin-cover
low-voltage
General wiring (nominal No. 3
wire for AVS
and lower)
automobile Soft polyvinyl chloride -30 to +60
(Type 1) Annealed cop-
Thin-cover per for electric
low-voltage appliance For mid- to small-size excava-
wire for auto- CAVS tors
mobile (nominal No. 1.25 and lower)
(Type 2)
Heat- General wiring for extremely

resistant low- Heat-resistant cross cold weather specification
AEX -50 to +110
voltage wire linked polyethylene Wiring at high ambient temper-
for automobile ature place
WB93R-8 00-35
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor
Cross-
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 —
Coating 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/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor
Cross-
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 — — — — — — — — —
Coating 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
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
strands/ 7/round compres- 11/round compres- 16/round compres-
— — —
Diameter of sion sion sion
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D
CAVS Standard — 1.6 — 1.8 — 2.1
a "f" of nominal No. denotes "flexible".
00-36 WB93R-8
Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire

B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
a Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the sec-
ond color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
Types of circuits and color codes
Type of wire AVS, AV, CAVS AEX

Charge R WG — — — — R —
Ground B — — — — — B —
Start R — — — — — R —
Light RW RB RY RG RL — D —
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB — L —
Type of circuit Br BrW BrR BrY BrB — — —
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Others Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —
WB93R-8 00-37
(ALL-1160-927-A-00-A)
PRECAUTIONS WHEN PERFORMING OPERATION

(Rev. 2012/10)
• When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly
and assembly" of the components, observe the following general cautions.
Precautions for removal and disassembly work

• If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the
sewage rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when install-
ing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and alter-
nately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
a The O-rings in the table are emergency parts used for disassembly or transportation of the machine.
When assembling, confirm the part numbers in the parts book and use the parts conforming to the
using condition.
Disconnection of face seal type hoses and tubes
Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
00-38 WB93R-8
Disconnection of taper seal type hoses and tubes
Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
Disconnection of split flange type hoses and tubes
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a Flange (1)
b (2) (3)
07379- 01010-
04 38.1 17.5 07371-30400 07378-10400 07000-12021 01643-50823
00400 80825
07379- 01010-
05 42.9 19.8 07371-30500 07378-10500 07000-13022 01643-50823
00500 80830
07379- 07372-
06 47.6 22.2 07371-30640 07378-10600 07000-13025 01643-51032
00640 51035
07379- 07372-
10 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032
01044 51035
07379- 07372-
58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032
01250 51035
12
07379- 01010-
66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232
01260 81245
07379- 07372-
14 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232
01460 51240
WB93R-8 00-39
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
07379- 01010-
79.4 36.5 07371-51470 07378-11410 07000-13048 01643-31445
01470 81455
07379- 07372-
77.8 42.8 07371-32076 07378-12000 07000-12060 01643-51232
02071 51240
20
07379- 01010-
96.8 44.5 07371-52080 07378-12010 07000-12060 01643-31845
02080 81865
07379- 07372-
24 88.9 50.8 07371-12484 07378-12400 07000-12070 01643-51232
02484 51240
07379- 07372-
30 106.4 62 07371-13010 07378-13000 07000-12085 01643-51645
03010 51650
07372-
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 01643-51645
51650
07379- 07372-
40 130.2 77.8 07371-14012 07378-14000 07000-12110 01643-51645
04012 51650
07372-
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 01643-51645
51655
Removal of pipe joints of O-ring boss type
Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
00-40 WB93R-8
Removal of pipe joints of taper pipe thread type
Nominal thread Plug (1)

Nominal No.
size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108
02 R1/4 07042-00211 07043-00211
03 R3/8 07042-00312 07043-00312
04 R1/2 07042-00415 07043-00415
06 R3/4 07042-00617 07043-00617
10 R1 07042-01019 07043-01019
12 R1 1/4 07042-01222 07043-01222
14 R1 1/2 07042-01422 07043-01422
20 R2 07042-02026 07043-02026
Precautions for installation and assembly work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified.
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if
they are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the
threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure
that the surface is free from dirt or damage.
• Clean all of the parts, and repair any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then con-
nect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of
the eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening
on one side.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receives pressure.
However, if the threaded portion is difficult to degrease, you may use a seal tape.
• When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing
direction of the threads, seeing from the screw end and starting at the third thread.
a If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is
pushed out, and that can cause oil leakage.
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleed-
ing of the hydraulic circuit according to the following procedure.
WB93R-8 00-41
1.Start and run the engine at low idle.

2.Repeat the operation to extend and retract each cylinder of the work equipment to approximately
100 mm before the stroke end four to five times.
3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke.
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
Precautions at the time of completing work
Refilling of coolant, oil and grease

• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the pip-
ing, and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Testing installed condition of cylinder heads and manifolds

• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Testing of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suc-
Intake and exhaust
tion and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for water
Cooling system leakage.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
Fuel system leakage.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If
any part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting
parts for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function

• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly
and assembly".
00-42 WB93R-8
(ALL-Q210-13V-K-00-A)
PRACTICAL USE OF KOMTRAX

(Rev. 2012/10)
KOMTRAX system transmits various machine information by use of the radio communication and KOMT-
RAX operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the KOMT-
RAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)
Merit of using KOMTRAX

• The working place of the machine can be checked in the map on PC.
• Operation information such as service meter reading, operating hours, fuel consumption, occurred cau-
tion and failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic
oil filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time,
etc.) can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice tool for the user and operator.
How to use KOMTRAX practically

With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc.
through KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority fail-
ure code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed fail-
ure code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replace-
ment work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.
How to operate KOMTRAX

For the operating method of each screen of KOMTRAX, see "Global KOMTRAX Web Reference Manual
(For Key Person)".
WB93R-8 00-43
(ALL-M140-03B-P-01-A)
STANDARD TIGHTENING TORQUE TABLE

(Rev. 2012/10)
Table of tightening torque for bolts and nuts

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6.0 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10.0 to 12.5}
(*1, *2) 17
14 22 157 to 196 {16 to 20}
24
16 245 to 309 {25 to 31.5}
(*1) 22
18 27 343 to 427 {35 to 43.5}
20 30 490 to 608 {50 to 62}
22 32 662 to 829 {67.5 to 84.5}
24 36 824 to 1,030 {84 to 105}
27 41 1,180 to 1,470 {120 to 150}
30 46 1,520 to 1,910 {155 to 195}
33 50 1,960 to 2,450 {200 to 250}
36 55 2,450 to 3,040 {250 to 310}
39 60 2,890 to 3,630 {295 to 370}
*1: Split flange bolt.

*2: Flanged bolt.
00-44 WB93R-8
a Tighten the following flanged bolt on which “7“ is stamped on its top to the tightening torque shown in the
following table.
Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}
Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the
table below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch, type
of thread Range Target Range Target
1/4-20UNC 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
3/4-10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
7/8-9UNC 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
1-8UNC 883 to 1,196 {90 to 122} 1,040 {106} 245 to 333 {25 to 34} 284 {29}
1 1/8-7UNC 1,187 to 1,608 {121 to 164} 1,393 {142} 333 to 451 {34 to 46} 392 {40}
1 1/4-7UNC 1,598 to 2,157 {163 to 220} 1,873 {191} 451 to 608 {46 to 62} 530 {54}
1 1/2-6UNC 2,354 to 3,177 {240 to 324} 2,765 {282} 657 to 892 {67 to 91} 775 {79}
WB93R-8 00-45
Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch, type
of thread Range Target Range Target
1/4-28UNF 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4} 37.3 {3.8} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.6 {6}
5/8-18UNF 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
7/8-14UNF 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
1-14UNF 1,020 to 1,373 {104 to 140} 1,196 {122} 284 to 382 {29 to 39} 333 {34}
1 1/8-12UNF 1,353 to 1,844 {138 to 188} 1,598 {163} 382 to 520 {39 to 53} 451 {46}
1 1/4-12UNF 1,804 to 2,432 {184 to 248} 2,118 {216} 510 to 686 {52 to 70} 598 {61}
1 1/2-12UNF 2,707 to 3,658 {276 to 373} 3,177 {324} 765 to 1,030 {78 to 105} 892 {91}
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})

Nominal No. diameter across flats
(mm) (mm) Range Target
02 14 Varies 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 depending on 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 type of con- 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 nector. 128 to 186 {13.0 to 19.0} 157 {16.0}
00-46 WB93R-8

10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the table below.
a The table is applied to the threads coated with engine oil (wet threads)
WB93R-8 00-47
Tightening torque (Nm {kgm}) Taper seal Face seal

Width
Nominal Nominal No. -
across Thread root
No. of Thread size threads per
flats Range Target diameter (mm)
hose (mm) inch, type of
(mm) (reference)
thread
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16-18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16-16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1 3/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —
Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Tightening torque (Nm {kgm}) Face seal

Outer diam- Width
Nominal No. - Thread root
eter of pipe across flats
Range Target threads per inch, diameter (mm)
(mm) (mm)
type of thread (reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1 3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114
series engines to the torques shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})

6 10 ± 2 {1.02 ± 0.20}
8 24 ± 4 {2.45 ± 0.41}
10 43 ± 6 {4.38 ± 0.61}
12 77 ± 12 {7.85 ± 1.22}
14 —
00-48 WB93R-8
Tightening torque table for 102, 107, and 114 series engines (joint bolts)
a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to
the torque shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})

6 8 ± 2 {0.81 ± 0.20}
8 10 ± 2 {1.02 ± 0.20}
10 12 ± 2 {1.22 ± 0.20}
12 24 ± 4 {2.45 ± 0.41}
14 36 ± 5 {3.67 ± 0.51}
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe
thread (NPT))
a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107,
and 114 series engines to the torques shown in the table below.
Material of female screw In cast iron or steel In aluminum

Nominal thread size Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
1/16 15 ± 2 {1.53 ± 0.20} 5 ± 1 {0.51 ± 0.10}
1/8 20 ± 2 {2.04 ± 0.20 15 ± 2 {1.53 ± 0.20}
1/4 25 ± 3 {2.55 ± 0.31} 20 ± 2 {2.04 ± 0.20}
3/8 35 ± 4 {3.57 ± 0.41} 25 ± 3 {2.55 ± 0.31}
1/2 55 ± 6 {5.61 ± 0.61} 35 ± 4 {3.57 ± 0.41}
3/4 75 ± 8 {7.65 ± 0.82} 45 ± 5 {4.59 ± 0.51}
WB93R-8 00-49
(ALL-0360-005-A-00-A)
ABBREVIATION
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline
of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text
of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major

Abbrevia-
Actual word spelled out applicable machine (*1), Explanation
tion
or component/system)
This is a function that releases the brake
Travel and brake when the tires skid (tires are not rotated).
ABS Antilock Brake System
(HD, HM) This function applies the brake again when
the tires rotate.
Automatic Idling Set- This is a function that automatically sets
AISS Engine
ting System the idle speed.
This is a function that performs the steering
operations with a lever instead of using a
Advanced Joystick Steering
AJSS steering wheel. This function performs
Steering System (WA)
gear shifting and changing forward and
reverse direction.
This is a function that automatically oper-
Automatic Retarder Travel and brake ates the retarder with a constant braking
ARAC
Accelerator Control (HD, HM) force when letting go of the accelerator
pedal on the downhill.
ates the retarder to ensure that the
Automatic Retarder Travel and brake
ARSC machine speed does not accelerate above
Speed Control (HD, HM)
the speed set by the operator when letting
go of the accelerator pedal on the downhill.
This is a function that drives both wheels
Automatic Spin Regu- Travel and brake automatically using the optimum braking
ASR
lator (HD, HM) force when the tire on one side spins on
the soft ground surfaces.
A function or component that can be added
ATT Attachment Work equipment
to the standard specification.
This is a valve that bypasses a part of the
Brake cooling oil con- BRAKE brake cooling oil to reduce the load applied
BCV
trol valve (HD) to the hydraulic pump when the retarder is
not being used.
This is one of communication standards
Controller Area Net- Communication and elec-
CAN that are used in the network on the
work tronic control
machine.
This is a regulator valve that is installed to
Crankcase Depres-
CDR Engine KCCV ventilator. It is written as CDR valve
sion Regulator
and is not used independently.
00-50 WB93R-8

Abbrevia-
tion
This is a system that can actuate multiple
Closed-center Load actuators simultaneously regardless of the
CLSS Hydraulic system
Sensing System load (provides better combined operation
than OLSS).
This is a function that maintains optimum
fuel injection amount and fuel injection tim-
CRI Common Rail Injection Engine ing. This is performed the engine controller
which electronically controls supply pump,
common rail, and injector.
This is an electronic control device that
send the command to actuators using the
Electronic Control
ECM Electronic control system signals from the sensors on the machine
Module
so that the optimum actuation is per-
formed. (Same as ECU)
This is a proportional electromagnetic
Electronic Control Transmission valve that decreases the transmission
ECMV
Modulation Valve (D, HD, WA, etc) shock by gradually increasing oil pressure
for engaging clutch.
This is a device that ensures smooth
Electronically Con-
Travel high-speed travel by absorbing vibration of
ECSS trolled Suspension
(WA) machine during travel with hydraulic spring
System
effect of accumulator.
ECU Electronic Control Unit Electronic control system signals from the sensors on the machine
formed. (Same as ECM)
This is a function that recirculates a part of
Exhaust Gas Recircu- exhaust gas to combustion chamber, so
EGR Engine
lation that it reduces combustion temperature,
and reduces emission of NOx.
This is a function with which operator can
Equipment Manage- check information from each sensor on the
EMMS ment Monitoring Sys- Machine monitor machine (filter, oil replacement interval,
tem malfunctions on machine, failure code, and
failure history).
Electromagnetic proportional control This
Electromagnetic Pro-
EPC Hydraulic system is a mechanism with which actuators oper-
portional Control
ate in proportion to the current.
This structure protects the operator's head
from falling objects. (Falling object protec-
Falling Object Protec-
FOPS Cab and canopy tive structure)
tive Structure
This performance is standardized as ISO
3449.
Forward-Neu-
F-N-R Operation Forward - Neutral - Reverse
tral-Reverse
WB93R-8 00-51

Abbrevia-
tion
Communication
Global Positioning Sys- This system uses satellites to determine
GPS (KOMTRAX, KOMTRAX
tem the current location on the earth.
Plus)
Communication
Global Navigation Sat- This is a general term for system uses sat-
GNSS (KOMTRAX, KOMTRAX
ellite System ellites such as GPS, GALILEO, etc.
Plus)
This is a function that enables the machine
to turn without steering clutch by control-
Hydrostatic Steering Steering
HSS ling a difference in travel speed of right and
System (D Series)
left tracks with a combination of hydraulic
motor and bevel shaft.
Hydraulic transmission system that uses a
Hydro Static Transmis- Transmission combination of hydraulic pump and
HST
sion (D, WA) hydraulic motor without using gears for
stepless gear shifting.
A general term for the engineering and its
Information and Com- Communication and elec-
ICT socially applied technology of information
munication Technology tronic control
processing and communication.
This is a valve that adjusts the fuel intake
amount at the pump inlet in order to control
IMA Inlet Metering Actuator Engine
the supply pump fuel discharged volume.
(Same as IMV)
This is a device to detect the angle (or
Inertial Measurement
IMU Engine angular velocity) and acceleration of the 3
Unit
axes that control motions.
IMV Inlet Metering Valve Engine
the supply pump combustion discharged
volume. (Same as IMA)
This is a mechanism that burns the blowby
Komatsu Closed gas again by separating oil from blowby
KCCV Engine
Crankcase Ventilation gas and returning it to the intake side. It pri-
marily consists of filters.
This is a filter that captures soot in exhaust
Komatsu Catalyzed
KCSF Engine gas.
Soot Filter
It is built in to KDPF.
This is a catalyst that is used for purifying
Komatsu Diesel Oxida- exhaust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the
muffler.
This is a component that is used to purify
the exhaust gas. KDOC (catalyst) and
Komatsu Diesel Partic-
KDPF Engine KCSF (filter to capture soot) are built-in it.
ulate Filter
It is installed instead of the conventional
muffler.
00-52 WB93R-8

Abbrevia-
tion
This is a function that performs braking
with the optimum force and recovers the
Komatsu Traction Con- Travel and brake driving force of the wheels by actuating the
KTCS
trol System (HM) inter-axle differential lock when the wheels
runs idle while the machine travels on the
soft ground.
This is an image display equipment such
LCD Liquid Crystal Display Machine monitor as a monitor in which the liquid crystal ele-
ments are assembled.
This is a semiconductor element that emits
LED Light Emitting Diode Electronic parts light when the voltage is applied in forward
direction.
Local Interconnect Net- Communication and elec-
LIN that are used in the network on the
work tronic control
machine.
This is a function that detects differential
LS Load Sensing Hydraulic system pressure of pump, and controls discharged
volume corresponding to load.
Low Voltage Differen- Communication and elec-
LVDS that are used in the network on the
tial Signaling tronic control
machine.
This indicates engine intake air flow. This is
not used independently but is used as
MAF Mass Air Flow Engine
combined with sensor. Mass air flow sen-
sor can be called as MAF sensor.
This is a service that allows transmission
Multimedia Messaging and reception of short messages consist-
MMS Communication
Service ing of characters or voice or images
between cell phones.
This is a characteristic of electrical or
Electrical system, hydrau- hydraulic circuits. Circuit is normally closed
NC Normally Closed
lic system if it is not actuated, and it opens when it is
actuated.
Electrical system, hydrau- hydraulic circuits. Circuit is normally open if
NO Normally Open
lic system it is not actuated, and it closes when it is
actuated.
This is a hydraulic system that can operate
Open-center Load
OLSS Hydraulic system multiple actuators at the same time regard-
Sensing System
less of the load.
Pressure Compensa- This is a function that corrects the oil pres-
PC Hydraulic system
tion sure.
This is a function that electrically controls
Palm command con- Steering the engine and transmission in an optimal
PCCS
trol system (D Series) way with the controller instantly analyzing
data from levers, pedals, and dials.
WB93R-8 00-53

Abbrevia-
tion
Pre-stroke Control
PCV Engine amount at the pump inlet in order to control
Valve
fuel discharged volume of supply pump.
Proportional Pressure This is a system that operates actuators in
PPC Hydraulic system
Control proportion to the oil pressure.
Piston Pump and Hydraulic system

PPM Piston type hydraulic pump and motor.
Motor (D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
This is a function that performs hydraulic
Power Tilt and power Work equipment
PTP control of the tilt and pitch of the dozer
Pitch dozer (D Series)
blade of the bulldozer.
ROPS is a protective structure that
intended to protect the operator wearing
seat belt from suffering injury which may
Roll-Over Protective be caused if the cab is crushed when the
ROPS Cab and canopy
Structure machine rolls over. (Roll-over protective
structure)
3471 or ISO 12117-2.
This is an exhaust gas purifier using urea
water that converts nitrogen oxides (NOx)
Selective Catalytic into harmless nitrogen and water by oxida-
SCR Urea SCR system
Reduction tion-reduction reaction. It may also be
mentioned as exhaust gas purification cat-
alyst or part of the name of related devices.
Abbreviation for "International System of
Le Systeme Interna-
Units" It is the universal unit system and "a
SI tional d' Unites (Inter- Unit
single unit for a single quantity" is the basic
national unit system)
principle applied.
This is an actuator that consists of a sole-
noid and an iron core that is operated by
SOL Solenoid Electrical system
the magnetic force when the solenoid is
energized.
This is a protective structure that intended
to protect the operator wearing seat belt
from suffering injury which may be caused
Tip-Over Protective if the cab is crushed when the machine tips
TOPS Cab and canopy
Structure over. (Roll-over protective structure of
hydraulic excavator)
12117.
This is a solenoid valve that switches over
TWV 2-Way Valve Hydraulic system
direction of flow.
This is a turbocharger on which the
Variable Geometry
VGT Engine cross-section area of the exhaust passage
Turbocharger
is variable.
00-54 WB93R-8

Abbrevia-
tion
This is a function that finely controls the
Variable Horse Power maximum output of the machine so that
VHPC Engine control
Control high work efficiency and low fuel consump-
tion rate are both achieved.
*1: Code for applicable machine model D: Bulldozer

HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out

A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
WB93R-8 00-55

SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
00-56 WB93R-8
(ALL-2150-931-A-00-A)
CONVERSION TABLE
(Rev. 2012/10)
Method of using the conversion table

• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches

1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit
from millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches

1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm =
21.65 in.
Millimeters to inches
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 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
WB93R-8 00-57
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 2.847 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 52.91 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
l to U.S. Gallons
1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
00-58 WB93R-8
l to U.K. Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
WB93R-8 00-59
kg/cm² to lb/in2
1 kg/cm² = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
00-60 WB93R-8
Temperature
Conversion of Fahrenheit to Celsius

• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahr-
enheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Cel-
sius values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
WB93R-8 00-61
00-62 WB93R-8
WB93R-8
HYDRAULIC EXCAVATOR
WB93R-8

01 SPECIFICATION 01-
WB93R-8 01-1
01 SPECIFICATION
CONTENTS
CONTENTS .............................................................................................................................................. 01-2
SPECIFICATIONS .................................................................................................................................... 01-3

OVERALL DIMENSIONS....................................................................................................................... 01-3
WORKING RANGE DRAWINGS ........................................................................................................... 01-4
SPECIFICATIONS ................................................................................................................................. 01-6
WEIGHT TABLE .................................................................................................................................. 01-11
TABLE OF FUEL, COOLANT, AND LUBRICANTS............................................................................. 01-13
01-2 WB93R-8
01 SPECIFICATION
OVERALL DIMENSIONS
SPECIFICATIONS
OVERALL DIMENSIONS
RKA79660
Item Unit Measurement

A Overall length mm 5990
Overall height (standard boom) 3750
B mm
Overall height (telescopic arm) 3820
C Overall width mm 2340
D Wheel base mm 2175
E Loader bucket reach mm 2190
F Backhoe reach mm 1625
G Cab height mm 2900
H Loader bucket height mm 200
WB93R-8 01-3
01 SPECIFICATION
WORKING RANGE DRAWINGS
RKA79670

A Loader bucket reach (in transport) mm 2190
B Max. dumping reach (45°) mm 725
C Max. height mm 4300
D Hinge pin height mm 3430
E Forks loading max. height mm 3180
F Max. dumping height mm 2580
G Digging depth mm 140
H Wheel base mm 2175
I Backhoe swing centre distance mm 1325
Dumping height SAE mm 3720
Max. dumping height mm 4170
L
- with telescopic arm SAE mm 4550
- with telescopic arm max. mm 4890
Max. digging height mm 5790
M
- with telescopic arm mm 6415
01-4 WB93R-8
01 SPECIFICATION

Digging depth SAE mm 4260
N
Reach at max. height mm 2795
O
Max. reach from swing centre mm 5755
P
Max. digging depth mm 4980
Q
Digging reach mm 1970
R
WB93R-8 01-5
01 SPECIFICATION
SPECIFICATIONS
SPECIFICATIONS
Machine model WB93R-8
Unit
Serial No. F80004 and up
Operating mass (ISO 6016) 9500
kg
Total mass (for Italian and German homologation) from 7590 to 9000
Loader bucket capacity (SAE 7546) 1.03
m³
Backhoe bucket capacity (SAE 7451) 0.19
Performance
Unit
Serial No F80004 and up
Loader working ranges
Max. digging height mm 140
Max. dumping height mm 2580
Max. dumping reach (45°) mm 725
Forks loading max. height mm 3180
Backhoe working ranges
Max. digging depth mm 4980 [6050]
Max. vertical wall digging depth mm -
Max. digging reach mm 5755 [6770]
Max. digging reach at ground level mm 5705 [6725]
Max. digging height mm 5790 [6415]
Max. dumping height mm 4170 [4890]
Boom swing angle (Left/Right) deg. 90/90
Loader max lifting force kg 5300
Backhoe max. digging force kg 6500
[ ]: values valid with telescopic arm
Dimensions
Unit
Serial No F80004 and up
Overall lenght mm 5990
Overall height (standard mm 3750
Overall height (telescopic mm 3820
Overall width mm 2340
Wheel base mm 2175
Loader bucket reach mm 2190
Backhoe reach mm 1625
Cab height mm 2900
Loader bucket height mm 200
01-6 WB93R-8
01 SPECIFICATION
SPECIFICATIONS
Engine
Unit
SAA4D99E-1
4-cycle, water-cooled, in-line, vertical, and
Model —
direct injection type with variable geometry tur-
bocharger and air-cooled aftercooler
No. of cylinders - bore x stroke mm 4 - 99 x 110
Total piston displacement l {cc} 3.400 {3400}
Performance
Rated horsepower
SAE J1995 (gross) kW/{rpm} 75.0/ 2300
ISO 14396 kW/{rpm} 75.0/ 2300
ISO 9249/SAE J1349 (net) kW/{rpm} 75.0/ 2300
Max. torque Nm /rpm 430/1400

Fuel consumption ratio at rated horse- g/kWh 227,1
power
Max. speed with no load rpm 2430
Min. speed with no load rpm 950
Starting motor — 12 V, 4.2 kW
Alternator — 12V, 120A
Battery — 12V, 110 Ah
Radiator core type — Aluminum V-fin
Type of aftercooler core — Corrugated aluminum
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horse-
power measured on the basic engine unit. While, net denotes the value measured of an engine under the
condition essentially the same as that when it is installed on a machine.
WB93R-8 01-7
01 SPECIFICATION
SPECIFICATIONS
Undercarriage
Unit
Maximum load on front axle kg 4480
Maximum load on rear axle kg 7100
Inflation pressure for individual tyres
Front tyre pressure
• 12.5/80-18 PR14 (146A6) bar 3.60
• 320/80-R18 XMCL bar 3.20
• 340/80-18 POWER CL bar 3.00
Rear tyre pressure
• 16.9-28 RL4 PR12 (*) bar 2.60
• 440/80-R28 XMCL bar 2.80
• 480/80-26 POWER CL bar 3.00
Load capacity of individual front tyre (*1)
• 12.5/80-18 PR14 (146A6) kg 2385
• 320/80-R18 XMCL kg 2845
• 340/80-18 POWER CL kg 3010
Load capacity of individual rear tyre (*1)
• 16.9-28 RL4 PR12 kg 4010
• 440/80-R28 XMCL kg 4740
• 480/80-26 POWER CL kg 5360
(*1): load capacity referred to travel speed of 10 km/h
Power transmission
Unit
4WD Power shuttle
Hydraulic reverse change
Power transmission type -
4WD positive locking system
4 mechanical speed
Travel speed
• Forward (1st) 5.7
• Forward (2nd) 9.3
• Forward (3rd) 20.4
• Forward (4th) km/h 39.0
• Reverse (1st) 5.7
• Reverse (2nd) 9.3
• Reverse (3rd) 20.4
• Reverse (4th) 39.0
01-8 WB93R-8
01 SPECIFICATION
SPECIFICATIONS
Hydraulic system
Unit
Hydraulic pump
Type x quantity — Variable displacement piston type
Capacity cm³/rev 10 to 75
Set pressure
Work equipment MPa {kg/cm²} 24.5 {250}
Control valve
Type x quantity — 11-spool type x 1 pc.
Operating method — Mechanical and hydraulic assist type
Hydraulic tank — Box-shaped sealed type
Hydraulic oil filter — Tank return side
Hydraulic oil cooler — Air cooled

Unit
Loader arm cylinder
Model — Double-acting piston type
Cylinder bore mm 90
Piston rod diameter mm 50
Stroke mm 570
Max. distance between pins mm 1750
Min. distance between pins mm 1170
Loader bucket cylinder
Type — Double-acting piston type
Cylinder bore mm 70
Stroke mm 745

Unit
Outrigger cylinder
Cylinder bore mm 40
Stroke mm 635
WB93R-8 01-9
01 SPECIFICATION
SPECIFICATIONS

Unit
Backhoe boom swing cylinder
Cylinder bore mm 100
Stroke mm 230
Backhoe boom cylinder
Stroke mm 850
Backhoe side digging boom cylinder
Cylinder bore mm 85
Stroke mm 265
Backhoe arm cylinder
Stroke mm 700
Backhoe bucket cylinder
Cylinder bore mm 90
Stroke mm 765
01-10 WB93R-8
01 SPECIFICATION
WEIGHT TABLE
WEIGHT TABLE
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg

Engine assembly
Engine
Transmission 679
Hydraulic pump
Air filter
Radiator - exchanger 37
Hydraulic oil tank (empty) 10
Fuel tank (empty) 68
Front counterweight 372
Engine hood 32
Cabin (without seat) 595
Seat 34
Engine-gear box-pump group 740
Piston pump 36.8
Transmission 232
Front axle 295
Rear axle 435
Front wheel Rear wheel 65 163
Loader work equipment

• Loader arm 313
• Loader bucket 436
• Loader fulcrum levers 13x4
• Loader tilt levers 32.5x2
• Loader arm cylinder 46x2
• Loader bucket cylinder 35x2
Backhoe work equipment (assembly)
• with standard boom and arm 750
• with standard boom and telescopic arm 1030
• with side digging boom and arm 902
• with side digging boom and telescopic arm 1156
Backhoe boom 248
Backhoe arm 213
Boom swing bracket 162.5
Sliding frame 246
Control valve (8-spool) 42.1
Control valve (11-spool) 47.5
Backhoe telescopic arm 472
Outriggers 39x2
WB93R-8 01-11
01 SPECIFICATION
WEIGHT TABLE

Boom cylinder 87.5
Arm cylinder 67
Bucket cylinder 52.5
Outriggers cylinder 27.5x2
Swing cylinder 34x2
01-12 WB93R-8
01 SPECIFICATION
TABLE OF FUEL, COOLANT, AND LUBRICANTS

a For details of notes (Note 1, Note 2...) in the table, see the Operation and Maintenance Manual.
Ambient temperature,
Reservoir Fluid type degrees Celsius Recommended Komatsu Fluids
Min Max
Engine oil pan Engine oil -20°C 45°C SHELL RIMULA R5 LE (Note.1)
Transmission Transmission oil -20°C 45°C OIL GM DEXRON® IID (Note.2)
UTTO FLUID 68F/100
Front axle Transmission oil -20°C 45°C SAE J1306: 80W-80
MIL-L-2105 D
UTTO FLUID 68F/100
Rear axle Transmission oil -20°C 45°C SAE J1306: 80W-90
MIL-L-2105 D
HO46-HM
Hydraulic system Hydraulic oil -20°C 50°C
(KES)
Hydraulic system with
Synthetic biode- B046-G4
synthetic biodegrada- -20°C 40°C
gradable oil (KES)
ble oil
G2-TE
Hyper grease -20°C 50°C
(KES) (Note.3)
Grease fitting
G2-LI
Lithium EP grease -20°C 50°C
(KES)
Non-Amine Engine
AF-NAC
Cooling system Coolant -30°C 50°C
(KES) (Note.4)
(AF-NAC)
-30°C 20°C
Fuel tank Diesel fuel EN 590
-10°C 50°C
DEF tank DEF -30°C 50°C DEF (Note.5)
Unit: l
WB93R-8
Applicable part
Specified capacity Refill capacity
Engine oil pan 11 8
Transmission 18 18
Front and rear axles differential (each) 7 7
Front and rear axles final reduction gears
0.8 0.8
(each)
Brake system 0.8 0.8
Hydraulic oil system 110 41.5
Cooling system 12 -
Fuel tank 135 -
DEF tank 16.5 -
WB93R-8 01-13
01 SPECIFICATION
01-14 WB93R-8
WB93R-8
HYDRAULIC EXCAVATOR
WB93R-8

10 STRUCTURE AND FUNCTION 01-
WB93R-8 10-1
CONTENTS
CONTENTS
CONTENTS ............................................................................................................................................. 10-2
ABBREVIATION LIST .............................................................................................................................. 10-3
UREA SCR SYSTEM ............................................................................................................................. 10-10

LAYOUT DRAWING OF UREA SCR SYSTEM .................................................................................. 10-10
INDUCEMENT STRATEGY ................................................................................................................ 10-17
COMPONENT PARTS OF UREA SCR SYSTEM .............................................................................. 10-24
DEF TANK .......................................................................................................................................... 10-28
DEF PUMP .......................................................................................................................................... 10-30
DEF INJECTOR .................................................................................................................................. 10-31
DEF HOSE .......................................................................................................................................... 10-32
DEF TANK HEATING VALVE ............................................................................................................. 10-33
POWER TRAIN ...................................................................................................................................... 10-34

POWER TRAIN DESCRIPTION ......................................................................................................... 10-34
UNDERCARRIAGE AND FRAME ......................................................................................................... 10-37

4WD TRANSMISION .......................................................................................................................... 10-37
FRONT AXLE ...................................................................................................................................... 10-47
REAR AXLE ........................................................................................................................................ 10-51
HYDRAULIC SYSTEM ........................................................................................................................... 10-56

LAYOUT DRAWING OF HYDRAULIC SYSTEM ................................................................................ 10-56
HYDRAULIC TANK ............................................................................................................................. 10-58
HYDRAULIC PUMP ............................................................................................................................ 10-59
CONTROL VALVE - 9-spool loader and backhoe valves ................................................................... 10-73
CONTROL VALVE - 11-spool loader and backhoe valves ................................................................. 10-84
CLSS ................................................................................................................................................... 10-95
WORK EQUIPMENT SYSTEM ............................................................................................................ 10-115

LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ................................................................. 10-115
LOADER WORK EQUIPMENT PPC VALVE .................................................................................... 10-118
OUTRIGGER PPC VALVE ............................................................................................................... 10-131
STEERING UNIT .............................................................................................................................. 10-136
BRAKE PUMP ................................................................................................................................... 10-137
SOLENOID VALVE ........................................................................................................................... 10-138
ACCUMULATOR .............................................................................................................................. 10-140
HOLDING VALVE ............................................................................................................................. 10-141
WORK EQUIPMENT ............................................................................................................................ 10-146

LOADER WORK EQUIPMENT ......................................................................................................... 10-146
BACKHOE WORK EQUIPMENT ...................................................................................................... 10-147
10-2 WB93R-8
ABBREVIATION LIST
ABBREVIATION LIST
of the meaning.

Abbrevia-
tion
the tires rotate.
AISS Engine
reverse direction.
ARAC
ASR
BCV
not being used.
work tronic control
machine.
Crankcase Depres-
sion Regulator
WB93R-8 10-3
ABBREVIATION LIST

Abbrevia-
tion
than OLSS).
Electronic Control
Module
ECMV
Electronically Con-
System
EGR Engine
failure history).
portional Control
tive Structure
3449.
Forward-Neu-
tral-Reverse
10-4 WB93R-8
ABBREVIATION LIST

Abbrevia-
tion
Communication
Plus)
Communication
Plus)
System (D Series)
HST
(Same as IMV)
Unit
KCCV Engine
Komatsu Catalyzed
KCSF Engine gas.
Soot Filter
KDOC Engine
muffler.
ulate Filter
muffler.
WB93R-8 10-5
ABBREVIATION LIST

Abbrevia-
tion
KTCS
soft ground.
direction.
work tronic control
machine.
machine.
MMS Communication
NC Normally Closed
actuated.
NO Normally Open
actuated.
Open-center Load
Sensing System
less of the load.
PC Hydraulic system
tion sure.
PCCS
10-6 WB93R-8
ABBREVIATION LIST

Abbrevia-
tion
Pre-stroke Control
Valve

Motor (D, PC, etc)
ROPS Cab and canopy
structure)
3471 or ISO 12117-2.
SCR Urea SCR system
Le Systeme Interna-
principle applied.
energized.
TOPS Cab and canopy
12117.
direction of flow.
Variable Geometry
Turbocharger
is variable.
WB93R-8 10-7
ABBREVIATION LIST

Abbrevia-
tion
VHPC Engine control

HD: Dump truck
WA: Wheel loader
10-8 WB93R-8
ABBREVIATION LIST

A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
WB93R-8 10-9
UREA SCR SYSTEM
UREA SCR SYSTEM

LAYOUT DRAWING OF UREA SCR SYSTEM
2
2
3
1
VIEW Z
4
7
6
9
5
RKA82110
1. DEF pressure hose

2. KDOC (include DEF mixing tube)
3. DEF injector
4. SCR assembly
5. DEF tank heating valve
6. DEF tank coolant outlet hose
7. DEF tank coolant inlet hose
8. DEF tank
9. DEF pump
10-10 WB93R-8
UREA SCR SYSTEM
13
12
13 12
11
10
RKA82120
10. DEF tank sensor

11. DEF filler port
12. DEF return hose
13. DEF suction hose
WB93R-8 10-11
UREA SCR SYSTEM
14 16
14
15
VIEW A
17
18
17
19
RKA82130
14. Turbocharger outlet NOx sensor

15. SCR inlet temperature sensor
16. KDOC inlet temperature sensor
17. SCR outlet NOx sensor
18. SCR outlet temperature sensor
19. NH3 sensor
10-12 WB93R-8
UREA SCR SYSTEM
UREA SCR SYSTEM DIAGRAM

1
5 12
4
2 6 10 13 14
7 9 11 15 16 18 19
3
C B
8
17 20
21
26 23
28
A
B
27
30
29 24
31
25
22
RKA82140
A: Coolant inlet (from engine block) 15. SCR temperature sensor

B: Coolant outlet 16. SCR outlet NOx sensor
C: Coolant return (to engine block)
17. SCR outlet NOx sensor controller
1. Mass air flow and temperature sensor 18. SCR outlet temperature sensor
2. Engine 19. Ammonia sensor
3. Engine controller 20. Ammonia sensor controller
4. Exhaust throttle valve 21. Smart sensor
5. KDOC 22. DEF system
6. KDOC unit 23. DEF tank heating valve
7. Turbocharger outlet NOx sensor 24. DEF tank
8. Turbocharger outlet NOx sensor controller 25. DEF tank sensor
9. KDOC temperature sensor controller 26. DEF suction line
10. DEF mixing tube 27. DEF return line
11. DEF injector 28. DEF pressure line
12. SCR assembly 29. DEF pump
13. Upstream SCR catalyst 30. DEF line heater relay
14. Downstream SCR catalyst and ammonia oxi- 31. Machine monitor
dation catalyst (integrated type)
WB93R-8 10-13
UREA SCR SYSTEM
FUNCTION OF UREA SCR SYSTEM
5
CO N2
1 NOx H2O
HC CO2
6 7 8
2
4
3
A4P16366
1. Engine 5. DEF injector

2. Engine controller 6. KDOC
3. DEF pump 7. SCR catalyst
4. DEF tank 8. Downstream SCR catalyst and ammonia oxi-
dation catalyst (integrated type)
• Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harm-
less nitrogen and water.
• By spraying DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and the
ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.
FUNCTION OF DEF SYSTEM
5 1.DEF tank
2.DEF suction hose
6
3.DEF pump
4 3A: Flow control valve
3B: Pump
3C: DEF filter
3D: Pressure sensor
2
4.DEF return hose
1 5.DEF pressure hose
6.DEF injector
3A 3D
P
3C
3B 3
A4P14892
10-14 WB93R-8
UREA SCR SYSTEM
• DEF system consists of DEF tank (1), DEF hoses (2), (4), (5), DEF pump (3), and DEF injector (6).
• The DEF system is a part of the Komatsu Urea SCR system and its function is to provide DEF into the
SCR Catalyst Assembly.
• However, the comprising devices, such as the DEF pump, may not start functioning till certain conditions
are fulfilled.
• The DEF system has heating systems to thaw and prevent DEF from freezing because DEF freezes at
-11 °C.
FUNCTION OF DEF INJECTION SYSTEM

• The DEF pump pressurizes DEF and delivers it into the DEF mixing tube through the DEF injector.
• The amount of DEF injection is controlled by the Engine Controller.
• The amount of DEF injection is calculated based on the information of the turbocharger outlet NOx sen-
sor, the SCR catalyst temperature sensor, the SCR outlet temperature sensor, the ammonia sensor, the
SCR outlet NOx sensor and the exhaust gas flow rate.
• DEF injection is also controlled by the system temperature because Urea SCR systems are not effective
in low temperature. For the monitoring of the system temperature, the KDPF outlet temperature sensor
is used in addition to the SCR temperature sensors.
• If any abnormality is detected in any of the sensors that are used for the calculation of the amount of
DEF injection and the monitoring of the system temperature, the Engine Controller commands termina-
tion of DEF injection. When this occurs, alerts will be activated and failure codes will be registered.
• Some abnormalities may cause large amount of urea precipitation inside the DEF mixing tube and result
in deposit of urea on the inner surfaces. If it continues and urea deposit accumulates DEF injection can
be blocked at the DEF injector or the exhaust gas flow can be choked in the passages.
WB93R-8 10-15
UREA SCR SYSTEM
FUNCTION OF PURGE SYSTEM

• The DEF purging is incorporated to purge remaining DEF in the DEF injector, DEF hoses and the DEF
pump to prevent DEF from solidifying inside by precipitation or freezing.
• The DEF purging is activated automatically when the engine is shut down or the ambient temperature
falls so low that the heating systems is not capable of maintaining fluidity of DEF.
• In the case of the DEF purging of the engine shutdown, the purging operation continues several minutes
after the engine stops. Once the purging operation completes, the Engine Controller shuts itself down
automatically.
a Do not turn the battery disconnect switch to the OFF position till the System Operating Lamp in the bat-
tery box goes out. The System Operating Lamp will go out when the system shuts itself down after the
purging operation completes.
10-16 WB93R-8
UREA SCR SYSTEM
INDUCEMENT STRATEGY
• The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions
control system.
• Inducement strategy is a control action to ensure prompt correction of various failures in the engine
emissions control system. It requires actions to limit engine performance and defines required indication
such as warning lamps and messages, as well as alarms while the control actions are imposed.
• The categories of abnormalities that have triggered Inducement are displayed on the “Aftertreatment
system” screen of the machine monitor.
INDUCEMENT STRATEGY WHEN THE DEF LEVEL IN THE TANK BECOMES LOW
• When the DEF level in the tank becomes low, DEF level caution lamp on the machine monitor lights up,
the audible alert sounds, the action level is displayed and inducement strategy including engine power
deration is activated.
• The Inducement strategy progresses in 3 levels from Warning, Low-Level Inducement, and Severe
Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of DEF in
the DEF tank.
• The Inducement strategy status can be checked on “Aftertreatment system” screen of the user menu.
• The table shows warning indications and engine power deration by each Inducement strategy status.
DEF level Machine monitor

(*1) Message of Tone of audi- Engine dera-
Status DEF level Activated fail-
(DEF level SCR Infor- ble alert tion (*3)
gauge) caution lamp ure code (*2)
mation (Action level)
Red #T0215
1: DEF low
1 Warning < 10% level warn- No sound SCRCtl_War No deration
ing appears. nStgy_WarnL
vl1
Red
65% Torque
#T0216 reduction
Low-Level 2: Engine
60% engine
Inducement power is
2 < 5% Red Intermittently SCRCtl_War speed
(Inducement under dera-
nStgy_Warn ramped in
1) tion
Lvl2 within
40 minutes
Red
Torque:
100%
Machine Idle
Severe 0% #T0301
3: Engine is 50%
Inducement (No suction
3 running at Continuously Engine com-
(Inducement of DEF possi- Red UDCRdcA-
low idle. manded to
2) ble) gRmn
Low idle
within 30
minutes
*1: It is shown the value of Monitoring ID 19110: "DEF Level".
WB93R-8 10-17
UREA SCR SYSTEM
*2: These failure codes are displayed on "Current Abnormality" in the operator mode, or "Abnormality Record"
in the service mode. For the failure codes, see TROUBLESHOOTING,
"TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM".
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio
from the rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE DEF QUALITY

OR IN THE UREA SCR SYSTEM DEVICES
• DEF system caution lamp lights up on machine monitor, and an action level is displayed when an abnor-
mality occurs in quality in DEF or in urea SCR system. In addition to the caution by the DEF system cau-
tion lamp, alarm sounds as time passes after the abnormality occurred. Then, inducement strategy
starts so that the engine output is lowered.
• The Inducement strategy status and the categories of abnormalities can be checked on the “Aftertreat-
ment System” screen of the machine monitor.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
Failure
DE F sys-
Elapsed Failure code for Engine der-
Status Message of tem cau- Tone of
time (*1) code for Induce- ation (*5)
SCR Infor- tion lamp audible
abnormal- ment strat-
mation (Action alert
ity (*2) egy status
level)
(*3)
Yellow
#T0266
1: Please
inspect and
SysDiag-
1 Warning 50 minutes maintain No sound No deration
IndcRgntQ-
the
lyWarn
machine.
Red
Torque
reduction:
2: Engine #T0264
Moderate 65%
3 hours power is
Induce- Long inter- Engine
2 and 30 under SysDiag-
ment Red mittently speed 60%
minutes heavy der- IndcRgntQl
(2nd step) ramped in
ation yLvl1
within 40
minutes
Red
#T0265 Torque:
Severe
3: Engine is 50 % and
induce- Until repair- Continuous
3 running at SysDiag- Low idle
ment (Final ing Red ly
low idle IndcRgntQl engine
step)
yLvl3 speed
10-18 WB93R-8
UREA SCR SYSTEM
*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting
“Warning” stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record”
in the service mode. The failure code shown here is an example of failure code which is displayed on the
machine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING,
"TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM".
*3: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record”
in the service mode.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYSTEM

BY FAILURE TAMPERING DETECTION
• The Inducement strategy is same if Inducement is triggered by abnormalities in the EGR system.
Although the 3 warning indications are different and engine power deration (over 25% torque reduction)
starts form that of "Warning".
Machine monitor
Failure Failure
Elapsed code for code for Engine der-
Status Message of Tone of
time (*1) Caution abnormal- Induce- ation (*4)
SCR Infor- audible
lamp ity (*2) ment strat-
mation alert
(Action egy status
level) (*3)
Red (*5)
1: Please #T0260
inspect and Long inter- Torque:
1 Warning 25 minutes maintain mittently SysDiag- over 25%
Red (*5)
SCR sys- (*5) IndcEGRV- (*5)
tem. lvWarn
Red (*5)
#T0259 Torque
Red #T0056
Moderate 3: Engine reduction
Induce- 3 hours power is Long inter- 50%
2
ment - 2nd and 30min under dera- mittently SysDiagInd ramped in
Step tion. within 30
cEGRVlvLvl
minutes
Red 1
WB93R-8 10-19
UREA SCR SYSTEM
Machine monitor
Failure Failure
SCR Infor- audible
mation alert
(Action egy status
level) (*3)
Red
4: Engine Red
Severe
power is
Induce- Until repair Continu- Torque:
3 under
ment - ing ously over 50%
heavy der-
Final step
ation.
Red
"Warning" stage. Final Inducement is not cleared till abnormality is repaired.
machine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING,
"TROUBLESHOOTING POINTS FOR EGR SYSTEM".
*5: Values diversify with other EGR-related errors.
10-20 WB93R-8
UREA SCR SYSTEM
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE SCR SYSTEM BY

FAILURE TAMPERING DETECTION
• The Inducement strategy is same if Inducement is triggered by abnormalities in the SCR system.
Although the 3 warning indications are different and engine power deration (over 25% torque reduction)
starts form that of "Warning".
Machine monitor
Failure Failure
SCR Infor- audible
mation alert
(Action egy status
level) (*3)
Red
#T0263
SysDiag-
1: Please Red IndcIn-
inspect and Long inter- trDosWarn Torque:
1 Warning 25 minutes maintain mittently over 25%
SCR sys- (*5) #T0269 (*5)
tem. SysDiag-
Red IndcTam-
prgWarn
Red (*5)
#T0261
Torque
SysDiagInd
Red reduction
cIntrDosLvl
Moderate 3: Engine 65%, 60%
1
Induce- power is Long inter- engine
2 2 hours
ment - 2nd under dera- mittently speed
#T0267
Step tion. ramped in
SysDiagInd
within 40
Red cTamprgLv
minutes
l1
WB93R-8 10-21
UREA SCR SYSTEM
Machine monitor
Failure Failure
SCR Infor- audible
mation alert
(Action egy status
level) (*3)
Red
#T0262
SysDiagInd
4: Engine Red cIntrDosLvl 50%
Severe
power is 3 machine
Induce- Continu-
3 4 hours under idle
ment - ously
heavy der- #T0268
Final step
ation. SysDiagInd Max torque
Red cTamprgLv
l3
"Warning" stage. Final Inducement is not cleared till abnormality is repaired.
machine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, "TROUBLE-
SHOOTING POINTS FOR UREA SCR SYSTEM".
*5: Values diversify with other SCR-related errors.
SCR SYSTEM TAMPERING INDUCEMENT STRATEGY

• Vehicle reach final inducement after 4 hours of operation after failure detection.
• Three full power restarts (validation restarts for healing) part of 4 hours time frame.
• Validation restarts.
NOTICE
• Validation restart is available only for failures that need heated up after treatment system or
active dosing – not for electrical failures, DEF quality or DEF level.
• Validation restarts allowed any time after detection.
• Validation restarts are key cycle locked to avoid unintended activation.
• Limited to 30 minutes each.
• After expiring of the 30 minutes is the engine immediately ramped down to previous level of inducement.
1. In order to heal the inducement the driver can use the validation restart phase.
This phase allow to get full power at every engine restart.
The legislation allows to use the validation restart phase only 3 times within 40 hours.
10-22 WB93R-8
UREA SCR SYSTEM
2. When validation mode is activated: full power restart in case of inducement activation Monitor has mes-
sage #T0272.
3. Validation mode is a deactivation of inducement for several (default=three) full power restart.
4. During Validation mode, the vehicle: full power for several minutes (default=30) to allow detection of
replaced component or elimination of a previous active fault.
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40 HOURS

• The Urea SCR system continuously monitors its operation conditions and stores information on inappro-
priate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, "Abnormality Counter"
("Abnormality Counter" is also called “Repeated offender”). "Abnormality Counter" is required by the
authorities. The abnormality counting spans 40 hours and it monitors the abnormalities that trigger
Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected a second time within 40 hours inducement is activated
and locked with the last level reached (Repeated offender).
REMARK
• Repeated offender do not apply to DEF level failure
• Abnormality record of Service menu shows the error message #T0270
• If a third abnormality/abnormalities is detected within 40 hours inducement is locked and can be reset
only with the Service Tool.
REMARK
• Abnormality record of Service menu shows the error message #T0271
• To unlock the inducement you need to use “Inducement counter reset” routine with the diagnostic
tool. This will be also reset the validation restart counters.
WB93R-8 10-23
UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM

KDOC
Structure of KDOC and DEF mixing tube
3 5
7 6
RKA82150
A: Exhaust gas inlet (from turbocharger)

B: Exhaust gas outlet (to SCR)
1. KDOC assembly (includes DEF mixing tube)

2. DEF injector
3. DEF mixing tube
4. Mixer
5. KDOC
6. Exhaust gas inlet (from turbocharger)
7. Exhaust gas outlet (to SCR)
Structure
• KDOC assembly consists of the inlet pipe (6) which leads the exhaust gas from the engine, the DEF mix-
ing tube (3) mixes DEF injected from DEF injector with exhaust gas, the KDOC (7) which stores the oxi-
dation catalyst, and the outlet pipe (5) which discharges the exhaust gas. All of these parts are welded
as a unit.
• KDOC (7) consists of ceramic honeycomb equipped with the oxidation catalyst.
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the
ceramics under the vibration condition of the engine and machine body.
10-24 WB93R-8
UREA SCR SYSTEM
Function of KDOC
• KDOC is installed in order to conform to the severe regulations of exhaust gas. KDOC has a function of
oxidization of SOF (soluble organic fraction in particles of exhaust gas), HC (unburned combustible con-
tent), and CO (carbon monoxide) to clean the exhaust gas.
• Function of oxidation catalyst:
1. Oxidizes SOF (soluble organic fraction in particles of exhaust gas)
2. Oxidizes HC (unburned combustible content)
3. Oxidizes CO (carbon monoxide)
Function of DEF mixing tube

It mixes DEF injected from DEF injector with exhaust gas, and decomposes it to ammonia which is needed
to purge NOx from SCR assembly.
WB93R-8 10-25
UREA SCR SYSTEM
SCR ASSEMBLY
Structure of SCR assembly
2 6
1
3 5
7
RKA82160
1. Hanger plate
2. SCR temperature sensor
3. SCR body
4. SCR outlet NOx sensor
5. SCR outlet NOx sensor controller
6. SCR outlet temperature sensor
7. Ammonia sensor controller
8. Ammonia sensor
10-26 WB93R-8
UREA SCR SYSTEM
9
11
12
10
13
RKA82170
9. SCR exhaust gas inlet (from KDOC)

10. Diffuser partition
11. Upstream SCR catalyst
12. Downstream SCR catalyst and ammonia oxidation catalyst (integrated type)
13. SCR exhaust gas outlet
• SCR assembly consists of upstream SCR catalyst (11), downstream SCR catalyst, ammonia oxidation
catalyst (integrated type) (12).
• Ammonia oxidation catalyst (a part of 12) oxidizes ammonia to water and nitrogen with ammonia oxida-
tion catalyst (a part of 12) to prevent ammonia which is supplied to SCR assembly from being released
out because SCR catalyst (a part of 12, 11) cannot completely consume it.
• Each 1 piece of SCR temperature sensor (2), SCR outlet temperature sensor (6), ammonia sensor (8),
and SCR outlet NOx sensor (5) are installed. These sensors are usable for various troubleshooting,
such as they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst
properly functions or not.
• SCR catalyst (a part of 12, 11) uses the ceramic honeycomb.
WB93R-8 10-27
UREA SCR SYSTEM
DEF TANK
Structure of DEF tank
B D
E 5
1
3 6
RKA82180
A: Coolant inlet
B: Coolant outlet
C: To DEF pump
D: From DEF pump
E: To breather
1. Sensor flange assembly
2. DEF filler cap
3. Sight gauge
4. DEF tank
5. DEF tank sensor
6. DEF tank filter
7. Drain plug
10-28 WB93R-8
UREA SCR SYSTEM
DEF TANK SENSOR

Structure of DEF tank sensor
1. Connector 3. Temperature sensing part

2. Concentration Sensing part 4. Level sensing part
Function of DEF tank sensor

• This sensor is installed to DEF tank and outputs DEF level, DEF concentration, and DEF temperature
through CAN communication.
• DEF level and DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, DEF level and DEF concentration are not measured.
WB93R-8 10-29
UREA SCR SYSTEM
DEF PUMP
Structure of DEF pump
1
A: Suction from DEF tank
B: Return to DEF tank 2
C: Pressurized sending to DEF injector
A
1. DEF pump
C
2. DEF inlet connector (color is BLACK)
4
3. DEF backflow connector (color is NATURAL) B
4. DEF outlet connector (color is BLACK)
5. Electric connector 3
6. DEF filter cap
7. DEF filter (built-in)
5
7 6
RKA82190
a The followings are built-in:

• the filter to collect the dust in DEF
• the valve to switch the flow direction when purging
• the heater to thaw DEF when it is frozen.
• It purges DEF from DEF tank, pressurizes it to 470-530 kPa {4.80-5.30 kg/cm²} and sends it to DEF
injector.
• To prevent wrong connection of connectors, the backflow connector is white and can be distinguished
from others. The sizes of inlet connector and outlet connector are different and they cannot be con-
nected each other.
DEF
injector
Purge
30-60 kPa
pump
Main pump Main filter
Pressure
15 kPa 30-60 kPa Pressure sensor
damper
Engine
M controller
DEF
tank
RKA82200
10-30 WB93R-8
UREA SCR SYSTEM
DEF INJECTOR
Structure of DEF injector
A: Pressurized sending from DEF pump

B: Coolant inlet
C: Coolant outlet
1
1. DEF injector
2. DEF inlet connector
3
3. Coolant inlet connector
4. Coolant outlet connector
5. Electric connector
2
5
RKA82210
Function of DEF injector

• It injects DEF which is pressurized by DEF pump into DEF mixing tube.
• The injection amount is controlled by the valve opening or closing time while the pressure is constant.
• It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.
Operation of DEF injector
Principle of injection of the injector is described.

Following figure shows the state of injection.
1. Engine controller sends the electrical signal to
control DEF injector.
2. Solenoid (4) moves seal ball (2), and seal ball
(2) leaves from injection port (1) to make open-
ing state. Pressurized DEF by DEF pump is
injected.
3. When the electrical signal is not sent, seal ball
(2) closes injection port (1) with spring force
(3), so DEF is not injected.
WB93R-8 10-31
UREA SCR SYSTEM
DEF HOSE
Structure of DEF hose
1. Connector 5. Insulation tape

2. Housing 6. Heating wire
3. Coupling 7. Nylon tube
4. Corrugated tube
• It is used as DEF piping between DEF tank and DEF pump or between DEF pump and DEF injector.
• The shape of the engaging portion between DEF tank and DEF pump or DEF injector pin is based on 3/8
inches or 5/16 inches of SAE J2044. It can be disconnected or connected with one touch.
• There are 2 types of hose end shape such as straight shape and 90 deg. elbow shape.
• There are 2 types of nylon tubes of its outside diameter 5 mm and 8 mm. Choose the suitable one
according to the model and the part to use.
Function of DEF hose

• In the cold weather, the specified current flows in the heating wire immediately after the engine is
started. It heats nylon tube and thaws DEF which has frozen in the nylon tube.
• It also keeps temperature constant to prevent DEF from freezing again while machine is operated.
10-32 WB93R-8
UREA SCR SYSTEM
DEF TANK HEATING VALVE

Structure of DEF tank heating valve
A
C
B
RKA82220
A: Engine coolant inlet

B: Engine coolant outlet (to DEF injector)
C: Engine coolant outlet (to DEF tank)
1. Solenoid
Function of DEF tank heating valve

• DEF tank heating valve is a 3-way valve, switching the engine coolant DEF injector or to DEF tank when
DEF tank needs to be thaw DEF tank.
• Switching of the valve is done by solenoid (1).
• The opening position of valve is fixed and the control is only for selecting outlet B or C.
• When the solenoid (1) is de-energized, the valve select outlet B.
• When the solenoid (1) is energized, the valve select outlet C.
WB93R-8 10-33
POWER TRAIN
POWER TRAIN
POWER TRAIN DESCRIPTION
Description
1 2 3
5 7 8 6 RKA82240
• The engine (1) power is transmitted through the flywheel to the torque converter (2).
• The torque converter (2) uses hydraulic oil to convert the torque transmitted by the engine (1) into driving
power.
• The converter (2) transmits the movement to the transmission (3) drive shaft and to the hydraulic pump
(4) drive shaft.
• The transmission (3) has two clutches that can be selected by the operator using the FNR lever.
• The transmission is provided with 4 mechanical gears and thus the transmission has 4 forward speed
and 4 reverse speed.
• The driving power is transmitted from the transmission flanges (3) to the front (5) and rear (6) axles
through the front (7) and rear (8) propeller shafts.
• The driving power transmitted to the front (5) and rear (6) axles is reduced by the differentials and then
transmitted to the planetary gear through the differential shafts.
10-34 WB93R-8
POWER TRAIN
Overview
2 7 10
RKA82230
WB93R-8 10-35
POWER TRAIN
1. Diesel engine
2. Torque converter
3. Transmission
4. Main hydraulic pump
5. Front axle
6. Rear axle
7. Front propeller shaft
8. Rear propeller shaft
9. Rear wheels
10. Front wheels
Specifications
Front axle Rear axle
Mechanica
l gears Transmis- Transmis-
Differential Planetary Total Differential Planetary Total
sion sion
1st gear 5.603 82.768 5.603 92.450
2nd gear 3.480 51.407 3.480 57.420
2.462 6.000 2.750 6.400
3rd gear 1.584 23.399 1.584 26.136
4th gear 0.793 11.714 0.793 13.085
10-36 WB93R-8
UNDERCARRIAGE AND FRAME

4WD TRANSMISION
Mechanical diagram
2 Z=29 Z=27 3 5 4
Z=27
1
6
Axis D Z=29
Axis A
Axis B Z=39
Z=28
Axis C
7
Z=17
Z=33
Z=12
Axis E
Axis D Z=23
Z=44
Axis A
Z=50 Z=45
9
8 Z=36
Axis B
Axis C
Forward
Reverse
1st speed
2nd speed
Axis E
3rd speed
4th speed
Front PTO
RKA82250
1. Engine
2. Torque convertor
3. Forward clutch
4. Mechanical transmission
5. Reverse clutch
6. Hydraulic pump
7. Rear flange
8. 4WD clutch
9. Front flange
WB93R-8 10-37
10-38
PARTS NOT SUPPLIED
BY CARRARO
0.5÷3.5 bar
11 22 ON FWD/RVS CLUTCH POSITION
10
LOCATED IN THE PUMP 9
OPENING 3.5÷5.5 bar t° 0.5÷5,0 bar
ON NEUTRAL CLUTCH POSITION
HOSE HOSE
3 TEETH REMOVED ON
8 TORQUE CONVERTER
2. Transmission pump
(~10 mm 2)
3. Spin-on filter (10 μm)

1. Suction filter (250 μm)
TRANSMISSION CONTROL VALVE UNIT
Hydraulic circuit diagram
11÷13.0 bar BEARING
29 13 24
21
16
15
14
0.5÷9.0 bar FWD
2nd GEAR
REV
5.
6.
4.
28 1st GEAR
4
12 23
REAR AXLE 20
UNIT 17
11÷13.0 bar
4th GEAR
25
11÷13.0 bar
900 rpm 13.0÷14.0 bar BY-PASS

3rd GEAR
Oil relief valve

2200 rpm 13.0÷15.5 bar 3 OPENS AT
6 3.45 BAR
Pressure regulator
26 27
5 2
BEARING
LOCATED
4WD IN THE PUMP
OPENS AT 23 bar AIR
BREATHER 19
7
18
1
4WD disengagement solenoid valve

TRANSMISSION SUMP
RKA82260
WB93R-8
7. 4WD clutch 19. 4WD pressure check port

8. Torque converter relief valve 20. Torque converter pressure check port
9. Torque converter 21. Oil cooler back to shaft lubrication pressure
10. Oil cooler check port
11. Oil cooler back to shaft lubrication temperature 22. FWD/REV/HDL main pressure check port
thermostat port 23. Forward pressure check port
12. Flow divider 24. Reverse pressure check port
13. FWD/REV modulating valve 25. 1st,2nd,3rd,4th gear shaft lubrication
14. Modulation relief valve 26. Air breather
15. FWD/REV selection valve 27. Oil return
16. Forward clutch 28. Hydraulic differential lock device (rear axle)
17. Reverse clutch 29. Hydraulic differential lock solenoid valve
18. FWD/REV shaft lubrication
WB93R-8 10-39
External view
1 2 7 8 6 14
b
a
Z 12
11
10
4 3
15
View Z
13 5
RKA82270
a. From the oil cooler

b. To the oil cooler
1. Spin-on filter (10 μm) 8. Oil temperature sensor (X105)
2. Oil pump group (max pressure: 1.6 MPa {16.3 9. Suction filter (250 μm)
kg/cm2}) 10. Magnetic oil drain plug
3. Forward solenoid valve (X108) 11. Dipstick interface
4. Reverse solenoid valve (X203) 12. 4th gear selected sensor (X104)
5. 4WD engagement solenoid valve (X106) 13. Differential lock solenoid valve (X94)
6. Breather plug 14. Torque converter
7. Gear shift lever 15. Speed sensor (TUV 40 km/h specification)
10-40 WB93R-8
Sectional view (1/3)
E E
F F
1 2 3 4 5
A
G-G
8
6 A
RKA84200
1. Spin-on filter (10 μm) 5. Spring

2. Pressure control valve 6. Suction filter (250 μm)
3. Pressure control spring 7. Reverse shaft (Axis D)
4. Ball 8. Primary shaft (Axis B)
WB93R-8 10-41
3 5
10
6
7
9 A-A
8
RKA84210
1. Main hydraulic pump drive shaft 6. Rear output shaft

2. Input drive shaft 7. Secondary shaft (Axis C)
3. Transmission hydraulic pump 8. 4WD shaft (Axis E)
4. Transmission control valve 9. Front output shaft
5. Input shaft (Axis A) 10. Torque converter
10-42 WB93R-8
3
2
3 4
6
5 7 E-E 8 9
Y-Y
11
F-F
10 12 13
RKA84220
1. Shift lever 8. Rod

2. Spring 9. 4th gear selected sensor
3. 3rd and 4th gear shift fork 10. Spring
4. 1st and 2nd gear shift fork 11. Ball
5. Spring 12. Rod
6. Ball 13. 1st and 2nd gear selecting fork
7. 3rd and 4th gear selecting fork
WB93R-8 10-43
Input shaft (Axis A)
2 3 4 5 6 7
RKA84230
a. Port commanding reverse clutch

b. Port commanding forward clutch
c. Lubrication port
1. Input shaft 5. Reverse gear piston
2. Forward gear 6. Reverse gear clutch
3. Forward gear clutch 7. Reverse gear gear
4. Forward gear piston
Secondary shaft (Axis C)
1 2 3 4 5 6 7
RKA84240
1. 2nd speed driven gear 5. 3rdt/4th gear synchroniser

2. 1st/2nd gear synchroniser 6. 3rd speed driven gear
3. 1st speed driven gear 7. 3rd and 4th gear selecting fork
4. 4th speed driven gear 8. Shaft
10-44 WB93R-8
4WD shaft (Axis E)
2 3 4 5
a 1
RKA84250
a. 4WD activation port
1. Shaft 4. 4WD clutch

2. 4WD driven gear 5. 4WD clutch piston
3. Spring
WB93R-8 10-45
TRANSMISSION CONTROL VALVE
1 2 3 4 5 6
16 15 14 13 12 11 10
RKA84650
1. Spool return spring

2. Spool
3. Spool return spring
4. Differential lock solenoid valve
5. Forward direction solenoid
6. Reverse direction solenoid
7. Ball
8. Spring
9. Piston
10. Spring
11. Spring
12. Pin
13. Valve
14. Valve
15. Valve
16. Spring
10-46 WB93R-8
FRONT AXLE
External view
1 2 3 2 1
4 6 5 4
7 7
8
7 7
a b
9
Filling position
10 Drain position
RKA82280
a.From steering unit

b.From steering unit
1. Final reduction 6. Oil filling plug

2. Tie-rod 7. Grease fitting
3. Steering cylinder 8. Axle body
4. Steering angle adjusting screw 9. Pinion
5. Drain plug 10. Final reduction oil filling/drain plug
Specifications
• Axle oil quantity: 7.5l
• Final reduction (each) oil quantity: 0.8l
WB93R-8 10-47
Pinion and differential
1 2 3 4
14
7
13
12 8
9
11
10
RKA82290
1. Sun gear 8. Spacer

2. Crown wheel 9. Bearing
3. Pin 10. Seal ring
4. Planetary gear 11. Ring nut
5. Ring nut 12. Bearing
6. Half shaft 13. Pinion
7. Differential housing 14. Pin
Specifications
10-48 WB93R-8
Final reduction
1 2 3 4 5 6 7 8 9
10 11
12
22 14 13
21 20 19 18 17 16 15
RKA82300
1. Planetary carrier 12. Half shaft

2. Planetary gear 13. Axle body
3. Ring gear 14. Ball bushing
4. Ring gear support 15. Washer spring
5. Wheel hub 16. Lower pin
6. Seal ring 17. Swivel housing
7. Washer spring 18. Seal ring
8. Upper pin 19. Bearing
9. Bushing 20. Centering bush
10. Seal ring 21. Stud bolt
11. Bushing 22. Oil drain/filling plug
Specifications
• Final reduction (each) oil quantity: 0.8l
WB93R-8 10-49
Steering and toe-in angle
A A
E
Section A
D
500
A
500
C
RKA82310
Toe-in specification
• Toe-in measured at planetary carrier border:
from B = A to B = A - 2 mm
• Toe-in measured at 500 mm from planet carrier revolution axis:
from D= C to D= C - 6 mm
Steering angle adjustment
Quote E
Tyre dimension
With mudguard Without mudguard
340x80 R18 32.5 - 33.5 32.5 - 33.5
12.5x18 34.5 - 35.5 27.5 - 28.5
365/70 R18 44.5 - 45.5 44.5 - 45.5
400/70 R20 44.5 - 45.5 44.5 - 45.5
a After adjustment verify that steering wheels do not touch any component of the machine when fully
steering in both direction
10-50 WB93R-8
REAR AXLE
External view
1 2 3 4 1
5 5 6 5
b 7 8
8 a b
b 8
RKA82320
a.Hydraulic differential lock port
b.Working brake port
1. Final reduction 5. Oil drain plug

2. Axle body 6. Oil filling plug
3. Parking brake disk 7. Breather
4. Parking brake caliper 8. Working brake air bleeder
Specifications
WB93R-8 10-51
Pinion and differential
1 2 3 4 5
14
13
12 8
11
9
10
RKA82330
1. Bearing 8. Bearing
2. Sun gear 9. Ring nut
3. Crown wheel 10. Seal ring
4. Planetary gear 11. Flange and parking brake disk
5. Differential housing 12. Spacer
6. Ring nut 13. Pinion
7. Half shaft 14. Pin
Specifications
• Amount of oil: 15.5l
10-52 WB93R-8
Final reduction
1 2 3 4
6
12
11 10 9 8
RKA82340
1. Stud bolt 7. Oil drain plug

2. Planetary carrier 8. Ring gear
3. Wheel hub 9. Bush
4. Planetary gear 10. Bearing
5. Half shaft 11. Seal ring
6. Axle body 12. Wheel flange
WB93R-8 10-53
Brakes
1
2 3 4 3 5
A
DETAIL A
9
10
11 DETAIL B
6
RKA82350
1. Working brake air bleeder 7. Flange and parking brake disk

2. Brake piston 8. Self adjust kit
3. Brake disk (n°2 each side) 9. Screw
4. Counter plate 10. Washer spring (n° 4 each)
5. Counter plate 11. Bush
6. Parking brake caliper
10-54 WB93R-8
Differential lock
1 2
10 9 8 7 6 5 4 3
RKA82360
a.Hydraulic differential lock port
1. Pin 6. Spring
2. Sleeve 7. Fork
3. Cover 8. Spacer
4. Piston 9. Spring
5. Spacer 10. Rod
WB93R-8 10-55
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
Chassis part
3
4
2
6
5
RKA82400
1. Hydraulic tank
2. Main pump
3. Control valve
4. Solenoid valve group
5. Loader attachment solenoid valve
6. Hydraulic oil exchanger
10-56 WB93R-8
HYDRAULIC SYSTEM
Around cab and floor
RKA82420
1. Steering unit
2. Loader PPC valve
3. PPC lock switch
4. Outrigger PPC valve
WB93R-8 10-57
HYDRAULIC SYSTEM
HYDRAULIC TANK
A
5
4
D
FW
7
8
6
Section A-A
Detail B
RKA82430
1. Hydraulic tank 6. Drain plug

2. Sight gauge 7. Suction strainer
3. Oil filler cap 8. Filter element (with by-pass valve)
4. Breather cap 9. Cyclon
5. Breather (with pressure and suction valve)
Specifications
Hydraulic tank capacity (l) 55
Hydraulic oil in tank (l) 41.5
Bypass valve set pressure 0.25MPa {2.5 bar}
Breather cap set pressure 16.7 ± 6.9 kPa {1.67 ± 0.69 bar}
Release pressure: 100 ± 15kPa {1.00 ± 0.15 bar}
Breather set pressure
Suction pressure: 2.0 ± 0.3 kPa {0.02 ± 0.003 bar}
10-58 WB93R-8
HYDRAULIC SYSTEM
HYDRAULIC PUMP
External view
PS
Pd2
View X
P1L PLS
P1C
Pd
3
Z X
2 3 Pen
PM 1 P1
View Z Pd3
RKA82440
1. Main pump 4. LS-EPC valve

2. LS valve 5. PC-EPC valve
3. PC valve
P1: Pump delivery port Pd3: Drain port

P1C: Pump delivery pressure detection port Pen: Pump control pressure detection port
P1L: Pump pressure input port PLS: Load pressure input port
Pd: Drain port PM: PC mode change pressure checking port
Pd2: Drain port PS: Pump suction port
Outline
This pump consists of a variable displacement swash plate piston pumps, PC valve and LS valve.
WB93R-8 10-59
HYDRAULIC SYSTEM
Main pump
A
View X
Z X
B B
Pd4 Pa PM
D
C C
D
Pe Pd5
View Z
RKA82450
Pa: Control basis pressure port

Pd4: Drain port
Pd5: Drain port
Pe: Control pressure port
PM: PC mode change pressure port
10-60 WB93R-8
HYDRAULIC SYSTEM
Main pump - Sectional view
1 1 14
Section A - A Section C - C
3 4 5 6 7 8
13
Section D - D
12 11 10
9
RKZ09520
1. Bearing 8. Valve plate

2. Shaft 9. End cap
3. Case 10. Shoe guide ring
4. Rocker cam 11. Control piston
5. Shoe 12. Spring
6. Piston 13. Seal ring
7. Cylinder block 14. Ball
WB93R-8 10-61
HYDRAULIC SYSTEM
Function
3 4 5 6 7 8
11 a
A
RKZ09791
• The rotation and torque of the engine are transmitted to the shaft of this pump and converted into
hydraulic energy in this pump. This pump discharges the pressurized oil according to the load.
• The discharge of this pump can be changed by changing the swash plate angle in it.
Structure
• Cylinder block (7) is supported on shaft (1) through spline a. Shaft (1) is supported by the front and rear
bearings.
• The end of piston (6) has a spherical hollow which is combined with shoe (5). Piston (6) and shoe (5)
form a spherical bearing.
• Rocker cam (4) has plane A. Shoe (5) is kept pressed against plane A and slid circularly. Rocker cam (4)
slides around ball (11).
• Piston (6) in each cylinder of cylinder block (7) moves relatively in the axial direction.
• Cylinder block (7) rotates relatively against valve plate (8), sealing the pressurized oil, and the hydraulic
balance is maintained properly.
• The oil in each cylinder of cylinder block (7) can be sucked and discharged through valve plate (8).
10-62 WB93R-8
HYDRAULIC SYSTEM
Operation of pump
6 1
7
X
a
9 A
RKZ09530
• Cylinder block (1) rotates together with shaft (2) and shoe (6) slides on plane A.
At this time, swash plate (7) tilts around ball (9).
As a result, angle a between center line X of swash plate (7) and the axis of cylinder block (1) changes.
Angle a is called the swash plate angle.
• If angle is made between center line X of swash plate (7) and the axis of cylinder block (1), plane A
works as a cam for shoe (6).
6 5 1
7
E
X
a
9 A F
RKZ09540
• Accordingly, piston (5) slides inside cylinder block (1) and a difference is made between volumes E and
F in cylinder block (1).
As a result, each piston (5) sucks and discharges oil by F – E.
• In other words, if cylinder block (7) rotates and the volume of chamber E is decreased, the oil is dis-
charged from chamber E. On the other hand, the volume of chamber F is increased and the oil is sucked
in chamber F. (In the figure, chamber F is at the end of the suction stroke and chamber E is at the end of
the discharge stroke.)
WB93R-8 10-63
HYDRAULIC SYSTEM
3 6 E
F
RKZ09550
• If center line X of swash plate (7) is equal to the axis of cylinder block (1) (the swash plate angle a is 0),
there is not a difference between volumes E and F in cylinder block (1) and oil is not sucked or dis-
charged. (The swash plate angle is not set to 0 actually, however.)
• In short, swash plate angle a is in proportion to the pump discharge.
Control of discharge amount

• If swash plate angle is increased, the difference between volumes E and F is increased, and so dis-
charge Q is increased. Swash plate angle a is changed with servo piston (11).
• Servo piston (11) reciprocates straight according to the signal pressure of the servo valve. This straight
motion is transmitted to swash plate (7). Then, swash plate (7) supported on ball (9) slides around ball
(9).
7 E
8 9
X
a
11 F
RKZ09560
10-64 WB93R-8
HYDRAULIC SYSTEM
Servo valve
Pe Pd5
Pd4 Pa PM
A A
B B
RKZ09430
1. Plug
2. Locknut
3. Sleeve
4. Spring
5. Seat
6. Spool
7. Piston
8. Sleeve

Pd4: Drain port
Pd5: Drain port
Pe: Control pressure port
WB93R-8 10-65
HYDRAULIC SYSTEM
LS valve
1 2 T 3 4 5
PPLS PPL Pe Pa Pd4 PLS
Section B - B
RKZ09781
1. Plug
2. Spool
3. Seat
4. Spring
5. Nut
6. Plug
Pa: Pump discharge pressure

Pe: Control piston pressure
PLS: LS pressure input
PPL: PC valve output pressure
PPLS: LS pump pressure input
T: Drain
10-66 WB93R-8
HYDRAULIC SYSTEM
Function
• The LS valve controls the pump delivery according to the stroke of the control valve lever, i.e., in function
of the delivery demands made by the actuators.
• The LS valve detects the actuator’s delivery needs by means of the differential pressure dPLS existing
between pressure PPLS (control valve input pressure) and pressure PLS (control valve output pres-
sure). The sensing of this differential pressure permits control of the main pump delivery Q. (PPLS, PLS
and dPLS are, respectively, the pump pressure, the Load Sensing pressure, and the difference in pres-
sure between these two values).
• In other words, the LS valve detects the pressure difference dPLS generated by the passage of the oil
flow through the surface freed by the control valve spool, and controls the pump delivery Q so as to keep
the pressure drop constant. It can therefore be assumed that the pump delivery is proportional to the
demands made known by the control valve.
• Pump pressure PPLS (pump pressure at control valve input) and pressure PLS (Load Sensing pres-
sure) are introduced into the LS valve. The relation between differential pressure dPLS and pump deliv-
ery varies as shown in the diagram on the right.
Pump delivery Q
LS differential pressure dPLS bar
RKZ09570
WB93R-8 10-67
HYDRAULIC SYSTEM
PC valve
2 3 4 5 6 7 8
1
9
Pd4 PPL Pa PM Pa
Section A - A
RKZ09770
1. Lever
2. Spring
3. Retainer
4. Spool
5. Spool
6. Sleeve
7. Piston
8. Seal
9. Piston

Pd4: Drain port
PPL: PC valve output pressure
10-68 WB93R-8
HYDRAULIC SYSTEM
Function
• The PC valve limits the oil flow to a certain level (according to the discharge pressure) even if the stroke
of the control valve is increased extremely so that the horsepower absorbed by the pump does not
exceed the engine horsepower, as long as pump discharge pressure (PA) is high.
• In other words, the PC valve decreases the pump delivery when the load is increased and the pump dis-
charge pressure rises, and increases it when the pump discharge pressure lowers.
• If pressure PC is increased, the relationship between the pump pressure (PA) and pump delivery (Q) is
translated in proportion to the pressing force of pressure PC.
• In other words, since the pressing force pressure PC is added to the pressing force on the left side
caused by the pump pressure applied to spool (5), the relationship between pump pressure (PA) and (Q)
is translated from [1] to [2].
5
Pump delivery Q
Pump pressure PA bar
WB93R-8 10-69
HYDRAULIC SYSTEM
Operation
PA
1 5 4
Check valve
D C B
PT
Engine
C B 3
2
F
LS valve
Solenoid
valve
G
J
RKZ09490
Operation of spring
• The spring load of spring (1) at the PC valve is decided by the position of the swash plate.
• If servo piston (2) moves to the right, spring (1) is compressed through lever (3) and its spring load
changes.
When pump pressure PA is low

• The pressing force of piston (4) is decreased and spool (5) is a little to the right. 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 (2) moves to the left.
• Consequently, the pump delivery is increased.
• As servo piston (2) moves, lever (3) moves to the left and spring (1) expands, weakening its spring force.
Consequently, spool (5) moves to the left, disconnecting between ports (C) and (D) and connecting
pump discharge pressure ports (B) and (C).
• As a result, the pressure in port (C) rises and the piston pressure is increased and servo piston (2) stops
moving to the left.
10-70 WB93R-8
HYDRAULIC SYSTEM
When pump pressure PA is high
PA
1 5 4
Check valve
D C B
PT
Engine
C B 3
2
F
LS valve
Solenoid
valve
G
J
RKZ09500
• The pressure of piston (4) is increased and spool (5) is a little to the left. 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 (2) moves to the right.
• Consequently, the pump delivery is decreased.
• As servo piston (2) moves, lever (3) moves to the right and spring (1) is compressed, strengthening its
spring force. Consequently, spool (5) moves to the right, disconnecting ports (C) and (B) and connecting
drain pressure ports (D) and (C).
• As a result, the pressure in port (C) lowers and the piston pressure is decreased and servo piston (2)
stops moving to the right.
WB93R-8 10-71
HYDRAULIC SYSTEM
When balanced
PA
1 5 4
Check valve
D C B
PT
Engine
C B 3
2
F
LS valve
Solenoid
valve
G
J
RKZ09510
• The stopping position (= pump delivery) of servo piston (2) is decided by the position where the pressure
caused by pressure (PA) applied to piston (4) is balanced with the force of spring (1) applied through
spool (5).
10-72 WB93R-8
HYDRAULIC SYSTEM
CONTROL VALVE - 9-spool loader and backhoe valves
AC AC
B0 A0
AL AL
B1 A1
AB AB
PPPC T
DLS
AA AA
LS P D
N N
A2
B2
M M
B3 A3
PA3 X
L L
A4
B4
K K
B5 A5
J J
B8 A8
PA6
F F
E E
PA8 D
PA7
Z
SS
B9 A7
View Z
B10 A10
RKA54181
WB93R-8 10-73
HYDRAULIC SYSTEM
Outline
External view
a Since the valves are single add-on type, they can be added and removed one by one at any time.
A0: To the backhoe attachment

A1: To the backhoe arm cylinder (Head side)
A2: To the backhoe boom swing cylinder (Bottom side)
A3: To the loader bucket cylinders (Bottom side)
A4: To the backhoe boom cylinder (Bottom side)
A5: To the backhoe bucket cylinder (Head side)
A8: To the loader arm raise cylinder (Bottom side)
A9: To the RH outrigger cylinder (Bottom side)
A10: To the LH outrigger cylinder (Bottom side)
B0: To the backhoe attachment
B1: To the backhoe arm cylinder (Bottom side)
B2: To the backhoe boom swing cylinder (Head side)
B3: To the loader cylinders (Head side)
B4: To the backhoe boom cylinder (Head side)
B5: To the backhoe bucket cylinder (Bottom side)
B8: To the loader arm raise cylinder (Head side)
B9: To the RH outrigger cylinder (Head side)
B10: To the LH outrigger cylinder (Head side)
D: To the steering unit
DLS: From the steering unit
LS: To the hydraulic pump
P: From hydraulic pump
PA3: From the loader PPC valve
PA9: From the outriggers PPC valve
PPPC: To solenoid valve
SS: To the backhoe lock plate cylinders
T: To hydraulic tank
TS: To hydraulic tank
10-74 WB93R-8
HYDRAULIC SYSTEM
AE
C B A
PP
PB3
PB8
C B A
PB10 PB9
View X
RKA54191
PB3: From the loader PPC valve

PB9: From the outriggers PPC valve
PP: To the hydraulic pump
WB93R-8 10-75
HYDRAULIC SYSTEM
Sectional view 1/4
7
8
6
20
9
19
21 5
23
10
18
22 17
4
3
11
16 2 12
15 1
13
14
B-B A-A
AE - AE RKA82880
10-76 WB93R-8
HYDRAULIC SYSTEM
1. Suction valve (backhoe bucket)

2. Safety valve (backhoe boom)
3. Suction valve (loader bucket dump)
4. Safety valve (backhoe boom swing)
5. Suction valve (backhoe arm)
6. Safety valve (service)
7. Safety valve
8. Suction valve (service)
11. Safety valve (loader bucket curl)
12. Suction valve (backhoe boom)
14. Spool (shovel arm)
15. Spool (backhoe bucket)
16. Spool (backhoe boom)
17. Spool (loader bucket)
18. Spool (backhoe boom swing)
19. Spool (backhoe arm)
20. Spool (service)
21. Spool (priority valve)
22. LS by-pass plug
23. Unloading valve
WB93R-8 10-77
HYDRAULIC SYSTEM
Sectional view 2/4
AD
18 8
7
19 9
6
15
20
10
5
11
21
22
4
12
23 3
13
2
24
14
17 16 AD
D-D C-C
25
26
AD - AD
RKA82590
10-78 WB93R-8
HYDRAULIC SYSTEM
1. Pressure compensation valve F (shovel boom)

2. Pressure compensation valve F (backhoe bucket)
3. Pressure compensation valve F (backhoe boom)
4. Pressure compensation valve F (loader bucket)
5. Pressure compensation valve F (backhoe boom swing)
6. Pressure compensation valve F (backhoe arm)
7. Pressure compensation valve F (service)
8. Pressure compensation valve R (service)
9. Pressure compensation valve R (backhoe arm)
10. Pressure compensation valve R (backhoe boom swing)
11. Pressure compensation valve R (loader bucket)
12. Pressure compensation valve R (backhoe boom)
13. Pressure compensation valve R (backhoe bucket)
14. Pressure compensation valve R (shovel boom)
15. Main relief valve (LS safety valve)
16. Check valve
17. Check valve
18. Check valve
19. Check valve
20. Check valve
21. Check valve
22. Check valve
23. Check valve
24. Check valve
25. LS bypass plug
26. LS, DLS pressure signal check valve
F: Flow control valve

R: Pressure reducing valve
WB93R-8 10-79
HYDRAULIC SYSTEM
Sectional view 3/4
3 4
14 15
2 13
1 K-K
E-E 16
17
19 20
5
18
F-F L-L
7 21 22
6
24
9 25
8 23
10
J-J M-M
11 12 26 27
RKA82900
10-80 WB93R-8
HYDRAULIC SYSTEM
Outrigger/Sliding plate
1. Spool (R.H. outrigger)
2. Spool (L.H. outrigger)
3. Backhoe sliding plate lock solenoid valve
4. Backhoe sliding plate lock valve
Loader arm valve

5. Spool
6. Pressure compensation valve R
7. Pressure compensation valve F
Backhoe bucket valve

8. Spool
9. Suction valve
10. Suction valve
Backhoe boom valve

13. Spool
14. Suction safety valve
15. Suction valve
Loader bucket valve

18. Spool
19. Suction valve
Backhoe boom swing valve

23. Spool
WB93R-8 10-81
HYDRAULIC SYSTEM
Sectional view 4/4
17
AC - AC
N-N
4 13 14
5 12
3
2 15 AL - AL
AA - AA 16
6
8
7 9
10 AB - AB
11
RKA82910
10-82 WB93R-8
HYDRAULIC SYSTEM
Block
1. Unloading valve
2. Servocontrol reducing valve
3. Spool
4. Sequential reducing valve
5. Priority valve
6. LS relief valve
Backhoe arm valve

7. Spool
8. Suction valve
9. Suction valve
Service valve
12. Spool
15. Suction valve
16. Suction valve
Cover
17. Air bleeding plug
WB93R-8 10-83
HYDRAULIC SYSTEM
CONTROL VALVE - 11-spool loader and backhoe valves
B0 A0
B1 A1
DLS
PPPC T
LS P D
B2 A2
X B3 A3
PA3 B4 A4
B5 A5
B6 A6
PA8
B7 A7
B8 A8
PA7 PA10
Z
B9 SS A9
B10 View Z A10

RKA82690
10-84 WB93R-8
HYDRAULIC SYSTEM
Outline
External view
A0: To the backhoe attachment
A1: To the backhoe arm cylinder (Head side)
A2: To the backhoe boom swing cylinder (Bottom side)
A3: To the loader bucket cylinders (Bottom side)
A4: To the backhoe boom cylinder (Bottom side)
A5: To the backhoe bucket cylinder (Head side)
A6: To the loader bucket 4 in 1 cylinder (Bottom side)
A7: To the backhoe telescopic arm cylinder (Bottom side)
A8: To the loader arm raise cylinder (Bottom side)
A9: To the RH outrigger cylinder (Bottom side)
A10: To the LH outrigger cylinder (Bottom side)
B0: To the backhoe attachment
B1: To the backhoe arm cylinder (Bottom side)
B2: To the backhoe boom swing cylinder (Head side)
B3: To the loader cylinders (Head side)
B4: To the backhoe boom cylinder (Head side)
B5: To the backhoe bucket cylinder (Bottom side)
B6: To the backhoe bucket 4 in 1 cylinder (Head side)
B7: To the backhoe telescopic arm cylinder (Head side)
B8: To the loader arm raise cylinder (Head side)
B9: To the RH outrigger cylinder (Head side)
B10: To the LH outrigger cylinder (Head side)
D: To the steering unit
DLS: From the steering unit
LS: To the hydraulic pump
P: From hydraulic pump
PPPC: To solenoid valve
SS: To the backhoe lock plate cylinders
TS: To hydraulic tank
WB93R-8 10-85
HYDRAULIC SYSTEM
AE
C B A
PP
PB3
PB8
PB10 C B A PB9
AE
View Z
RKA82700

PB6: From solenoid valve group
PP: To the hydraulic pump
10-86 WB93R-8
HYDRAULIC SYSTEM
Sectional view 1/4
8
9
25 7
10
24
26
6
28 11
27
23 5
4
22 12
21 13
3
20 14
2
19 15
1
18
16
17
B-B A-A
AE - AE
RKA82830
WB93R-8 10-87
HYDRAULIC SYSTEM
1. Suction valve (bucket 4 in 1)

3. Safety valve (backhoe boom)
4. Suction valve (loader bucket dump)
7. Safety valve (service)
8. Safety valve
9. Suction valve (service)
12. Safety valve (loader bucket curl)
13. Suction valve (backhoe boom)
15. Suction valve (bucket 4 in 1)
16. Suction valve (backhoe telescopic arm)
17. Spool (shovel arm)
18. Spool (backhoe telescopic arm)
19. Spool (loader bucket 4 in 1)
20. Spool (backhoe bucket)
21. Spool (backhoe boom)
22. Spool (loader bucket)
23. Spool (backhoe boom swing)
24. Spool (backhoe arm)
25. Spool (service)
26. Spool (priority valve)
27. Unloading valve
28. LS by-pass plug
10-88 WB93R-8
HYDRAULIC SYSTEM
Sectional view 2/4
22 10
9
11
23
8 19
24
12
25 7 13
26
6
14
5
27 15
28
4 16
3
17
2
29
18
D-D AD C-C
21 20
30
31
AD - AD
RKA82
WB93R-8 10-89
HYDRAULIC SYSTEM
1. Pressure compensation valve F (shovel boom)

2. Pressure compensation valve F (backhoe telescopic arm)
3. Pressure compensation valve F (loader bucket 4 in 1)
4. Pressure compensation valve F (backhoe bucket)
5. Pressure compensation valve F (backhoe boom)
6. Pressure compensation valve F (loader bucket)
7. Pressure compensation valve F (backhoe boom swing)
8. Pressure compensation valve F (backhoe arm)
9. Pressure compensation valve F (service)
10. Pressure compensation valve R (service)
11. Pressure compensation valve R (backhoe arm)
12. Pressure compensation valve R (backhoe boom swing)
13. Pressure compensation valve R (loader bucket)
14. Pressure compensation valve R (backhoe boom)
15. Pressure compensation valve R (backhoe bucket)
16. Pressure compensation valve R (loader bucket 4 in 1)
17. Pressure compensation valve R (backhoe telescopic arm)
18. Pressure compensation valve R (shovel boom)
20. Check valve
21. Check valve
22. Check valve
23. Check valve
24. Check valve
25. Check valve
26. Check valve
27. Check valve
28. Check valve
29. Check valve
30. LS bypass plug
31. LS, DLS pressure signal check valve

10-90 WB93R-8
HYDRAULIC SYSTEM
Sectional view 3/4
3
4
F-F
1 6 7
E-E
13 14
9
12
8
G-G 11 H-H
10 15 16
18
23 24
17
19
22
J-J
20 21 K-K
25 26
RKA82850
Outrigger/Sliding plate
1. Spool (R.H. outrigger)
2. Spool (L.H. outrigger)
4. Backhoe sliding plate lock valve
WB93R-8 10-91
HYDRAULIC SYSTEM
Loader arm valve

5. Spool
Backhoe telescopic arm

8. Spool
9. Suction valve
Loader bucket 4 in 1 valve

12. Spool
13. Suction valve
14. Suction valve
Backhoe bucket valve

17. Spool
18. Suction valve
19. Suction valve
Backhoe boom valve

22. Spool
24. Suction valve
10-92 WB93R-8
HYDRAULIC SYSTEM
Sectional view 4/4
2
3 7
1
6 8
L-L 5
4
M-M
9 10
11 14
15
13
16
N-N
12 AA - AA
18 27
17
19
21
20 AB - AB 23 AC- AC
22
24
25 26
AL- AL
RKA82860
WB93R-8 10-93
HYDRAULIC SYSTEM
Loader bucket valve

1. Spool
2. Suction valve
Backhoe boom swing valve

6. Spool
Block
11. Unloading valve
13. Spool
14. Sequential reducing valve
15. Priority valve
16. LS relief valve
Backhoe arm valve

17. Spool
18. Suction valve
19. Suction valve
Service valve
22. Spool
24. Suction valve
Cover
27. Air bleeding plug
10-94 WB93R-8
HYDRAULIC SYSTEM
CLSS
a CLSS: Abbreviation for Closed center Load Sensing System
Structure of CLSS
Features
• Fine controllability not influenced by load
• Control performance that allows digging even under fine control operation condition
• Easy combined operation ensured by the flow dividing performance that is determined by the opening
areas of spools during combined operations
Energy saving by variable discharge pump control
Configuration
• CLSS consists of variable capacity piston pump, control valves, and respective actuators.
• The hydraulic pump consists of a pump body, PC valve, and LS valve.
WB93R-8 10-95
HYDRAULIC SYSTEM
Basic principle
Pump swash plate angle control
• The pump swash plate angle (pump discharged volume) is so controlled that LS differential pressure
(ΔPLS), which is the differential pressure between pump discharged pressure (PP) and control valve outlet
LS pressure (PLS) (actuator load pressure), is kept constant.
• [LS differential pressure (ΔPLS) = Pump discharged pressure (PP) - LS pressure (PLS)]
• The pump swash plate shifts toward the maximum angle position when LS differential pressure (ΔPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high).
• The pump swash plate shifts toward the minimum angle position when LS differential pressure is higher
than the set pressure (when the actuator load pressure is low).
10-96 WB93R-8
HYDRAULIC SYSTEM
LS differential pressure (ΔPLS) and pump swash plate angle
a For details of the operation, see "HYDRAULIC PUMP".
Pressure compensation control
WB93R-8 10-97
HYDRAULIC SYSTEM
• A pressure compensation valve is installed to the inlet port side of the control valve to balance the load.
• When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet port)
and downstream (outlet port) of the spool of each valve is kept the same among them regardless of the
level of the load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and (S2)
of each valve.
10-98 WB93R-8
HYDRAULIC SYSTEM
Function and operation by valve

Hydraulic circuit diagram and name of valves
PP
14
A0
11
B0
Service
19
15
A1
10 Backhoe arm
B1
19 15
D
20
DLS
LS
P
T
21 12
13
Ts
PPPC
16
A2
9 B2 Backhoe boom swing
19
16
17
A3 Loader bucket
PB3
8 B3
19 PA3
15
A4 Backhoe boom
7 B4
19 15
18
A5 Backhoe bucket
6 B5
19
15
5
A6 Loader bucket 4 in 1
PB6 B6
19 PA6
15
4
A7 Backhoe telescopic arm
PB7 B7
19 PA7
3
A8 Loader arm
PB8 B8
19 PA8
22 A9 R.H. outrigger
PB9
2 B9
PA9
SS
A10 L.H. outrigger
1 B10
PB10 PA10
RKA82710
WB93R-8 10-99
HYDRAULIC SYSTEM
a The hydraulic circuit diagram shows the 11-spool valve (With backhoe telscopic arm and loader bucket 4
1in 1).
1. L.H. outrigger spool
2. R.H. outrigger spool
3. Loader arm spool
4. Backhoe telescopic arm spool
5. Loader bucket 4 in 1 spool
6. Backhoe bucket spool
7. Backhoe boom spool
8. Loader bucket spool
9. Backhoe boom swing spool
10. Backhoe arm spool
11. Service spool
12. Unloading valve:
Set pressure: LS pressure + 2.75 MPa {28.0 kg/cm²}
13. LS relief valve
Set pressure: 21.5 MPa {219 kg/cm²}
14. Safety valve
15. Suction valve
16. Safety valve
17. Safety valve
18. Safety valve
Set pressure: 34.4MPa {350 kg/cm²}
19. Pressure compensation valve
20. Priority valve
10-100 WB93R-8
HYDRAULIC SYSTEM
Unload valve
When control valve is at NEUTRAL
PP A
1
S2
S1
S3
T 2 PLS
RKA82920
Function
• When the control valve is at NEUTRAL, pump discharge amount Q discharged by the minimum swash
plate angle is release to the tank circuit.
• When this happens, pump discharge pressure PP is set to 2.75 MPa {28 kg/cm²} by spring (2) inside the
valve. (LS pressure PLS: 0 MPa {0 kg/cm²}).
Operation
• On the left side of spool (1), pump discharge pressure PP is applied to the area of S1. On the right side,
pump discharge pressure PP is applied to the area of S2 and LS pressure PLS is applied the area of S3.
• When the control valve is at neutral, LS pressure PLS is 0, so only pump discharge pressure PP has any
effect, and PP is set only by the load of spring (2).
• Spool (1) moves to the right until pump discharge pressure PP rises and PP x S1 =PP x S2 + force of
spring (2). Pump circuit PP is connected to tank circuit T through the hole of spool (1).
• In this way, pump discharge pressure PP is set to 2.75 MPa {28 kg/cm2}.
WB93R-8 10-101
HYDRAULIC SYSTEM
When control valve is in fine control
PP A
1
B S2
S1
S3
2 PLS
T
RKA82930
Function
• When the control valve is in the fine control mode, if the demand flow for actuator is less then the value
corresponding to the minimum swash plate angle of the pump, pump pressure PP is set LS pressure
PLS + 2.75 MPa {28 kg/cm2}.
• If the difference pressure between pump pressure PP and LS pressure PLS becomes equal to the load
of spring (2) (2.75 MPa {28 kg/cm2}), the unload valve opens.
• Accordingly, LS differential pressure DPLS is (2.75 MPa {28 kg/cm2}) at this time.
Operation
• When the control valve is operated finely, LS pressure PLS is generated and applied to area S3 at the
right end of spool (1). At this time difference between LS pressure PLS and pump discharge pressure
PP is large, since the opening area of the control valve spool is narrow.
• When the difference between pump discharge pressure PP and LS pressure PLS reaches the load of
spring (2), spool (1) moves to the right and pump circuit PP and tank circuit T are connected to each
other.
• In other words, pump discharge pressure PP is set to a pressure equal to force of spring (2) (2.75 MPa
{28 kg/cm2}) + LS pressure PLS, and differential pressure DPLS becomes (2.75 MPa {28 kg/cm2})
10-102 WB93R-8
HYDRAULIC SYSTEM
When control valve is being operated
PP A
1 S2
S1
S3
T 2 PLS
RKA82940
Function
• When the control valve is operated, if the demand flow for actuator exceeds the values corresponding to
the minimum swash plate angle of the pump, the outflow to tank circuit T is shut off and all of pump dis-
charge amount Q is sent to the actuator circuit.
Operation
• When the control valve is operated large, LS pressure PLS is generated and applied to area S3 at the
right end of spool (1). At this time, difference between LS pressure PLS and pump discharge pressure
PP is small, since the opening area of the control valve spool is wide.
• For this reason, the differential pressure between pump discharge pressure PP and LS pressure PLS
does not reach the load of spring (2) (2.75 MPa {28 kg/cm²}), so spool (1) is pushed to the left by spring
(2).
• As a result, pimp circuit PP and tank circuit T are shut off, and all the pump discharge amount Q flows to
the actuator circuit (3).
WB93R-8 10-103
HYDRAULIC SYSTEM
Introduction of the LS pressure

Work equipment valve (backhoe boom, backhoe arm, backhoe bucket, backhoe boom
swing, backhoe telescopic arm, loader arm, loader bucket, loader bucket 4 in 1)
b a
A
SLS
PLSS
2
3
PP PLS
SA PA
4
DISEGNO DA RINUMERARE
RKZ09220
Function
• The LS pressure is the actuator load pressure at the outlet port end of the control valve.
• Actually, pump discharge pressure PP is reduced by reducing valve (3) of the pressure compensation
valve to the same pressure as actuator circuit pressure A and sent to LS circuit PLS.
• In the stabilizer valve, actuator circuit pressure A is directly introduced to LS circuit PLS.
Operation
• When spool (1) is operated, pump discharge pressure PP from flow control valve (2) through notch a in
the spool and bridge passage b to actuator circuit A.
• At the same time, reducing valve (3) also moves to the right, so pump discharge pressure PP is reduced
by the pressure loss at notch c. It goes to LS circuit PLS, and then goes to spring chamber PLSS.
• When this happens, LS circuit PLS is connected to tank circuit T from LS bypass plug (4) (See the sec-
tion on the LS bypass plug).
• The areas at both ends of reducing valve (3) are the same (SA = SLS), and actuator circuit pressure PA
acts on the SA end. The reduced pump discharge pressure PP acts on SLS at the other end.
• As a result, reducing valve (3) is balanced at a position where actuator circuit pressure PA and the pres-
sure of spring chamber PLSS are the same. Pump discharge pressure PP reduced at notch c becomes
actuator pressure A and is introduced into LS circuit PLS.
10-104 WB93R-8
HYDRAULIC SYSTEM
Outrigger valve
A a PP
b PLS
RKZ09240
Operation
• When spool (1) is operated, pump pressure PP flows from notch a in the spool to actuator circuit A.
• At the same time, actuator circuit pressure A flows holes b of spool and goes LS circuit PLS.
a The outrigger circuit is different from the work equipment circuit: actuator circuit pressure goes directly to
LS circuit.
WB93R-8 10-105
HYDRAULIC SYSTEM
LS bypass plug
b a
T
PLS
PP
T
RKZ09250
Function
• This releases the residual pressure of LS pressure PLS.
• It makes the speed of the rise in pressure of LS pressure PLS more gentle. In addition, with this dis-
carded throttled flow, it creates a pressure loss in the throttled flow of the spool of shuttle valve, and
increases the stability by lowering the effective LS differential pressure.
Operation
• The pressurized oil for LS circuit PLS passes from filter a of bypass plug (1) through orifice b and flow to
the tank circuit T.
10-106 WB93R-8
HYDRAULIC SYSTEM
Pressure compensation valve
T
Side receiving Side giving
compensation compensation
A A
aB
aB
PLSS PPA
PA
2 PA
PPA
PP PLS
RKZ09260
Function
• During compound operations, if the load pressure on either actuator becomes lower than the other actu-
ator and the oil flow is about to increase, compensation is made.
a When this happens, the other actuator being used for compound operation (right side) is at a high load
then the actuator on this side (left side).
Operation
• When the load pressure on the other actuator (right side) becomes higher during compound operations,
the oil flow in actuator circuit A on the side (left side) starts increasing.
• When this happens, the LS pressure PLS on the other actuator acts on spring chamber PLSS and
reducing valve (1) and flow control valve (2) are pushes to the left.
• Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA to
cause a pressure loss between PP and PPA.
• Flow control valve (2) and reducing valve (1) are balanced in a position where the difference between
PLS and PA acting on both ends of reducing valve (1) and the pressure loss made between PP and PPA
on the sides of flow control valve (2) will be the same.
• In this way, the pressure difference between upstream pressure PPA and downstream pressure PA of
both spools used during compound operation is the same, so the pump flow is divided in proportion to
the area of opening of notch a of each spool.
WB93R-8 10-107
HYDRAULIC SYSTEM
Area ratio of pressure compensation valve
A b T
S1 S2
3 1
PPA
2 PA PLS
PP
RKZ09230
Function
• The pressure compensation valve determines the compensation characteristics by carrying out fine
adjustment of the area ratio (S2/S1) between (left) area S1 of flow control valve (2) and (right) area S2 of
reducing valve (1) to match the characteristics of each actuator.
S1: Area of flow control valve (2) - area of piston (3).
S2: Area of reducing valve (1) - area of piston (3).
Area ratio (S1:S2) and compensation characteristics

• When ratio is 1.00:
PP - PPB = PLS - PA (= A)] and oil flow is divided in proportion to area of opening of spool.
• When ratio is more than 1.00
PP - PPB > PLS - PA (= A) and oil flow is divided in a proportion less than area of opening of spool.
• When ratio is less than 1.00
PP - PPB < PLS - PA (= A) and oil flow is divided in a proportion more than area of opening of spool.
10-108 WB93R-8
HYDRAULIC SYSTEM
Priority valve
PP
D DLS
1
P LS
RKZ09270
Function
• The function of the priority valve is to distribute oil to the steering unit and to the other hydraulic compo-
nents.
• Distribution is determined by the position of the valve (1) of the priority valve in function of:
• the steering LS signal
• the pump discharge pressure PP
• the steering pressure D
• the pressure of the hydraulic circuit.
• The position of the valve is such as to guarantee that delivery to the steering unit will always correspond
to the actual need.
WB93R-8 10-109
HYDRAULIC SYSTEM
Self-pressure reducing valve

Function
• This valve reduces pump discharge pressure PP and supplies the pilot main pressure of 2.90 MPa {30.0
kg/cm2} to the PPC valve. When the actuator circuit pressure is low, the self-pressure sequence valve is
closed to raise pump discharge pressure PP to secure the pilot main pressure.
Operation
When the control valve is held
PPPC
PP
5
2
TO ACTUATORS
PLS
1
TS
T
RKZ09280
• Unload spool (1) moves and pump discharge pressure PP is set to 2.90 MPa {30.0 kg/cm²}. (See the
explanation of the unload valve).
• Pump discharge pressure PP is reduced to 2.90 MPa {30.0 kg/cm²} by self-pressure reducing spool (2)
and self-pressure reducing pilot relief valve (3), and the main pressure oil is supplied through the PPPC
port to the PPC valve.
10-110 WB93R-8
HYDRAULIC SYSTEM
When the control valve is operated
PPPC
PP
5
2 TO ACTUATORS
1 PLS
TS
RKZ09290
• Unload spool (1) moves to the left and pump discharge pressure PP becomes higher than the LS differ-
ential pressure. (See the explanation of unload valve).
• When pump discharge pressure PP is higher than 2.90 MPa {30.0 kg/cm²}, it is reduced to of 2.90 MPa
{30.0 kg/cm²} by self-pressure reducing spool (2) and self-pressure reducing pilot relief (3), and the pres-
sure oil is supplied through the PPPC port to the PPC valve (4) is kept open.
WB93R-8 10-111
HYDRAULIC SYSTEM
PPPC
PP 5
2 TO ACTUATORS
1 PLS
TS
RKZ09300
• When pump discharge pressure PP is below 2.90 MPa {30.0 kg/cm²}, self-pressure sequence valve (4)
moves to the right to reduce the opening area between PP and actuator circuit (5).
• As a result, differential pressure is made between PP and actuator circuit (5) and PP is raised to above
2.90 MPa {30.0 kg/cm²}, then it is reduced to 2.90 MPa {30.0 kg/cm²} by self-pressure reducing spool (2)
and self-pressure reducing pilot relief valve (3), and the pressure oil is supplied through the PPPC port to
the PPC valve.
10-112 WB93R-8
HYDRAULIC SYSTEM
Backhoe sliding plate lock valve
S3 Lock cylinder
1 4
T
T
PP
RKZ09310
Function
• This valve introduce pump pressure PP to sliding plate lock valve circuit and lock the backhoe work
equipments.
Operation
• When the solenoid (1) is OFF the pump discharge pressure PP goes through orifice (2) and check valve
(3) to sliding plate lock circuit port SS.
• The sliding plate lock circuit pressure SS is close by check valve (3) and side shift valve (4).
• As a result, the sliding plate lock circuit pressure SS is always equal the maximum pump discharge pres-
sure and backhoe work equipment is locked by lock cylinders.
WB93R-8 10-113
HYDRAULIC SYSTEM
S3 Lock cylinder
1 4
T
T
PP
RKZ09320
• When solenoid (1) is ON side shift lock circuit SS is connected to tank circuit T from side shift valve pis-
ton (4).
• As a result, clamps circuit pressure SS becomes low and work equipment is released.
10-114 WB93R-8
WORK EQUIPMENT SYSTEM

LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
Loader part
3
1
RKA82730
1. Loader bucket cylinders

2. Loader arm cylinders
3. Loader bucket 4 in 1 cylinders
WB93R-8 10-115
Body and cab parts
5
9
10
11
RKA82740
4. Steering unit
5. Brake pumps
6. Loader PPC valve
7. Outrigger PPC valve
8. Solenoid valve group
9. Control valve
10. Accumulator (for PPC circuit)
11. Hydraulic pump
10-116 WB93R-8
Backhoe part
14
13
15
12
16
17
18
19 18
RKA82750
12. Backhoe bucket cylinder

13. Backhoe telescopic arm cylinder
14. Backhoe arm cylinder
15. Backhoe boom cylinder
16. Backhoe boom lock cylinder
17. Backhoe sliding plate lock cylinders (n° 4)
18. Outrigger cylinders (n° 2)
19. Backhoe boom swing cylinders
WB93R-8 10-117
LOADER WORK EQUIPMENT PPC VALVE

a PPC: Abbreviation for Proportional Pressure Control
Standard version
P2 P4
P3 P1
Z
E E
D D
B T P
A C
C A
View Z
RKZ09330
P: From solenoid valve group

P1: To control valve (loader bucket curl port)
P2: To control valve (loader bucket dump port)
P3: To control valve (loader arm raise port)
P4: To control valve (loader arm lower port)
10-118 WB93R-8
5
7
4
8
3
2 9
1 10
A-A B-B
D-D
C-C
E-E
RKZ09340
1. Spool
2. Centering spring
3. Metering spring
4. Piston
5. Disk
6. Nut
7. Joint
8. Cover
9. Retainer
10. Valve body
WB93R-8 10-119
Operation
When valve is in neutral
• Ports (A) and (B) of the valve and ports (P1) and (P2) of the PPC valve are connected respectively through
fine control hole (f) of spool (1) to drain chamber (D).
10-120 WB93R-8
When valve is in fine control range (neutral to fine control range)
• When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downward.
• Almost at the same time when fine control hole (f) is disconnected from drain chamber (D), it is connected
to pump pressure chamber (PP).
• The pilot pressure oil of main pump is transmitted from port (P1) to port (A) through fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to
release the pressure in port (P1).
• Spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the stroke of the control lever.
• The pressure in port (P1) also increases in proportion to the stroke of the control lever.
• Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the return spring of the control valve spool.
WB93R-8 10-121
When valve is in fine control range (when control lever is returned)
• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the pressure
in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• When the pressure in port (P1) decreases too much, spool (1) is pushed down by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber
(PP) almost at the same time.
• The pump pressure is supplied until the pressure in port (P1) recovers to the pressure corresponding to the
lever position.
• When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine con-
trol hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
chamber (B) to replenish the port with pressurized oil.
10-122 WB93R-8
When control lever is fully operated
• Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1).
(PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) through fine control hole (f') into drain chamber (D).
WB93R-8 10-123
Float and return to dig version
P2 P4
P3 P1
D D
T T
B A
C C
A B
View Z
RKZ08920

P1: To control valve (loader bucket curl port)
P2: To control valve (loader bucket dump port)
P3: To control valve (loader arm raise port)
P4: To control valve (loader arm lower port)
10-124 WB93R-8
5 7
4 8
3
9
2
10
1
A-A 11 C-C
D-D
B-B
RKZ08980
1. Spool 7. Joint
2. Centering spring 8. Cover
3. Metering spring 9. Retainer
4. Piston 10. Piston
5. Disk 11. Valve body
6. Disk
WB93R-8 10-125
Operation
When valve is in neutral
D D
f f
T T
P2 P1 1 P3 P4 1
A Control B A Control B
valve valve
RKZ08990
• Ports (A) and (B) of the valve and ports (P1) and (P2) of the PPC valve are connected respectively through
fine control hole (f) of spool (1) to drain chamber (D).
10-126 WB93R-8
10
9
D
11 T
P
f
PP
1
P2 P1
A Control B
valve
RKZ09001
• When piston (4) and piston (10) are pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by
metering spring (2) and moves downward.
• Almost at the same time when fine control hole (f) is disconnected from drain chamber (D), it is connected
to pump pressure chamber (PP).
• The pilot pressure oil of main pump is transmitted from port (P1) to port (A) through fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to
release the pressure in port (P1).
• Spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1).
• The positional relationship between spool (1) and valve body (11) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the stroke of the control lever.
• The pressure in port (P1) also increases in proportion to the stroke of the control lever.
• Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the return spring of the control valve spool.
WB93R-8 10-127
When valve is in fine control range (when control lever is returned)
9
D 3
2
f
T
P
f’
PP
1
P2 P1
A Control B
valve
RKZ09011
• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the pressure
in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• When the pressure in port (P1) decreases too much, spool (1) is pushed down by metering spring (2).
(PP) almost at the same time.
• The pump pressure is supplied until the pressure in port (P1) recovers to the pressure corresponding to the
lever position.
• When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine con-
trol hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
chamber (B) to replenish the port with pressurized oil.
10-128 WB93R-8
9
D
f
T
P
f’
PP
P2 P1
A Control B
valve
RKZ09022
• Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1).
(PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) through fine control hole (f') into drain chamber (D).
WB93R-8 10-129
When control lever is moved to float position
5
4’
4
11
10
D
T
P
PP
P3 P4
A Control B
valve
RKZ09021
• If piston (4) and piston (10) of the spool controlling the arm (port P4) are pushed downwards by disk (5),
the mechanism inside the PPC valve will start locking the spool halfway along its travel.
• If piston (4’) is pushed upwards and the solenoid in the PPC valve is energized, the force generated by
the solenoid will retain the piston (4’) in place and the arm float condition will be retained – even if the
lever is released.
• At the same time, the control valve will also be activated and retained in the arm float position.
When control lever is moved from float back to neutral position

• The disk (5) can be moved back to neutral position by applying a force that exceeds the force applied by
the solenoid.
• The floating state can also be cancelled, and the lever can move back to neutral position, denergizing
the solenoid.
10-130 WB93R-8
OUTRIGGER PPC VALVE

P2 P4
P2
P4
P1
P3
P T
P1 P3
Z
RKA82950

P1: To control valve (backhoe L.H. outrigger lower port)
P2: To control valve (backhoe L.H. outrigger rise port)
P3: To control valve (backhoe R.H. outrigger lower port)
P4: To control valve (backhoe R.H. outrigger rise port)
WB93R-8 10-131
2
3
4
5
6 7
RKZ09370
1. Knob
2. Nut
3. Lever
4. Boot
5. Plate
6. L.H. PPC valve body
7. R.H. PPC valve body
10-132 WB93R-8
Operation
Control lever in neutral position
P2 P1
A Control B
valve
RKZ09380
• Ports A and B of control valve and ports P1 and P2 of PPC valves are connected to the tank circuit.
• Hence, the spool is in neutral position.
WB93R-8 10-133
P2 P1
A Control B
valve
RKZ09390
• When the lever (1) is moved in the direction shown by the arrow, the valves (2) are rotated and a passage is
opened between delivery duct a and port P1, while port P2 remains connected to the tank circuit.
• Pressure at port P1 increases as the travel of lever (1) increases. Consequently, the spool of the control
valve moves to the left by a distance that is proportional to the travel of the lever (1).
10-134 WB93R-8
P2 P1
A Control B
valve
RKZ10610
• When lever (1) is moved fully to the left, the valves (2) are fully rotated.
• Port P1 is then connected directly to delivery duct a whereas port P2 is connected to tank circuit only,
and the spool of the control valve performs its full travel.
WB93R-8 10-135
STEERING UNIT
LS
L
R
T P
RKA82960
L: to steering cylinder
R: to steering cylinder
T: to hydraulic tank
P: from control valve
LS: to control valve
Specifications
Steering unit type: OSPC 160 LS
Nominal stroke: 160 cc/rev
Safety valve setting: 22.5 to 24.5 MPa {229.4 to 250 kg/cm2}
Relief valve setting: 17.0 to 17.5 MPa {173.4 to 178.5 kg/cm2}
Function
• The steering unit is composed of a control valve and a rotating oil dispenser, and is of the hydrostatic
type.
• When the steering wheel is turned, the control valve sends oil from the pump (by means of the rotating
oil dispenser) to one of the sides of the steering cylinder.
• The rotating dispenser ensures that the volume of oil supplied to the cylinder is proportionate to the
angle of rotation of the steering wheel.
• In the event of malfunction, the oil dispenser will function automatically as a hand-pump, thus guarantee-
ing emergency steering.
10-136 WB93R-8
BRAKE PUMP
F
B
C
R RKA82780
B- To rear axle brake

C- Brake pressure balancing port
F - Brake pressure switch port
R - Brake oil tank
Specifications
Brake piston diameter: 27/23
Brake displacement: 14.5 - 19.5 cc
Brake pressure: 5.0±.0.5 MPa {51±.5 kg/cm2}
WB93R-8 10-137
SOLENOID VALVE
9-spool solenoid valve specification
1. Boom unlock solenoid valve (Y95)

2. PPC solenoid valve (Y93)
3. Power mode solenoid valve (Y91)
Acc: accumulator
P1: pick-up pressure port
P2: to outriggers PPC valve
A2: to backhoe boom unlock cylinder
UL: to loader PPC valve
PM: to hydraulic pump (power mode port)
P: from control valve
T: to hydraulic tank
10-138 WB93R-8
11-spool solenoid valve specification
1. Boom unlock solenoid valve (Y95)

2. PPC solenoid valve (Y93)
3. loader bucket 4 in 1 solenoid valve (Y98)
4. loader bucket 4 in 1 solenoid valve (Y99)
5. Power mode solenoid valve (Y91)
Acc: accumulator A1: to control valve (loader bucket 4 in 1 close port)

P1: pick-up pressure port B1: to control valve (loader bucket 4 in 1 open port)
P2: to outriggers PPC valve PM: to hydraulic pump (power mode port)
A2: to backhoe boom unlock cylinder P: from control valve
UL: to loader PPC valve T: to hydraulic tank
WB93R-8 10-139
ACCUMULATOR
PPC CIRCUIT ACCUMULATOR
1
RKA82790
1. Oil port
Outline
This accumulator is installed to the solenoid valve. Even if the engine is stopped while the work equipment is
raised, pilot oil pressure can be supplied to the work equipment control valve with the pressure of the
compressed nitrogen gas in the accumulator to operate the spool and lower the work equipment by its own
weight.
Specifications
Gas used Nitrogen gas

Volume of gas (cc) 350
Charged pressure (MPa) {kg/cm } 2 1.20 - 1.30 {12.2 - 13.3}
Max. pressure used (MPa) {kg/cm } 2 4.0 {40.8}
10-140 WB93R-8
HOLDING VALVE
Loader arm
PiL A
C2
V2 V2
2
3 4
5
50
Pressure ' p (bar)
45
40
35
30
25 a
20 b
15
10
c
5
0 0
10 20 30 40 50 60 70 80 90 100
Flow Q (l /min)
Sezione A - A
RKA82970
PiL: from loader arm lifting cylinders (head)

V2: from control valve (loader arm raise)
C2: to loader arm lifting cylinders (bottom side)
1 - Solenoid valve
2 - Adjusting screw
3 - Spring
4 - Spool
5 - Unlock screw
Characteristics
Safety valve setting: 22.0 - 23.0 MPa {224 - 234 kg/cm2}
WB93R-8 10-141
Loader bucket
PiL
V2 C2
Pressure Dp (bar)
Flow Q (l/min)
RKA82980
PiL: from loader bucket cylinders (bottom side)

V2: from control valve (loader bucket curl)
C2: to loader bucket cylinders (head side)
Characteristics
Safety valve setting: 22.0 - 23.0 MPa {224 - 234 kg/cm2}
10-142 WB93R-8
Backhoe boom
PiL
V2
C2
PiL
C2
V2
C2 2
Pressure Dp (bar)
1
PiL
V2 Flow Q (l/min)
RKA82990
PiL: from backhoe boom cylinder (bottom side)

V2: from control valve (backhoe boom raise)
C2: to backhoe boom cylinder (head side)
Characteristics
Safety valve (1) setting: 25.0 - 26.5 MPa {254 - 265 kg/cm2}
Safety valve (2) setting: 20.0 - 22.5 MPa {224 - 229 kg/cm2}
WB93R-8 10-143
Backhoe arm
PiL
C2
V2
Pressure Dp (bar)
Flow Q (l/min)
RKA83000
PiL: from backhoe arm cylinder (bottom side)

V2: from control valve (backhoe arm dump)
C2: to backhoe arm cylinder (head side)
Characteristics
Safety valve setting: 30.0 - 31.0 MPa {306- 316 kg/cm2}
10-144 WB93R-8
Outrigger
V2 V1
A A
A-A
C2 C1
Differential pressure Dp (bar)
Amount Q (</min)
RKA83010
C1: to outrigger cylinders (bottom side)

C2: to outrigger cylinders (head side)
V1: from control valve (outrigger lower)
V2: from control valve (outrigger raise)
Characteristics
Pilot ratio: 7:1
WB93R-8 10-145
WORK EQUIPMENT
WORK EQUIPMENT
LOADER WORK EQUIPMENT
1
2
3
4
5
RKA82720
1. R.H. loader bucket cylinder

2. R.H. loader arm cylinder
3. Loader arm
4. R.H. bucket link
5. L.H. loader bucket cylinder
6. L.H. loader arm cylinder
7. L.H. bucket link
8. Loader bucket (bucket 4 in 1 is shown in the picture)
10-146 WB93R-8
WORK EQUIPMENT
BACKHOE WORK EQUIPMENT
20
21
22
19
18
23
17
24
9
25
10
16
15
14
13
12
11 RKA82750
WB93R-8 10-147
WORK EQUIPMENT
9. Outrigger cylinder
10. Outrigger
11. Outrigger foot
12. Sliding support
13. Backhoe boom swing cylinders
14. Swing bracket
15. Backhoe bucket
16. Bucket link
17. Backhoe bucket cylinder
Backhoe telescopic arm

18. Telescopic movable arm
19. Telescopic arm cylinder
20. Telescopic fixed arm
21. Backhoe arm cylinder

22. Backhoe boom
23. Backhoe boom cylinder
24. Backhoe boom lock cylinder
25. Backhoe sliding plate lock cylinders (n° 4)
10-148 WB93R-8
WORK EQUIPMENT
WORK EQUIPMENT SHIM

Structure
• There are 2 types of work equipment shims, the iron shim and plastic shim.
• The work equipment shims are inserted to adjust the clearance of each joint of the work equipment to the
standard value.
Function
Steel shim
• The purpose of the iron shim is to reduce the play in the right and left direction of the work equipment.
a a Depending on the size of clearance, it may be required to insert the shim into either of the right and left
sides and insert no shim on the other side.
Plastic shim
• The purpose of the plastic shim is to reduce the play in the right and left direction of the work equipment
and prevent a creak and scuffing caused by rubbing of the end faces of steel parts of a joint.
WB93R-8 10-149
WORK EQUIPMENT
10-150 WB93R-8
WB93R-8
BACKHOE LOADER
WB93R-8

20 STANDARD VALUE TABLES01-
WB93R-8 20-1
CONTENTS
CONTENTS
CONTENTS .............................................................................................................................................. 20-2
ABBREVIATION LIST ............................................................................................................................... 20-3
STANDARD SERVICE VALUE TABLE .................................................................................................. 20-10

STANDARD VALUE TABLE FOR ENGINE......................................................................................... 20-10
STANDARD VALUE TABLE FOR MACHINE ...................................................................................... 20-15
20-2 WB93R-8
ABBREVIATION LIST
ABBREVIATION LIST
of the meaning.

Abbrevia-
tion
the tires rotate.
AISS Engine
reverse direction.
ARAC
ASR
BCV
not being used.
work tronic control
machine.
Crankcase Depres-
sion Regulator
WB93R-8 20-3
ABBREVIATION LIST

Abbrevia-
tion
than OLSS).
Electronic Control
Module
ECMV
Electronically Con-
System
EGR Engine
failure history).
portional Control
tive Structure
3449.
Forward-Neu-
tral-Reverse
20-4 WB93R-8
ABBREVIATION LIST

Abbrevia-
tion
Communication
Plus)
Communication
Plus)
System (D Series)
HST
(Same as IMV)
Unit
KCCV Engine
Komatsu Catalyzed
KCSF Engine gas.
Soot Filter
KDOC Engine
muffler.
ulate Filter
muffler.
WB93R-8 20-5
ABBREVIATION LIST

Abbrevia-
tion
KTCS
soft ground.
direction.
work tronic control
machine.
machine.
MMS Communication
NC Normally Closed
actuated.
NO Normally Open
actuated.
Open-center Load
Sensing System
less of the load.
PC Hydraulic system
tion sure.
PCCS
20-6 WB93R-8
ABBREVIATION LIST

Abbrevia-
tion
Pre-stroke Control
Valve

Motor (D, PC, etc)
ROPS Cab and canopy
structure)
3471 or ISO 12117-2.
SCR Urea SCR system
Le Systeme Interna-
principle applied.
energized.
TOPS Cab and canopy
12117.
direction of flow.
Variable Geometry
Turbocharger
is variable.
WB93R-8 20-7
ABBREVIATION LIST

Abbrevia-
tion
VHPC Engine control

HD: Dump truck
WA: Wheel loader
20-8 WB93R-8
ABBREVIATION LIST

A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
WB93R-8 20-9
STANDARD SERVICE VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE
Performace

Engine SAA4D99E-1
Standard value
Item Measurement condition Unit for new Repair limit
machine
• Engine coolant temperature: 75 to 94 °C
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MIN (Low idle) position
Target 2430 Target 2430
• Accelerator pedal: MAX (High idle) posi- rpm
Min. 2380 Min. 2380
tion
• Each control lever and control pedal:
NEUTRAL position
Engine speed at
high idle • Engine coolant temperature: 75 to 94 °C
• Torque converter oil
temperature: 75 to 85 °C
rpm 1900 ± 50 1900 ± 50
• Fuel control dial: MAX (High idle) position
• Accelerator pedal: MIN (Low idle) position
NEUTRAL position
Engine speed at temperature: 75 to 85 °C
rpm 950 900
low idle • Fuel control dial: MIN (Low idle) position
• Accelerator pedal: MIN (Low idle) position
NEUTRAL position
20-10 WB93R-8
Air intake and exhaust system

Engine SAA4D99E-1
Standard value
machine
• Engine coolant tempera- At sudden Bosch
N/A N/A
ture: 75 to 94 °C acceleration index
• Transmission direction
Exhaust gas color selection lever: Accelerator
in N (NEUTRAL) position pedal: MAX Bosch
N/A N/A
• After keeping it at normal (High idle) index
condition for 5 seconds position
WB93R-8 20-11
Main body

Engine SAA4D99E-1
Standard value
machine
Compression
• Engine at low idle bar 50 -
pressure
kPa Max. 0.98 1.47
Blow by pressure • Hydraulic oil temperature: 45 to 55 °C
{mmH2O} {Max. 100} {150}
• Engine speed: 2300 rpm
Oil pan pressure • Hydraulic oil temperature: 45 to 55 °C mbar 20 50
Fuel system

Engine SAA4D99E-1
Standard value
machine
kPa 883 to 1471 883 to 1471
Fuel pressure • Accelerator pedal: MAX (High idle) posi-
{kg/cm²} {9 to 15} {9 to 15}
tion
Engine speed
- 190
1600 rpm
Fuel return rate • Engine coolant tempera- 1700 rpm - 200

mℓ/min
from injector ture: 75 to 94 °C 1800 rpm - 210
1900 rpm - 220
2000 rpm - 230
Leakage from
• Engine coolant temperature to 94 °C mℓ/min 0 20
pressure limiter
20-12 WB93R-8
Lubrication system

Engine SAA4D99E-1
Standard value
machine
Fuel control
dial: MAX 0.29 to 0.69 Min. 0.21
• Engine coolant tempera- (High idle) {3.0 to 7.0} {Min 2.1}
Engine oil pres- ture: 75 to 94 °C position MPa
sure • Engine oil SAE10W40 {kg/cm²}
• Main gallery Fuel control
Min. 0.15 Min. 0.13
dial: MIN (Low
{Min. 1.5} {Min. 1.3}
idle) position
Engine oil
• Whole speed range (inside oil pan) °C 80 to 115 120
temperature
Cooling system

Engine SAA4D99E-1
Standard value
machine
• Measurement to be performed with a Belt
Fan belt tension Hz Max 150 Min 115
Frequency Meter
Air conditioner
• Measurement to be performed with a Belt
compressor belt Hz 142 to 147 132 to 137
Frequency Meter
tension
WB93R-8 20-13
Cooling fan

Engine SAA4D99E-1
Standard value
machine
• Engine coolant tempera- Engine speed:
2800 ±50 2800 ±100
ture: 75 to 94 °C 2400 rpm
• Hydraulic oil tempera-
Engine speed:
ture: 45 to 55 °C 2000 ±50 2000 ±100
Cooling fan 1700 rpm
• Transmission direction rpm
speed
selection lever:
Fuel control
in N (NEUTRAL) position
dial: MIN (Low 1120 ±50 1120 ±100
• Disconnect fan connector
idle) position
FC01
20-14 WB93R-8
STANDARD VALUE TABLE FOR MACHINE

Engine speed

Standard
Item Measurement condition Unit value for new Repair limit
machine
• Engine coolant temperature: 75 to
94 °C
• Hydraulic oil temperature: 45 to
55 °C
• Air conditioner: OFF
Engine low idle speed • Accelerator pedal: MIN (Low idle)
rpm Min. 940 Min. 900
with pump at relief position
• Fuel control dial: MIN (Low idle)
position
• Parking brake: ON
• Working mode: P (Power Mode)
• Transmission direction selection
lever: in N (NEUTRAL) position
• Backhoe boom RAISE: at relief
• Engine coolant temperature: to
94 °C
• Hydraulic oil temperature: to 55 °C
Engine high idle speed
• Accelerator pedal: MAX (High idle)
with torque converter rpm Min. 2170 Min. 2070
position
at stall
• Working mode: E (Economy Mode)
• Transmission mechanical
speed: 3rd gear
• Brake pedals: fully pressed
lever: in F (FORWARD) position
WB93R-8 20-15

Standard
machine
94 °C
55 °C
Engine high idle speed • Accelerator pedal: MAX (High idle)
with torque converter position
rpm Min. 2075 Min. 2075
at stall and pump at • Working mode: E (Economy Mode)
relief • Transmission mechanical
speed: 3rd gear
• Brake pedals: fully pressed
lever: in F (FORWARD) position
• Steering wheel: at relief in one
direction
• Shovel arm RAISE: at relief
94 °C
55 °C
Engine high idle speed
(fuel control dial set) rpm Min. 2370 Min. 2370
• Parking brake: ON
with pump at relief
• Fuel control dial: MAX (High idle)
position
• Transmission mechanical
speed: N (NEUTRAL)
• Backhoe boom RAISE: at relief
20-16 WB93R-8
SCR (Selective Catalytic Reduction)

Standard
machine
DEF Pump Pressure Perform UDST test using PTBox

- Passed Not passed
Up Test diagnosis tool.
DEF injector resist-

DEF injector 20 °C Ω 11.4 to 12.6 11.4 to 12.6
ance
DEF Injection Quantity Injection amount after finishing

mℓ 100 (+7/-26) 100 (+7/-26)
Test DEF Injection Quantity Test
DEF Line Heater Relay Within 900 seconds after starting

V 24.5±1.5 24.5±1.5
1 Test DEF Line Heater Relay 1 Test
DEF Line Heater Relay Within 900 seconds after starting

V 24.5±1.5 24.5±1.5
2 Test DEF Line Heater Relay 2 Test
DEF Pump Heater Within 900 seconds after starting

V 24.5±1.5 24.5±1.5
Relay Test DEF Pump Heater Relay Test
DEF Tank Heater Within 900 seconds after starting

V 24.5±1.5 24.5±1.5
Valve Test DEF Tank Heater Valve Test
Machine monitor display after

SCR Denitration Effi- SCR Denitration Efficiency Test is
- 1 (Normal) 1 (Normal)
ciency Test completed
DEF Injection Test Result
WB93R-8 20-17
Travel of loader control lever

Standard
machine
• Engine: stopped Neutral o Raise/
Arm control lever 80 to 110 80 to 110
• At center of Lower
lever knob
mm
• Read max. Neutral o Curl/
Bucket control lever value through 80 to 110 80 to 110
Dump
travel end
Travel of machine control pedal

Standard
machine
• Engine:
stopped
• Tip of pedal Neutral o Raise/
Accelerator pedal mm 65 to 95 65 to 95
• Read max. Lower
value through
travel end
Travel of backhoe control lever and pedal

Standard
machine
Neutral o Raise/
Boom control lever 80 to 110 80 to 110
Lower
Neutral o Curl/
Arm control lever 80 to 110 80 to 110
Dump
Neutral o Curl/
Bucket control lever • Engine: 80 to 110 80 to 110
Dump
stopped
Boom swing control • At center of Neutral o Swing
80 to 110 80 to 110
lever lever knob Left/ Swing Right
mm
Outrigger control • Tip of pedal Neutral o Raise/
• Read max. 25 to 45 25 to 45
lever (L.H. or R.H.) Lower
value through
Telescopic arm con- Neutral o Extend/
travel end 10 to 20 10 to 20
trol pedal (R.H. pedal) Retract
Side digging boom Neutral o Swing
10 to 20 10 to 20
(L.H. pedal) Left/ Swing Right
Attachment line pedal Neutral o L.H. side/
10 to 20 10 to 20
(L.H. pedal) R.H. side
20-18 WB93R-8
Control effort of loader control lever

Standard
machine
• For measuring posture, see 9.8 to 19.6 9.8 to 19.6
Arm control lever
"Fig. 19" {1.0 to 2.0} {1.0 to 2.0}
• Engine: Low idle
55°C N
• Measure by hooking push-pull {kg} 9.8 to 19.6 9.8 to 19.6
Bucket control lever scale at 80 mm from bottom of {1.0 to 2.0} {1.0 to 2.0}
knob
• Read max. value at 10 mm from
end of stroke
Control effort of machine control pedal lever

Standard
machine
55°C
N 24.5 to 53.9 24.5 to 53.9
Accelerator pedal • Measure by hooking push-pull
{kg} {2.5 to 5.5} {2.5 to 5.5}
scale to pedal end
• Read max. value at 10 mm from
end of stroke
WB93R-8 20-19
Control effort of backhoe control lever and pedal

Standard
machine
9.8 to 19.6 9.8 to 19.6
Boom control lever
{1.0 to 2.0} {1.0 to 2.0}
9.8 to 19.6 9.8 to 19.6
Arm control lever
• Engine: Low idle {1.0 to 2.0} {1.0 to 2.0}
• Hydraulic oil temperature: 45 to 7.8 to 17.6 7.8 to 17.6
Bucket control lever
55°C {0.8 to 1.8} {0.8to 1.8}
Boom swing control • For control lever, measure by 7.8 to 17.6 7.8 to 17.6
lever hooking push-pull scale to {0.8 to 1.8} {0.8to 1.8}
N
center of grip
Outrigger control lever • For control pedal, measure by {kg} 9.8 to 19.6 9.8 to 19.6
(L.H. or R.H.) hooking push-pull scale to {1.0 to 2.0} {1.0 to 2.0}
Telescopic arm control pedal tip 24.5 to 34.3 24.5 to 34.3
pedal (R.H. pedal) • Read max. value at 10 mm to {2.5 to 3.5} {2.5 to 3.5}
Side digging boom travel end 24.5 to 34.3 24.5 to 34.3
(L.H. pedal) {2.5 to 3.5} {2.5 to 3.5}
Attachment line pedal 24.5 to 34.3 24.5 to 34.3
(L.H. pedal) {2.5 to 3.5} {2.5 to 3.5}
20-20 WB93R-8
Hydraulic basic pressure

Standard value
Item Measurement condition Unit Repair limit
for new machine
55°C
• Engine speed: High idle MPa 2.94 to 3.92 2.94 to 3.92
Unload pressure
• Working mode: P (Power Mode) {kg/cm²} {30.0 to 40.0} {30.0 to 40.0}
• All levers and pedals in NEU-
TRAL position
55 °C
Steering circuit relief • Working mode: P (Power Mode) MPa 17.0 to18.5 17.0 to18.5
pressure • Steering wheel: at relief in one {kg/cm²} {173.3 to 188.6} {173.3 to 188.6}
direction
• Loader and backhoe levers:
in NEUTRAL position
55 °C
LS Differential pres- • Engine speed: Low idle MPa 2.65 to 3.05 2.65 to 3.05
sure in NEUTRAL • Working mode: P (Power Mode) {kg/cm²} {20 to 30} {20 to 30}
• All levers and pedals in NEU-
TRAL position
55 °C
LS Differential pres- • Engine speed: Low idle MPa 2.54 to 2.95 2.54 to 2.95
sure at relief • Working mode: P (Power Mode) {kg/cm²} {25 to 29} {25 to 29}
• Shovel arm RAISE: at relief
• Shovel bucket CURL: at relief
55 °C
• Engine speed: Low idle MPa 3.02 to 3.43 3.02 to 3.43
Servocontrol pressure
• Working mode: P (Power Mode) {kg/cm²} {30.8 to 35.0} {30.8 to 35.0}
• Shovel arm lever RAISE: at full
stroke
WB93R-8 20-21
Loader hydraulic pressure

Standard value
for new machine
23.5 to 26.5 23.5 to 26.5
Raise
{249.8 to 270.2} {249.8 to 270.2}
Arm relief pressure
23.5 to 26.5 23.5 to 26.5
Lower
{249.8 to 270.2} {249.8 to 270.2}
• Hydraulic oil temper-
ature: 45 to 55 °C 23.5 to 26.5 23.5 to 26.5
Curl
• Engine speed: {249.8 to 270.2} {249.8 to 270.2}
Bucket relief pressure
1800 rpm MPa 23.5 to 26.5 23.5 to 26.5
Dump
• Working mode: P {kg/cm²} {249.8 to 270.2} {249.8 to 270.2}
(Power Mode) 23.5 to 26.5 23.5 to 26.5
Front attachment line L.H. side
• Measurement {249.8 to 270.2} {249.8 to 270.2}
relief pressure
circuit: at relief
(Bucket 4 in 1, mixing 23.5 to 26.5 23.5 to 26.5
bucket, etc.) R.H. side
{249.8 to 270.2} {249.8 to 270.2}
Hand hammer relief
- -- --
pressure
20-22 WB93R-8
Backhoe hydraulic pressure

Standard value
for new machine
23.5 to 26.5 23.5 to 26.5
LOWER
{249.8 to 270.2} {249.8 to 270.2}
RAISE
(without 23.5 to 26.5 23.5 to 26.5
safety {249.8 to 270.2} {249.8 to 270.2}
valve)
RAISE
(with
Boom relief pressure safety 10.9 to 11.5 10.9 to 11.5
valve and {111.1 to 117.3} {111.1 to 117.3}
• Hydraulic oil tempera- standard
ture: 45 to 55 °C arm)
• Engine: High idle RAISE
• Working mode: P (with MPa
(Power Mode) safety 14.4 to 15.0 14.4 to 15.0
{kg/cm²}
• Hydraulic pump out- valve and {146.8 to 153.0} {146.8 to 153.0}
let pressure with telescopic
measurement circuits arm)
relieved
Side digging boom 23.5 to 26.5 23.5 to 26.5
relief pressure {249.8 to 270.2} {249.8 to 270.2}
23.5 to 26.5 23.5 to 26.5
Arm relief pressure
{249.8 to 270.2} {249.8 to 270.2}
Telescopic arm relief 23.5 to 26.5 23.5 to 26.5
pressure {249.8 to 270.2} {249.8 to 270.2}
23.5 to 26.5 23.5 to 26.5
Bucket relief pressure
{249.8 to 270.2} {249.8 to 270.2}
Boom swing relief 23.5 to 26.5 23.5 to 26.5
pressure {249.8 to 270.2} {249.8 to 270.2}
LH side
18.5 to 21.5 18.5 to 21.5
• Hydraulic oil tempera- (delivery
Attachment relief pres- {188.6 to 219.2} {188.6 to 219.2}
ture: 45 to 55 °C line
sure • Engine: High idle
(1 way specification) RH side
• Working mode: P MPa
(return -- --
(Power Mode) {kg/cm²}
line)
• Hydraulic pump outlet
pressure with meas- 18.5 to 21.5 18.5 to 21.5
Attachment relief pres- LH side
urement circuits {188.6 to 219.2} {188.6 to 219.2}
sure
(2 way specification) relieved 18.5 to 21.5 18.5 to 21.5
RH side
{188.6 to 219.2} {188.6 to 219.2}
WB93R-8 20-23
Loader work equipment

Standard
machine
Whole loader work • For measuring posture, see "Fig. 1"
Max. 150 Max. 300
equipment drift at • Hydraulic oil temperature: 45 to 55 °C
[Max. 210] [Max. 420]
bucket tooth tip • Measure hydraulic drift of bucket tooth
Loader arm cylin- tip.
Hydraulic drift
• Additional weight to be added: Max. 19 Max. 32

ders retraction
with standard bucket: 1500 kg [Max. 27] [Max. 45]
amount mm
with bucket 4 in 1: 1250 kg
with bucket 4 in 1 and forks: 1060 kg
Loader bucket cylin- • Engine speed: stopped
Max. 28 Max. 40
ders retraction • Measure immediately after setting [Max. 39] [Max. 56]
amount • Measure hydraulic drift every 5 min-
utes and judge at 15 minutes
[ ]: this value is for machines equipped with cold climate device

Standard
value for new
Item Measurement condition Unit machine Repair limit
• For measuring posture, see Raise 3.5 to 4.3 Max. 5.1

"Fig. 2"
Loader arm on
• Engine: High idle using
ground
accelerator control pedal
IO
• Working mode: P (Power Lower 2.6 to 3.2 Max. 3.8
Max. extension of
Mode)
cylinder
• Hydraulic oil temperature:
45 to 55 °C
Work equipment speed
• For measuring posture, see Curl 1.9 to 2.3 Max. 2.8

"Fig. 3"
Loader bucket
Max. extension of
cylinder sec.
• Working mode: P (Power Dump 2.3 to 2.9 Max. 3.5
IO
Mode)
Max. retraction
45 to 55 °C
• For measuring posture, see Open 1.5 to 1.9 Max. 2.3
"Fig. 4"
Bucket 4 in 1
Max. extension of
cylinder
• Working mode: P (Power Close 1.7 to 2.1 Max. 2.5
IO
Mode)
Max. retraction
45 to 55 °C
20-24 WB93R-8

Standard
machine
• For measuring posture, see "Fig. 5"
Time lag

Loader arm • Lower loader arm from max. raising sec. 0 Max. 2.0
position and measure time taken to
raise the machine after bucket reaches
ground
WB93R-8 20-25
Backhoe work equipment

Standard
machine
Whole loader work
Max. 220 Max. 350
equipment drift at
• For measuring posture, see "Fig. 6" [Max. 310] [Max. 543]
bucket tooth tip
Backhoe boom cylin- • With standard arm: add 410 to bucket
Max. 13 Max. 20
der retraction With telescopic arm: fully extend arm [Max. 18] [Max. 36]
amount and do not add weight to bucket
mm
Backhoe arm cylin- • Bucket weight: 155 kg
• Engine: stopped [*1] Max. 10 Max. 20
der extension
• Measure immediately after setting [Max. 14] [Max. 28]
amount
• Measure hydraulic drift every 5 min-
Backhoe bucket cyl-
utes and judge after 15 minutes Max. 8 Max. 15
inder retraction
[Max. 10] [Max. 19]
amount
• For measuring posture, see “Fig. 7”
• Bucket: With rated load (592 kg)
• Engine: stopped [*1]
Boom swing cylin- • Hydraulic oil temperature: 45 to 55 °C
Max. 15 Max. 15
der retraction • Measure immediately after setting mm
Hydraulic drift
[N/A] [N/A]
amount • Measure hydraulic drift of the
extended cylinder after 15 minutes
• Repeat the procedure on the other
side
Backhoe telescopic
• Hydraulic oil temperature: 45 to 55 °C Max. 8 Max. 15
arm cylinder exten- mm
• Measure immediately after setting [N/A] [N/A]
sion amount
• Measure hydraulic drift after 15 min-
utes
• For measuring posture, see “Fig. 9”
• Loader bucket raised from ground
• Fully extend both outrigger, then
retract them of about 30 mm with a
single movement of the operating
Outrigger cylinder Max. 7 Max. 15
lever. mm
retraction amount [N/A] [N/A]
• Measure immediately after setting
• Measure hydraulic drift every 5 min-
utes and judge at 15 minutes
[*1]: On cylinders without safety valves, release residual pressure from the cylinders with the following proce-
dure:
1. move the cylinder in the direction needed for testing until the relief pressure is reached
2. move the cylinder in the opposite direction of about 5-10 mm with a single short movement of the
operating lever/pedal.
[ ]: This value is for machines equipped with cold climate device
20-26 WB93R-8

Standard
value for new
Item Measurement condition Unit machine Repair limit
• For measuring posture, see 2.4 to 2.9

Backhoe boom on [2.4 to 3.0] Max. 3.6
"Fig. 10" Raise
ground (To just before [N/A]
• Engine: 1700 - 1750 rpm
IO cushion)
Max. retraction of
45 to 55 °C 2.1 to 2.6 Max. 3.1
cylinder Lower
• Bucket weight: 155 kg [3.0 to 3.6] Max [4.4]
Backhoe arm [3.1 to 3.7] Max. 5.5
"Fig. 11" Curl
Max. extension of (To just before Max [4.5]
• Engine: 1700 - 1750 rpm
cylinder cushion)
IO
45 to 55 °C 3.7 to 4.5 Max. 5.4
Max. retraction Dump
• Bucket weight: 155 kg [3.8 to 4.6] [N/A]
Work equipment speed
• For measuring posture, see Curl 2.6 to 3.2 Max. 3.8

Backhoe bucket
"Fig. 12"
Max. extension of
• Engine: 1700 - 1750 rpm
cylinder
• Hydraulic oil temperature: Dump sec. 2.0 to 2.4 Max. 2.9
IO
45 to 55 °C
Max. retraction
• Bucket weight: 155 kg
Boom swing Left (To just before Max. 3.6
"Fig. 13"
Max. extension of cushion)
• Engine: 1700 - 1750 rpm
cylinder
• Hydraulic oil temperature: 2.4 to 3.0
IO
45 to 55 °C Right (To just before Max. 3.6
Max. retraction
• Bucket weight: 155 kg cushion)
• For measuring posture, see Lower 2.9 to 3.5 Max. 4.2
"Fig. 14"
Outrigger
• Loader bucket raised from
Max. extension of
ground
cylinder
• Engine: 1700 - 1750 rpm Raise 2.57 to 3.1 Max. 3.7
IO
Max. retraction
45 to 55 °C
• Bucket weight: 155 kg
[ ]: this value is for machines equipped safety valve
WB93R-8 20-27

Standard
machine
• Engine speed: Low idle
Backhoe boom • With arm and bucket cylinders 0 Max. 2
extended fully, lower boom and meas-
ure time taken to raise the machine
after bucket reaches ground
• With boom ad 45°, arm cylinder fully
Backhoe arm 0 Max. 2
retracted and bucket cylinder fully
extended, CURL arm and measure
Time lag
time needed to start after it has

stopped in lower side sec.
Backhoe bucket 0 Max. 2
• With arm cylinder fully retracted CURL
bucket and measure time needed to
start after it has stopped in lower side
Outriggers • Lower outrigger from retract position 0 Max. 2
and measure time taken to raise the
machine after outrigger reaches
ground
20-28 WB93R-8
Pump performance

Discharged
Discharged
volume
Item Measurement condition Unit volume
Standard
Repair limit
value
• Engine speed: 2200 rpm using accelerator
control pedal.
Performance of Q Q
• Measure to be performed using the back- l/min
hydraulic pump (See graph) (See graph)
hoe arm element.
• Working mode: P (Power Mode).
a Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to
the specified speed by using the fuel control dial, take the pump discharged volume and the engine
speed at the time of measurement, and use them as a base for calculating the pump discharged volume
at the specified speed.
WB93R-8 20-29
Machine posture and procedure for measuring performance

Fig. 1
Fig. 2
Fig. 3
20-30 WB93R-8
Fig. 4
Fig. 5
Fig. 6
Fig. 7
RKA81250
WB93R-8 20-31
Fig. 8
Fig. 9
Fig. 10
Fig. 11
20-32 WB93R-8
Fig. 12
Fig. 13
Fig. 14
Fig. 15
WB93R-8 20-33
Fig. 16
Fig. 17
Fig. 18
Fig. 19
20-34 WB93R-8
WB93R-8
HYDRAULIC EXCAVATOR
WB93R-8

30 TESTING AND ADJUSTING 01-
WB93R-8 30-1
CONTENTS
CONTENTS .............................................................................................................................................. 30-2
ENGINE AND COOLING SYSTEM ........................................................................................................ 30-10

TEST ENGINE SPEED ........................................................................................................................ 30-10
TEST EXHAUST GAS COLOR............................................................................................................ 30-13
UNDERCARRIAGE AND FRAME .......................................................................................................... 30-15

CHECKING LEAKAGES IN THE STEERING CYLINDER................................................................... 30-15
TESTING STEERING CIRCUIT OIL PRESSURE ............................................................................... 30-16
TESTING THE BRAKING SYSTEM PRESSURE................................................................................ 30-17
TESTING THE BRAKE SYSTEM LEAKAGE....................................................................................... 30-19
BLEEDING AIR FROM THE BRAKE LINES........................................................................................ 30-20
METHOD FOR TESTING BRAKE PISTON STROKE ......................................................................... 30-21
METHOD FOR TESTING THE BRAKE PUMP BALANCING VALVE ................................................. 30-22
METHOD FOR TESTING THE BRAKE PEDAL STROKE .................................................................. 30-24
METHOD FOR ADJUSTING PEDAL BRAKING POSITION AND ALIGNMENT................................. 30-25
ADJUSTING TOE-IN-STEERING ANGLE WITH FRONT AXLE REMOVED FROM MACHINE......... 30-32
ADJUSTING TOE-IN-STEERING ANGLE WITH FRONT AXLE WITHOUT REMOVE THE AXLE FROM
MACHINE................................................................................................................................................ 30-35
TESTING AND ADJUSTING THE PARKING BRAKE SYSTEM ......................................................... 30-39
CHECKING THE DISTANCE BETWEEN THE BRAKE PADS AND DISC.......................................... 30-41
HYDRAULIC SYSTEM............................................................................................................................ 30-43

RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT ............................................. 30-43
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS................................ 30-44
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT CIRCUITS........................... 30-46
TESTING OIL PRESSURE OF CONTROL CIRCUIT.......................................................................... 30-52
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL OIL PRESSURE................................ 30-54
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT ............................ 30-58
TESTING OUTLET PRESSURE OF SOLENOID VALVE ................................................................... 30-60
TESTING PPC VALVE OUTLET PRESSURE..................................................................................... 30-62
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVES............................................................... 30-64
TESTING TRANSMISSION OIL PRESSURE CIRCUIT ...................................................................... 30-65
ISOLATING THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT........................... 30-67
BLEEDING AIR FROM HYDRAULIC CIRCUIT ................................................................................... 30-70
CHECK OF OIL LEVEL AND OPERATION......................................................................................... 30-71
ELECTRICAL SYSTEM .......................................................................................................................... 30-73

SET AND ADJUST EACH EQUIPMENT ............................................................................................. 30-73
SET AND OPERATE MACHINE MONITOR........................................................................................ 30-74
METHOD FOR STARTING UP KOMTRAX TERMINAL.................................................................... 30-101
30-2 WB93R-8
ADJUST FRONT PANEL SETTINGS................................................................................................ 30-109

HANDLING BATTERY DISCONNECT SWITCH............................................................................... 30-111
TESTING DIODES............................................................................................................................. 30-112
WORK EQUIPMENT ............................................................................................................................ 30-114

OUTRIGGER SENSOR AND SAFETY SYSTEM.............................................................................. 30-114
RETURN TO DIG SENSOR ADJUSTMENT ..................................................................................... 30-117
TELESCOPIC ARM GUIDE SLACK ADJUSTMENT......................................................................... 30-118
WB93R-8 30-3
ABBREVIATION LIST
of the meaning.
LIST OF ABBREVIATIONS USED IN THE TEXT

Abbrevia-
tion
the tires rotate.
AISS Engine
reverse direction.
ARAC
ASR
BCV
not being used.
work tronic control
machine.
Crankcase Depres-
sion Regulator
30-4 WB93R-8

Abbrevia-
tion
than OLSS).
Electronic Control
Module
ECMV
Electronically Con-
System
EGR Engine
failure history).
portional Control
tive Structure
3449.
Forward-Neu-
tral-Reverse
WB93R-8 30-5

Abbrevia-
tion
Communication
Plus)
Communication
Plus)
System (D Series)
HST
(Same as IMV)
Unit
KCCV Engine
Komatsu Catalyzed
KCSF Engine gas.
Soot Filter
KDOC Engine
muffler.
ulate Filter
muffler.
30-6 WB93R-8

Abbrevia-
tion
KTCS
soft ground.
direction.
work tronic control
machine.
machine.
MMS Communication
NC Normally Closed
actuated.
NO Normally Open
actuated.
Open-center Load
Sensing System
less of the load.
PC Hydraulic system
tion sure.
PCCS
WB93R-8 30-7

Abbrevia-
tion
Pre-stroke Control
Valve

Motor (D, PC, etc)
ROPS Cab and canopy
structure)
3471 or ISO 12117-2.
SCR Urea SCR system
Le Systeme Interna-
principle applied.
energized.
TOPS Cab and canopy
12117.
direction of flow.
Variable Geometry Tur-
bocharger
is variable.
30-8 WB93R-8

Abbrevia-
tion
VHPC Engine control

HD: Dump truck
WA: Wheel loader
WB93R-8 30-9
LIST OF ABBREVIATIONS USED IN THE CIRCUIT DIAGRAMS

A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
30-10 WB93R-8
TEST ENGINE SPEED
ENGINE AND COOLING SYSTEM

TEST ENGINE SPEED
k Place the machine on a level ground, lower the work equipment completely to the ground in a
stable posture and then stop the engine.
k Be careful not to touch any hot parts when installing or removing the testing tools.
Check this item under the following conditions.
• Transmission oil temperature: 75 to 85°C
For testing of engine speed to perform troubleshooting, Pm Clinic, or periodic maintenance, refer to this
section.
METHOD FOR TESTING ENGINE SPEED

PREPARATION FOR TESTING ENGINE SPEED
Check this item with “Self-defined monitoring” in the “Service menu” of the machine monitor.
1. Select the following monitoring items on “01 -
Self-defined monitoring” in the “Service Menu” of
the machine monitor. For details, see “SET AND
OPERATE MACHINE MONITOR”.
Monitoring code: 01002 “Engine Speed”.
Monitoring code: 04107 “Coolant Temperature”
Monitoring code: 02409 “Transmission Oil
Temperature”
TESTING ENGINE SPEED AT LOW IDLE

1. Start the engine.
2. Raise the coolant temperature and each oil tem-
perature to the specified range.
3. Set the fuel control dial to MIN (Low idle) posi-
tion.
4. Set the travel direction control lever in NEUTRAL
(N) and parking brake ON.
5. Check the engine speed when all control levers rpm
and control pedals are in NEUTRAL position. For

standard values, see STANDARD VALUE
TABLE, “STANDARD VALUE TABLE FOR
ENGINE”.
RKA81710
TESTING THE ENGINE SPEED AT HIGH IDLE

3. Check that all control levers and control pedals
are at NEUTRAL position, and then set the lock
lever to LOCK position.
4. Set the working mode to P (“Power Mode”).
WB93R-8 30-11
TEST ENGINE SPEED
6. Turn the fuel control dial to MIN (Low idle) posi-

tion.
7. Fully press the accelerator pedal and check the
engine speed when all control levers and control
pedals are in NEUTRAL position.
8. Release the accelerator pedal and turn the fuel
control dial to MAX (High idle) position.
9. Check the engine speed when all control levers
and control pedals are in NEUTRAL position. For rpm
standar d values, see STANDARD VALUE
ENGINE”.
RKA81700
ENGINE LOW IDLE SPEED TEST AT PUMP AT RELIEF

tion. rpm
6. Operate loader arm control lever to check the

engine speed at loader arm RAISE relief. For
standar d values, see STANDARD VALUE
MACHINE”. RKA81710
ENGINE HIGH IDLE SPEED TEST WITH TORQUE CONVERTER AT STALL

4. Set the parking brake OFF.
tion.
6. Select the 3rd mechanical speed. rpm
7. Fully press and maintain in position the service

brake pedals.
8. Set the travel direction control lever in FOR-
WARD.
RKA81720
9. Fully press the accelerator pedal and check the
engine speed in this condition. For standard val-
ues, see STANDARD VALUE TABLE, “STAND-
ARD VALUE TABLE FOR MACHINE”.
30-12 WB93R-8
TEST ENGINE SPEED
ENGINE HIGH IDLE SPEED TEST WITH PUMP AT RELIEF AND TORQUE CONVERTER AT
STALL
tion.
5. Set the parking brake OFF.
6. Select the 3rd mechanical speed. rpm
7. Fully press and maintain in position the service

brake pedals.
8. Set the travel direction control lever in FOR-
WARD.
RKA81720
9. Fully press the accelerator pedal.
10. Simultaneously operate steering in one direction
and loader arm raise at relief and check the
engine speed in this condition. For standard val-
ARD VALUE TABLE FOR MACHINE”.
ENGINE HIGH IDLE SPEED TEST WITH PUMP AT RELIEF (FUEL CONTROL DIAL SET)
5. Turn the fuel control dial to MAX (High idle) posi-
tion. rpm
6. Operate backhoe boom control lever to check the

engine speed at backhoe boom RAISE relief. For
standard values, see STANDARD VALUE
MACHINE”. RKA81720
WB93R-8 30-13
TEST EXHAUST GAS COLOR

• Tools for testing exhaust gas color
Symbol Part No. Part name Q'ty Remarks
A 799-201-9002 Handy smoke checker 1
Commercially
- Smoke meter 1
available
Commercially
B 1 Probe 1
available
Commercially
2 Accelerator switch 1
available
k Place the machine on a level ground, lower the work equipment completely to the ground in a
stable posture and stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn
injury. Wait for the temperature to go down, and then start the work.
If compressed air or electric power as power source is not available in the field, use handy smoke checker A.
When recording official data, etc., use smoke meter B. For testing of exhaust gas color to perform trouble-
shooting or others, refer to this section.
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER

Check this item with “Self-defined monitoring” in the “Service menu” of the machine monitor.
• Monitoring code: 04107 “Coolant Temperature”
3. Raise the engine oil temperature to the specified
range.
4. Fit a sheet of filter paper to the handy smoke
checker A.
5. Insert the exhaust gas intake pipe of handy
smoke checker A into tail pipe (1).
6. Accelerate the engine sharply from low idle to
high idle, and run it with fuel control dial at MAX
(High idle). When the engine speed is stabilized,
collect the exhaust gas to the filter paper by oper-
ating the handle of smoke checker A.
a When collecting the exhaust gas with fuel control
dial at MAX (High idle) position, stabilize the
engine speed by holding the dial in place for 5
seconds.
a Collecting time: 1.4±0.2 seconds
7. Remove the filter paper and compare it with the
attached scale for judgment. For standard val-
ARD VALUE TABLE FOR ENG INE”. After
finishing the test, remove the testing tools and
restore the machine.
30-14 WB93R-8
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER

1. Insert the probe B1 of smoke meter B into the tail
pipe (1), and fix it to tail pipe (1) with a clip.
2. Turn on the power switch of smoke meter B.
a For the operation method of the smoke meter B,
see Operation and Maintenance Manual for the
smoke meter B.
• Monitoring code: 04107 “Coolant Temperature”
5. Adjust the coolant temperature to the specified
range.
B
6. Turn off the auto-deceleration.
7. Accelerate the engine sharply from low idle to B2 2
high idle, and run it with fuel control dial at MAX
(High idle). When the engine speed is stabilized,
test the exhaust gas color.
a When collecting the exhaust gas with fuel control
B1
dial at MAX (High idle) position, stabilize the
engine speed by holding the dial in place for 5
seconds.
a For the operation method of the smoke meter B,
see Operation and Maintenance Manual for the
smoke meter B.
For standard values, see STANDARD VALUE
TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools and
restore the machine.
WB93R-8 30-15
CHECKING LEAKAGES IN THE STEERING CYLINDER

CHECKING LEAKAGES IN THE STEERING CYLINDER
k Place the machine on a level ground, fully raise the front work equipment and secure them with
the safety lock, so that it is stable, and then stop the engine.
For testing of steering cylinder leakage to perform troubleshooting, Pm Clinic, or periodic maintenance, refer
to this section.
METHOD FOR CHECKING LEAKAGES IN THE STEERING CYLINDER

1. Start the engine and execute a full steering
movement in one of the two directions.
2. Stop the engine.
3. Disconnect the supply hose (2) from the cylinder
(1) on the side of the fully extended piston rod
(3). Seal the hose securely.
4. Connect a provisional hose to the cylinder (1) to
collect any leaking oil.
5. Start the engine and put it into high idling.

6. Apply maximum force to the steering wheel and hold that position for 30 seconds; measure any oil leak-
ages for another full minute.
7. Release the steering wheel, bring the engine back to low idling, then switch off.
8. Check whether the amount of leakage is normal (See "20 STANDARD VALUE TABLES").
a Check the cylinder for one side only, since
just one seal separates the two chambers.
9. Re-assemble the hydraulic connections and execute several full steering movements in both directions
to release air from the circuit.
10. Use the same procedure to check the rear axle cylinder after having selected one of the two types of
steering.
30-16 WB93R-8
TESTING STEERING CIRCUIT OIL PRESSURE
TESTING STEERING CIRCUIT OIL PRESSURE

• Testing and adjusting tools for steering circuit oil pressure

799-101-5002 Hydraulic tester 1
1
790-261-1204 Digital hydraulic tester 1
K 799-101-5220 Nipple 1 10 × 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3300 Adapter 1 Size: 04
For testing of steering circuit to perform troubleshooting, Pm Clinic, or periodic maintenance, refer to this
section.
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE
1. Connect oil pressure gauge of hydraulic tester

K1 to port P1c on the main pump (1)
a Use the oil pressure gauge of 40 MPa {400
kg/cm²}. K1 1
2. Start the engine and set the working mode to
power P mode.
3. Set engine speed to 1500 rpm using fuel control
dial.
4. Measure the pressure when the steering wheel is
not operated. P1C
5. Turn the steering wheel up to end of stroke, and
forcing to end of stroke measure the pressure. RKZC3271
6. If pressure is not within the specification, it is

necessary to replace the steering unit or repair it
on a bench, because it is not possible to adjust it
when fitted on the machine.
WB93R-8 30-17
TESTING THE BRAKING SYSTEM PRESSURE

• Testing tools for braking system pressure
1
P 2 799-401-3100 Adapter 1 Size: 02
799-101-5220 Nipple 1 M10 x 1.25 mm
3
07002-11023 O-ring 1
• Rear axle oil temperature: 75 to 85 °C
For testing of brake system pressure to perform troubleshooting, Pm Clinic, or periodic maintenance, refer to
this section.
METHOD FOR TESTING BRAKING SYSTEM PRESSURE
1. Disconnect hose (1) of the brake line to be tested

and plug the pipe (2).
1
RKAD3590
2. Install on hose (1) the following components:

a) the adapter P2 and the nipple P3 From brake pump
1
b) an hydraulic tester P1 (6 MPa {60 kg/cm²}) 20
10
30
40
50
0 60
c) a cock (3) P1
d) a plug (4) P2
P3
a Brake hose and pipe thread: 1/2” - 20 UNF
3
2
4
RKA82670
30-18 WB93R-8
3. Bleed air from the circuit before proceeding with

the test (for details see "BLEEDING AIR FROM
THE BRAKE LINES").
4. Disconnect the pedal connecting pin and press
the corresponding brake pedal (left pedal for the
left side brake unit, right pedal for the right side
brake unit) until reaching 4.1 ± 0.5 MPa {41.8 ±
5.1 kg/cm2} while pressing the pedal with a force
of 294 ± 29.4N {30 ± 3 kg}.
REMARK
The pressure of 4.1 ± 0.5 MPa {41.8 ±
5.1kg/cm2} have to be reached when the force
of 294 ± 29.4N {30 ± 3 kg} is applied. If this situ-
ation does not occur, as example if the pres-
sure is not reached or the pressure is reached
with a higher force, there is a problem in the
brake system. Check the brake system for
leakages or brake pump problem.
5. Hold the brake pedal in that position without mov-
ing it for the next 2 minutes.
• If pressure decreases test the braking system
for leakage (see "TESTING THE BRAKE SYS-
TEM LEAKAGE").
• If the pressure value does not change, braking
the line tested is working correctly.
WB93R-8 30-19
TESTING THE BRAKE SYSTEM LEAKAGE
TESTING THE BRAKE SYSTEM LEAKAGE
1. Install between hose (1) and pipe (2) of the brak-

ing line to be checked the following components
starting from the brake pump side hose (1): 1
a) a cock (3)
b) the adapter P2 and the nipple P3
c) an hydraulic tester P1 (6 MPa {60 kg/cm²}) 2
a Brake hose and pipe thread: 1/2” - 20 UNF

2. Connect adapter P2 to pipe (2).
RKAD3590
From brake pump

1
3
30
20 40
10 50
0 60
P3
P2 P1
2
RKA82680

brake unit) until the braking pressure indicated by
the pressure gauge P1 reaches 4.3 MPa {43.8
kg/cm2}.
a Do not exceed the maximum admissible brake
pressure of 4.3 MPa {43.8 kg/cm2}
4. Close the cock (1) in order to maintain pressure
in the brake circuit to be tested.
5. Check the pressure for the next 2 minutes.
• If the pressure decreases the brake piston in
the axle is defective.
• If the pressure value does not change the
defect is in brake pump.
k If one of the brake piston is defective the oil level of the axle increases. In this case change all
sealing rings between the brake piston and the other axle sections.
30-20 WB93R-8
BLEEDING AIR FROM THE BRAKE LINES
BLEEDING AIR FROM THE BRAKE LINES

a Bleed air from both side of the rear axle.
1. Refill the expansion tank (1) up to maximum,
level.
RKAD3480
2. Connect a transparent flexible hose (2) to the

bleeding screw (3) in order to collect the oil.
3. Disconnect the pedal connecting pin. 3
2
4. Fully press and maintain in pressure the brake
circuit corresponding to the brake unit to be bleed
(left pedal for the left side brake unit, right pedal
for the right side brake unit).
5. Slowly loosen by a half turn the bleeding screw
(3) until oil runs out without any trace of air or the
pedal reaches the end of stroke.
6. Tighten the screw (3) and release the brake
pedal.
3 Bleeding screw (3): 8 to 12 Nm [0,82 to 1,22
RKZC3180
kgm]
7. Repeat the bleeding operation from step 3 to 5
until oil runs out of the screw without any trace of
air.
a Check frequently the oil level in the expansion
tank and refill every time level reaches the mini-
mum level.
8. Install the protective cap (4) on the bleeding
screw (3).
9. Repeat the whole procedure for the other side
brake unit.
4 3
RKZC3190
WB93R-8 30-21
METHOD FOR TESTING BRAKE PISTON STROKE
METHOD FOR TESTING BRAKE PISTON STROKE

1. Disconnect hose (1) of the brake line to be
tested.
1
RKAD3590
2. Install on hose (1) the following components:

1) the adapter P2 and the nipple P3
2) an hydraulic tester P1 (6 MPa {60 kg/cm²})
3) a cock (3) From brake pump
4) a union (4) to be connected to hose (2) 1
20
30
40
5) a cock (5) 10
0
50
60
6) a graduated hose (6) P1

P2
• Brake hose and pipe thread: 1/2" - 20 UNF
• Cock (5) has be located in a position higher P3
than all other components and pipes (2) 3
3. Open cock (3) and close cock (5).
4. Bleed air from the circuit before proceeding with
the test (for details see "BLEEDING AIR FROM
THE BRAKE LINES"). 6
5
brake unit) until reaching 4.1 ± 0.5 MPa {41.8 ±
2
of 294 ± 29.4N {30 ± 3 kg}. 4
REMARK
The pressure of 4.1 ± 0.5 MPa {41.8 ± 5.1
kg/cm2} have to be reached when the force of
294 ± 29.4N {30 ± 3 kg} is applied. RKA85470
6. Hold the brake pedal in that position without mov-
ing it for the next 1 minute.
7. Close cock (3) and release brake pedal.
8. Gradually open cock (5) and collect the brake oil
draining from cock (5) into a graduated container.
Wait for the next 2 minutes to allow all the oil to
drain
a Brake oil: more than 12 cc
• If the quantity of brake oil is below the limit, the
brake piston does not return back to its rest
position, causing the defect.
• If the quantity of brake oil inside the limit, the
brake piston return back to its rest position.
9. Wait 15 minutes and repeat the test 2 times with
interval of 15 minutes to validate the result of the
test.
30-22 WB93R-8
METHOD FOR TESTING THE BRAKE PUMP BALANCING VALVE

1. Remove protection (1).
RKAD3715
2. Remove front floor cover (2) and disconnect con-

nector PD1 and K14 of accelerator pedal.
2
RKAD3725
3. Disconnect brake hoses (3).

NOTICE
• Mark the position to avoid errors when
re-assembling. 5
• Plug all hoses to prevent entry of any impu- 3
rities.
4. Plug the pipe (4) of the right brake line and leave
the pipe (5) of the left brake line open.
NOTICE 4
• Use a proper container to collect the brake
oil that might flow out from the left brake RKAD4141
line pipe (5).

5. Verify if in the oil brake reservoir there is no dirty
and the brake oil is clean and at the right level.
6. Disconnect the brake pedals and press the right
pedal with a force of 294 ± 29.4N {30 ± 3 kg}.
7. Check the brake pedal position for the next 2
minutes.
• If the brake pedal does not move, the right
brake cylinder is working properly and the bal-
ancing valve is working properly, avoiding the
brake oil to flow from the right brake circuit to
the left brake circuit.
WB93R-8 30-23
• If the brake pedal moves slowly and there is no

leakages from the left circuit pipe (7), the right
brake cylinder is internally drifting and needs to
be replaced.
• If the brake pedal moves and there is leakages
from the left circuit pipe (7), the balancing
valve installed in the left brake pump is not
working properly allowing the brake oil to flow
from the right brake circuit to the left brake cir-
cuit. Remove the brake pump, and verify that
there is no dirty in the balancing valve, if nec-
essary replace it.
8. Repeat the procedure for the left brake line.
30-24 WB93R-8
METHOD FOR TESTING THE BRAKE PEDAL STROKE
METHOD FOR TESTING THE BRAKE PEDAL STROKE

a The test has to be performed on a single brake pedal each time.
1. Verify that the pedals are correctly aligned and
that the released position is correct (for detail see
"METHOD FOR ADJUSTING PEDAL BRAKING
POSITION AND ALIGNMENT").
2. In this position measure quote "A".
a The quote "A" is the distance of the brake
pedal edge from the metal floor, excluding
the floor mat.
3. Press with a single movement the brake pedal
until the brake pressure is 4.1 ± 0.5 MPa {41.8 ±
of 294 ± 29.4N {30 ± 3 kg} (for detail see "TEST-
ING THE BRAKING SYSTEM PRESSURE"). B
a In this condition the brake pump must not A
reach its mechanical end of stroke. If this
happens, the tested brake pump has to be RKA85480
replaced.
4. In this position measure quote "B".
a The quote "B" is the distance of the brake
pedal edge from the metal floor, excluding
the floor mat.
5. Calculate the pedal stroke "C = B - A".
• If the pedal stroke "C" is less than 124 mm the
brake pump is working correctly.
• If the pedal stroke "C" is greater than 124 mm
the brake pump is not working correctly.
Possible cause might be:
• Air in the brake line
• Brake pump defective
• Leakages in the brake circuit
a If the test is performed a second time within
30 seconds, there might the possibility that
the "C" stroke calculated is lower than the
first one. This is not symptom of defective-
ness.
WB93R-8 30-25
METHOD FOR ADJUSTING PEDAL BRAKING POSITION AND ALIGNMENT
METHOD FOR ADJUSTING PEDAL BRAKING POSITION AND ALIGN-

MENT
BRAKE PEDAL WITHOUT TRAVEL ADJUSTMENT
This check has to be performed when, in the case of some inconvenience to the brake system, any work has
been performed on the braking group.
To check and adjust the brake pedal stroke, proceed as follows:
1. Disconnect the connection pin (1).
2. Loose lock nuts (2) of both pedals.
3. Screw in both bumpers (3) until the left and right

pedal reach an idle stroke of 10–15 mm from the
free position up to when the push rod get in touch
with the brake pump.
4. Push both pedal up to when the push rod get in
touch with the brake pump and determine which
of the two pedals is the upper. This pedal is the
first to be adjusted.
30-26 WB93R-8
5. Unscrew the bumper (3) of the first pedal to be

adjusted until the idle stroke reaches the value of
3–8 mm and lock the position with lock nut (2).
3 Tightening torque: 22±4 Nm.
6. Connect the connection pin (1) and unscrew the
second bumper (3) until the connection pin can
be inserted easily.
7. Disconnect the connection pin (1) and check that
the pedals have an idle stroke within 3–8 mm
and that the difference of stroke between the two
pedals does not exceed 2.0 mm.
8. If necessary reduce (or increase) the idle stroke
of the first pedal of a amount "A" (i.e A= 1.00
mm) and increase (or reduce) the idle stroke of
the second pedal of the same amount "A".
9. Lock the position of bumpers (3) with lock nuts
(2).
3 Tightening torque: 22±4 Nm.
a A large difference of idle stroke (> 2,0 mm)
between the pedals can cause serious problem
while travelling on the road with the connection
pin inserted, specially during emergency opera-
tion. If all the components have been fitted cor-
rectly, a full revision to pedal system have to be
carried out.
For adjust the brake pedal stroke, contact your
Komatsu Dealer.
WB93R-8 30-27
SINGLE SIDE BRAKE PEDAL TRAVEL ADJUSTMENT

To check and adjust the brake pedal travel, proceed as follows:

pedal reach quota "A".
• Quote "A": 168 ± 10 mm
• Quote "A" can vary from machine to machine
because of tolerance in the cab frame, so it is
only a reference and not a final quote. The final
quote "A" for the left pedal will be defined in the
following steps.
RKA85490
4. In this position verify that the idle stroke of the left

pedal is correct.
a Idle stroke of pedal is the distance "C = B - A"
where distance "B" is the quote measured
when the pedal is manually pressed without
forcing against the brake pump until it stops.
a Idle stroke: 2 - 5 mm
• If idle stroke is outside the correct value, adjust
both pedals brake position using bumpers (3).
5. Lock the position of the left pedal with lock nut A
B
(2).
3 Tightening torque: 25 - 30 Nm. RKA85500
6. Insert the connection pin (1) and verify that it

moves freely inside the right pedal.
30-28 WB93R-8
• If the connection pin does not insert freely into

the right pedal, use the right bumper (3) to
adjust the position of the right pedal.
7. Lock the position of the right pedal with lock nut
(2).
3 Tightening torque: 25 - 30 Nm.
8. In this position verify that the right brake pedal
idle stroke "D".
a Right pedal idle stroke "D": "C" ± 2 mm.
A
B
RKA85500
9. If idle stroke is out of range, adjust it with the fol-

lowing procedure:
1) Move right boots (4) toward the right brake 4
pump (5)
RKA85510
2) Loosen nut (6) and loosen or tighten pushrod

(7) to adjust.
3) Tighten nut (6) and restore boots (4) original 8
position.
3 Tightening torque: 22 - 30 Nm. 7
a Do not damage brake pump piston (8) sur-
face because this can cause oil brake leak-
6
ages.
RKA85520
WB93R-8 30-29
DOUBLE SIDE BRAKE PEDAL TRAVEL ADJUSTMENT

To check and adjust the brake pedal travel, proceed as follows:

pedal reach quota "A".
• Quote "A": 168 ± 10 mm
• Quote "A" can vary from machine to machine
because of tolerance in the cab frame, so it is
only a reference and not a final quote. The final
quote "A" for the left pedal will be defined in the
following steps.
RKA85490
4. In this position verify that the idle stroke of the left

pedal is correct.
a Idle stroke of pedal is the distance "C = B - A"
where distance "B" is the quote measured
when the pedal is manually pressed without
forcing against the brake pump until it stops.
a Idle stroke: 2 - 5 mm
A
B
RKA85500
30-30 WB93R-8
5. If idle stroke is out of range, adjust it with the fol-

lowing procedure:
1) Move left boots (4) toward the left brake
pump (5). 4
RKA85530
2) Loosen nut (6) and loosen or tighten pushrod

(7) to adjust.
position.
face because this can cause oil brake leak- 6
ages.
6. Insert the connection pin (1) and verify that it
moves freely inside the right pedal.
• If the connection pin does not insert freely into
the right pedal, use the right bumper (3) to RKA85540
adjust the position of the right pedal.

7. Lock the position of the right pedal with lock nut
(2).
3 Tightening torque: 25 - 30 Nm.
8. In this position verify that the right brake pedal
idle stroke "D".
a Right pedal idle stroke "D": "C" ± 2 mm.
A
B
RKA85500
9. If right idle stroke is out of range, adjust it with the

following procedure:
1) Move right boots (9) toward the right brake 9
pump (10)
10
RKA85511
WB93R-8 30-31
2) Loosen nut (11) and loosen or tighten push-

rod (12) to adjust.
position.
face because this can cause oil brake leak-
11
ages.
RKA85521
30-32 WB93R-8
ADJUSTING TOE-IN-STEERING ANGLE WITH FRONT AXLE REMOVED FROM MACHINE
ADJUSTING TOE-IN-STEERING ANGLE WITH FRONT AXLE REMOVED

FROM MACHINE
TOE-IN ADJUSTMENT
1. Put two equal one-meter-long linear bars on the
wheel sides and lock them with two nuts on the
wheel hub stud bolt.
k The two bars should be fixed on their mid-
dle so that they are perpendicular to the
supporting surface and parallel to the pin-
ion shaft axis; align the two bars.
2. Measure the distance in mm M between the bars

ends with a tapeline.
REMARK
Keep the minimum value, swinging the meas-
urement point.
WB93R-8 30-33
3. Check that the difference of the measurements

between the wheel hubs diameters ends is within
the requested tolerance range.
The nominal toe-in value (A) is referred to the
external diameter of the wheel hubs flange, there-
fore the measured value (M) at the bars ends
must be related to the ratio between length of the
bar and flange diameter
• nominal toe-in measured at wheel hub external
diameter: A = 0 -> A= - 2
• measured toe-in measured at 1 m wheel hub
rotating axe: M = 0 -> M= - 8
4. If toe-in is incorrect, operate with two wrenches

on the guide rods (1) screwing in and out the two
joint tie rods (3) equally till the toe-in is within the
requested tolerance.
5. After adjusting, screw in the lock nuts (2) of the

guide rods (1) to the requested tightening torque.
3 Nuts (2): 300 Nm
STEERING ANGLE ADJUSTMENT

1. Use the same bars assembled for the toe-in
adjustment and a long bar perfectly leaned over
the machined part of the central body (pinion
side), so that the two bars form an acute angle at
the maximum steering.
30-34 WB93R-8
2. For the steering angle adjustment, set a protrac-

tor to the following calculated angle C:
• C= 90 °- S
Where S is the prescribed adjustment steering
angle.
• S = 55 -> S = 55 - 8
3. Position the protractor on the long bar.
4. Move a wheel side till it forms, with the two bars,
the calculated angle C.
5. Adjust the mechanical steering stop, screwing in

or out the stop bolts (4), locking them with the
nuts (5) to the requested tightening torque.
3 Nut: 150 Nm
6. Steer completely towards the other side and

repeat the same operations.
WB93R-8 30-35
ADJUSTING TOE-IN-STEERING ANGLE WITH FRONT AXLE WITHOUT REMOVE THE AXLE FROM MACHINE
ADJUSTING TOE-IN-STEERING ANGLE WITH FRONT AXLE WITHOUT

REMOVE THE AXLE FROM MACHINE
k Place the machine on a lever ground.
1. Raise the machine using front work equipment
until the wheels are about 50 mm lift from the
ground.
2. Set the work equipment lock lever to LOCK posi-
tion.
3. Stop the engine and release all residual pres-
sure.
4. Insert the parking brake.
5. Position two stands (a) under the machine.
a
RKA94320
METHOD CHECKING AND ADJUSTMENT
1. Place level (b) on the central hub to check the

axle perpendicularity with the ground.
RKA94330
2. Place level (c) on the steering cylinder rod and, if

necessary, position at the level by acting on the
stands, positioned under the axle.
REMARK
Use standard and possibly non- magnetic
level.
RKA94340
30-36 WB93R-8
3. Remove the front tires.

4. Align the hub bolt (1) with the steering regulating
screw (2) on both sides of the axle.
1
RKA94350
5. Check with a meter stick the measure from the

cardan shaft to the wheel hub for both sides
(right and left) and check the hubs alignment, if
adjustment is required act on the steering wheel
until the hubs are aligned.
RKA94360
6. Center the bolt with the fixing nut, on both sides.
RKA94380
7. Place the bar with length of 1 meter on both

wheel hubs. Check that the bars are on same
level (as step 1) and secure with the wheel fixing
nut, on both sides.
RKA94390
WB93R-8 30-37
8. Mark the bar at a distance of 200 mm (on both

sides, front and rear). Position the bars so that
their center line corresponds to the upper screw
of the wheel hub and that they are well locked on
the hub itself.
RKA94400
9. Check with the meter stick the distance between

the two bars on the rear side of the axle. The
measurement must be carried out within the area
marked 200 mm (from the external profile).
RKA94410
10. Check with the meter stick the distance between

the two bars on the front side of the axle. The
measurement must be carried out within the area
marked 200 mm (from the external profile).
REMARK
Check that the meter stick does not interfere
or touch the components mounted on the
machine.
RKA94430
11. At a distance of 400 mm, the dimension must be

between 0 and -2.5mm (+/-20%), while for bar of
different length (500 mm, 1000 mm).
The toe in change if the measure is taken at dif-
ferent distance from center of rotation.
See table below for the value.
RKA94440
30-38 WB93R-8
Toe-in at wheel hub outside diameter (mm) 0-2.00
Toe-in at a distance of 200 mm from center of wheel hub revolution (mm) 0-2.50
Toe-in factor to be multiplied by distance from center of wheel hub revolution
-2 * distance *0.00625
(mm)
REMARK
If the toe-in measurement is made with a manual procedure, the toe-in at wheel hub range might be
considered from +0.5 to -3.0 mm.
12. If the convergence is out of tolerance, act on the

guide rods by screwing/unscrewing the two tie
rods equally. Check that the quota is within the
established parameters.
k Be careful not to damage the tie rod's rub-
ber boot.
3 Nut: 250 Nm
3 Wheel tightening torque: 350 Nm
WB93R-8 30-39
TESTING AND ADJUSTING THE PARKING BRAKE SYSTEM

k Place the machine on a level ground, fully raise the front and rear work equipment and secure
them with the safety lock, so that it is stable, and then stop the engine.
• Rear axle oil temperature: 75 to 85 °C
For testing of parking brake system to perform troubleshooting, Pm Clinic, or periodic maintenance, refer to
this section.
METHOD FOR TESTING THE PARKING BRAKE
1. Remove cover (1).
RKAD3600
2. Engage the parking brake.

3. Start the engine at low idle and select the 2nd
mechanical speed.
RKAD3610
4. With the parking brake lever engaged, press the

parking brake switch (2) and select the forward
direction.
5. While raising the engine speed up to 1400 rpm,
verify when the machine attempts to move and
immediately release the parking brake switch (2)
to stop the machine from travelling.
2
• If the machine attempts to move before 1250
rpm adjust the parking brake.
• If the machine attempts to move at 1250 rpm
or above, there is no need to adjust the parking
brake. RKAD3620
30-40 WB93R-8
• If after two adjustment of the parking brake the

machine still attempts to move before 1550
rpm, there might be a problem with the parking
brake cable, the parking brake caliper or the
paring brake lining.
METHOD FOR ADJUSTING THE PARKING BRAKE
1. Release the parking brake lever and turn the

handle (1) counterclockwise of 2 complete turns.
RKAD3630
2. Engage the parking brake and test the functional-

ity.
NOTICE
• This procedure can be performed until the
force to activate the parking brake does not 2
exceed 40 daN (40,8 kg) when pulling the
parking brake handle in the middle of the
handle.
• In the case the force of 40 daN (40,8 kg) it is
not enough, it is mandatory to overhaul
completely the parking brake devices.
RKAD3611
WB93R-8 30-41
CHECKING THE DISTANCE BETWEEN THE BRAKE PADS AND DISC
k The lack of proper operating distance

between the brake pads and the disc can
cause the inefficiency of the device resulting
in serious personal injury.
1. Push the brake caliper in the direction of the

white arrow in the picture, so as to press the pad
(a) against the brake disc (7) and separate the
pad (b) from the same disc.
2. With a thickness gauge measure the space S

between the brake disc (7) and pad (b).
3. Verify that the measured value is in the pre-
scribed operating range.
Smax > S > Smin
a Smin = 0.7 mm
Smax = 0.9 mm
4. Using a thickness gauge, check that the play (S)

is within the tolerance limit.
30-42 WB93R-8
5. If the play (S) is out of tolerance, unscrew or

tighten the nuts to adjust to the correct value.
WB93R-8 30-43
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
HYDRAULIC SYSTEM
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE
1. Releasing remaining pressure from hydraulic tank
k The hydraulic tank is sealed and pressurized. Therefore, when removing a hose or a plug con-
nected to the hydraulic tank, release the remaining pressure in the hydraulic tank according to
the following procedure.
1) Lower the work equipment to the ground in a stable posture and stop the engine.
2) Loosen oil filler cap (1) of the hydraulic tank
gradually, and release the air in the tank.
1
RKAD3510
2. Releasing remaining pressure in loader hydraulic cylinder circuit

k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the
remaining pressure from the piping according to the following procedure.
1) Release the remaining pressure in the hydraulic tank. For details, see preceding "Releasing remain-
ing pressure in hydraulic tank".
a Leave the oil filler cap of the hydraulic tank removed.
2) Turn the starting switch to ON position, press the work equipment lock switch to UNLOCK and then
operate loader control lever forward and backward, and to the right and left.
a The control valve is operated by the pressure in the accumulator. The pressure in the accumula-
tor is used up, however, after the work equipment control levers are operated two to three times.
3) Start the engine and run it at low idle for 5 seconds to increase the pressure in the accumulator then
stop the engine.
a The engine does not start unless the travel direction lever is set to “N” (NEUTRAL) position.
4) Repeat above steps 2) and 3) 2 to 3 times, and all remaining pressure is released from the piping
completely.
3. Releasing remaining pressure backhoe cylinders circuit
1) Release the remaining pressure in the hydraulic tank. For details, see preceding "Releasing remain-
ing pressure in hydraulic tank".
a Leave the oil filler cap of the hydraulic tank removed.
2) Operate the backhoe control levers and pedals in all the directions and all remaining pressure are
released from the piping completely.
a Residual pressure can be found even after this procedure in those circuits where the weight of
the equipment forces to maintain the position or where safety valves are installed (i.e. backhoe
boom head side - backhoe boom rise).
30-44 WB93R-8
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC

CIRCUITS
• The control valve is composed by a single section supplied by main pump P1.
• This section is protected against overpressures by a main relief valve (LS safety valve) with an adjusting
cartridge, and a safety valve.
• The loader circuit spools are hydraulically operated, whilst the backhoe circuit spools are mechanically
operated.
• Some circuits are protected against overpressures by a secondary safety valve acting on a single side of
the circuit.
• In the control valve is installed a priority valve which provide hydraulic oil to the steering uint when the
operator perform steering.
STEERING UNIT
1
TRANSMISSION
MAIN PUMP P1c
ENGINE P1 3
3
3
Pen
CONTROL VALVE
RKA82490

2. Safety valve
3. Secondary safety valves
WB93R-8 30-45
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS
TESTING UNLOADING PRESSURE

• Testing and adjusting tools for unloading pressure

1
K 799-101-5220 Nipple 1 M10 × 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3300 Adapter 1 Size: 04
k Park the machine on a level ground, lower the work equipment to the ground, stop the engine.
k Loosen the hydraulic tank cap to release the pressure inside the hydraulic tank.
k Release the residual pressure in the hydraulic circuit. For details, see "RELEASING REMAINING
PRESSURE FROM HYDRAULIC CIRCUIT".
TESTING UNLOAD PRESSURE

kg/cm²}.
power P mode.
3. Run the engine at high idle, set all the levers and
pedals for work equipment control in neutral, and
test the oil pressure of main pump (1).
a The unload pressure is the pressure when 1
the unload valve is actuated by this test.
RKAD3640
ADJUSTING UNLOAD PRESSURE

a The unload valve cannot be adjusted.
30-46 WB93R-8
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT CIRCUITS
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT

CIRCUITS
• The section consist of the spools that govern:
Valve to be Pressure set-

Control Unit Ports
set ting
R.H. arm side A0 -- To tank

Attachment (1 way specifica-
tion) Secondary 18.5 to 21.5
L.H. arm side B0
safety valve {188.6 to 219.2}
Secondary 18.5 to 21.5

R.H. arm side A0
Attachment (2 way specifica- safety valve {188.6 to 219.2}
tion) Secondary 18.5 to 21.5
L.H. arm side B0
safety valve {188.6 to 219.2}
MPa
{kg/cm²} Main safety 23.5 to 26.5
CURL A1
valve {249.8 to 270.2}
Backhoe ARM
Main safety 23.5 to 26.5
DUMP B1
valve {249.8 to 270.2}

LEFT A2
valve {249.8 to 270.2}
Backhoe BOOM SWING
RIGHT B2
valve {249.8 to 270.2}
WB93R-8 30-47
Valve to be Pressure set-

Control Unit Ports
set ting

CURL A3
valve {249.8 to 270.2}
Loader BUCKET
DUMP B3
valve {249.8 to 270.2}
RAISE (See note Main safety 23.5 to 26.5

[1]) valve {249.8 to 270.2}
RAISE (See note Boom safety 10.9 to 11.5
A4
[2]) valve {111.1 to 117.3}
Backhoe BOOM
RAISE (See note Boom safety 14.4 to 15.0
[3]) valve {146.8 to 153.0}

LOWER B4
valve {249.8 to 270.2}

CURL A5
valve {249.8 to 270.2}
Backhoe BUCKET
DUMP B5
valve {249.8 to 270.2}

L.H. SIDE A6
MPa valve {249.8 to 270.2}
Loader ATTACHMENT
{kg/cm²} Main safety 23.5 to 26.5
R.H. SIDE B6
valve {249.8 to 270.2}

RETRACT A7
valve {249.8 to 270.2}
Backhoe TELESCOPIC ARM
EXTEND B7
valve {249.8 to 270.2}

LOWER A8
valve {249.8 to 270.2}
Loader ARM
RAISE B8
valve {249.8 to 270.2}

RAISE A9
valve {249.8 to 270.2}
Backhoe R.H. OUTRIGGER
LOWER B9
valve {249.8 to 270.2}

RAISE A10
valve {249.8 to 270.2}
Backhoe L.H. OUTRIGGER
LOWER B10
valve {249.8 to 270.2}
{ } : value in kg/cm²
[1]: value are referred to standard boom without safety valve
[2]: value are referred to standard boom with safety valve and standard arm
[3]: value are referred to standard boom with safety valve and telescopic arm
30-48 WB93R-8
• Testing and adjusting tools for oil pressure in work loader and backhoe equipment circuits.
1
799-101-5220 Nipple 1 M10 × 1.25 mm
K 2
07002-11023 O-ring 1
3 799-401-3300 Adapter 1 Size: 04
4 Nipple 1 G 1/4”
TESTING WORK EQUIPMENT RELIEF PRESSURE

kg/cm²}.
power P mode.
3. Run the engine at 1800 rpm using fuel control
dial and operate the work equipment control
lever or pedal to relieve the cylinder and test the
oil pressure. 1
a The work equipment relief pressure is the
pressure when the main relief valve is actu- RKAD3640
ated by this test.
a The secondary valve installed in backhoe
boom rise side can tested only on a testing
bench.
4. After finishing test, remove the testing tools and
return the removed parts.
ADJUSTING WORK EQUIPMENT RELIEF PRESSURE

a If the relief pressure of the work equipment circuit
is abnormal, adjust the corresponding safety
valve shown in the table above according to the
following procedure.
WB93R-8 30-49
ADJUSTING MAIN SAFETY VALVE (LS SAFETY VALVE)

1. Loosen locknut (1) on main relief valve and
adjust work equipment relief pressure by turning
screw (2). 1
a When the end cap is:
• Turned clockwise to the right, the set
pressure is increased.
• Turned counterclockwise to the left, the
set pressure is decreased.
a The amount of adjustment per turn of end
cap:
Approx. 19.6 MPa {Approx. 200 kg/cm²}
2. After adjusting, tighten locknut (1).
3 Locknut: 29.4 – 39.2 Nm {3 – 4 kgm}
RKAD3650
3. After finishing adjustment, check again that the

oil pressure is normal according to the above
described test procedure. 1
RKZ10930
30-50 WB93R-8
ADJUSTING SECONDARY VALVE

a Secondary valve are installed in:
• attachment L.H. line (A)
• attachment R.H. line (B) (only for 2-way attach-
ment)
• backhoe swing (both side) (C) (D)
• loader bucket (dump side) (E)
a The secondary valve installed in backhoe BOOM
RISE side can be adjusted only on a test bench.
1. Loosen locknut (1) on main relief valve and
adjust work equipment relief pressure by turning
screw (2). D C
B
a When the end cap is:
• Turned clockwise to the right, the set
pressure is increased.
• Turned counterclockwise to the left, the
set pressure is decreased.
Komatsu Ltd.
a The amount of adjustment per turn of end

cap:
Approx. 19.6 MPa {Approx. 200 kg/cm²}
2. After adjusting, tighten locknut (1).
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
A C RKZ10951
3. After finishing adjustment, check again that the

oil pressure is normal according to the above
1 2
described test procedure.
RKZ10940
TESTING BACKHOE BOOM OVERLOAD ALARM SWITCH

1. Remove oil pressure measurement plug (1) on
backhoe boom safety valve (2).
RKAD3660
WB93R-8 30-51
2. Install nipple K4 and connect oil pressure gauge

of hydraulic tester K1.
kg/cm²}.
power P mode. K4
4. Run the engine at 1800 rpm using fuel control
dial.
5. Operate the backhoe boom rise lever until stroke
end and increment the pressure to test the boom
overload alarm switch.
a The backhoe boom overload pressure is the RKAD3670
pressure set to avoid the raising of object

which can cause damage to the equipment
or the overtilting of the machine.
a If the pressure is not within the right value,
the overload alarm switch might be defective
or there might be an electrical problem in wir-
ing harness.
6. After finishing test, remove the testing tools and
return the removed parts.
30-52 WB93R-8
TESTING OIL PRESSURE OF CONTROL CIRCUIT

• Testing and adjusting tools for oil pressure of control circuit

1
M
799-101-5220 Nipple 1 M10 × 1.25 mm
2
07002-11023 O-ring 1
a Check this item under the following conditions.
• Hydraulic oil temperature: 45 to 55°C
TESTING
1. Connect it to nipple (1) of solevnoid valve group
(2) the oil pressure gauge of hydraulic tester M1.
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm²}.
2. Start the engine, set the working mode to power 1
mode (P).
3. Run the engine at low idle, set all of control
levers and pedals of work equipment in neutral,
and measure the oil pressure.
4. After finishing the test, remove the testing tools,
2
and restore the machine.
RKAD3680
WB93R-8 30-53
ADJUSTMENT
• When control circuit pressure is not normal,
adjust it with self reducing valve (1).
1. Loosen lock nut (2) and adjust the pressure by
turning adjusting screw (3).
• If the adjusting screw (3) is turned to the right,
the differential pressure rises.
• If the adjusting screw (3) is turned to the left,
the differential pressure falls.
3 Lock nut: 19.5 - 24.5 Nm {2.0- 2.5 kgm} 1
2. After the adjustment, re-tighten lock nut (2), con-
firm that control circuit pressure is normal, follow- RKAD3690
ing the steps for measurement explained earlier.
2
3
RKZ10980
30-54 WB93R-8
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL OIL PRESSURE
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL OIL PRES-

SURE
• Pump PC control circuit oil pressure inspection and adjustment tools

1
M
799-101-5220 Nipple 1 M10 × 1.25 mm
2
07002-11023 O-ring 1
MEASUREMENT
• Implement measuring the pump PC control circuit oil pressure after confirming that the work equipment
oil pressure as well as the control circuit oil pressure are normal.
1. Measurement of PC valve output pressure (servo
piston inlet pressure)
• Measure PC valve output pressure (servo pis-
ton inlet pressure) and pump delivery pressure
together, and compare the two pressures.
2. Remove front floor mat (1)
1
RKAD3700
3. Remove protection (2)
RKAD3710
WB93R-8 30-55
4. Remove floor cover (3).
3
RKAD3720
5. Remove oil pressure measurement plug (4) and

install tool M2.
a Plug (4): For measuring the pump delivery
pressure (Pen part)
RKAD3730
6. Connect ports Pen to oil pressure gauge of

hydraulic tester M1. M1
• Use an oil pressure gauge with the capacity of
58.8 MPa{600 kg/cm²}
M2
RKAD3740
30-56 WB93R-8
7. Connect port P1c to oil pressure gauge of

hydraulic tester M1.
• Use an oil pressure gauge with the capacity of
58.8 MPa{600 kg/cm²}
8. Start the engine and keep it running until the
hydraulic oil temperature rises to the operating
range.
9. Measure the pump delivery pressure and PC
valve output pressure (servo piston inlet pres-
sure) together with the engine running at high
idling, after setting the machine at the following M1
conditions. RKAD3750
• Working mode: P mode.

• Work equipment circuit: Arm digging relief
• Judgement method M1
When the ratio between the pump delivery
pressure and PC valve output pressure (servo
piston output pressure) reaches the following
values, both pressures are judged normal.
Ratio of oil
Tested oil pressure Control level
pressures
P1C
Pump discharge
1
pressure P1c Backhoe Arm IN RKZC3272
PC valve output at relief Approx. 0.6

pressure Pen x P1c
• Example:
P1c = 21 MPa
Pen ≈ 12.5 MPa
1) If there is any abnormality with PC valve or
servo piston one of the following condition
may occur:
• the PC valve output pressure (servo piston out-
put pressure) equals to the pump delivery
pressure
• approximates to 0 pressure.
2) Disconnect tools M1 and M2 install plug (4).
RKAD3730
WB93R-8 30-57
ADJUSTMENT
If any of the phenomena mentioned below occurs and
PC valve malfunctioning is suspected, adjust PC
valve (1).
• As workload increases, the engine rpm sharply
drops.
• While the engine rpm is normal, the work equip-
ment moves slowly. 1
1. Loosen lock nut (2) and make adjustment, turn-
ing adjusting screw (3).
• If the holder is turned to the right, the pump
absorption torque rises.
If the holder is turned to the left, the pump RKAD3741
absorption torque falls.

• The adjustable range with the adjusting screw 2
is as shown below.
Left turn: Less than 1 turn
Right turn: Less than 1/2 turn (less than 180
degrees)
3 Lock nut: 27.50–34.3Nm {2.8–3.5kgm}
2. Re-tighten lock nut (2).
3. Confirm that the PC valve output pressure (servo
piston inlet pressure) is normal after the adjust-
3
ment, following the measurement steps
explained earlier. RKZ10991
MAX 180 0°
MAX 180
RKZ11000
30-58 WB93R-8
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL

CIRCUIT
• Testing and adjusting tools for oil pressure in pump LS control circuit

1
2 799-401-2701 Differential pressure gauge 1
P
799-101-5220 Nipple 1 M10 × 1.25 mm
3
07002-11023 O-ring 1
4 799-401-3200 Adapter 1 Size: 03
TESTING
• Implement measuring the pump LS control circuit oil pressure after confirming that the work equipment
oil pressure as well as the control circuit oil pressure are normal.
MEASURING LS DIFFERENTIAL PRESSURE

a Check LS pressure (the load pressure of the actuator) at the same time as the pump discharged pres-
sure, and calculate the differential pressure.
1. Disconnect hose (1) and install adaptor P4 and
nipple P3 to pump port PLS, and connect it to oil
pressure gauge P1. 1
a Use the oil pressure gauge of 60 MPa {600 P4
kg/cm²}.
2. Connect to port P1c to oil pressure gauge P1.
kg/cm²}.
3. Start the engine and keep it running until the
hydraulic oil temperature rises to the operating P1C
range. P1
4. Measure pump delivery pressure and LS pres- RKAD3751
sure simultaneously at the following conditions:
• Hydraulic oil temperature: within operation
range
P1
P3
• Engine speed: low idling
• All levers and pedals in NEUTRAL position
RKAD3850
WB93R-8 30-59
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
5. Measure pump delivery pressure and LS pres-

sure simultaneously at the following conditions:
• Hydraulic oil temperature: within operation
range
• Engine speed: low idling
• Shovel arm RAISE and shovel bucket CURL at
relief simultaneously
6. Calculate the differential pressure.
• Calculation of LS differential pressure:
LS differential pressure = Pump delivery pressure – LS pressure
• If LS differential pressure is in the following conditions, it is judged normal.
Control lever position LS differential pressure

All levers in NEUTRAL Unload pressure (see standard value table)
During test Max. LS differential pressure (see standard value table)
7. Detach all the measurement tools after the measurement, and make sure that the machine is back to
normal condition.
ADJUSTMENT
• When LS differential pressure is not normal,
adjust it with LS valve (1).
1. Loosen lock nut (2) and adjust the pressure by 1
turning adjusting screw (3).
• If the adjusting screw (3) is turned to the right, 1
the differential pressure rises.
• If the adjusting screw (3) is turned to the left,
the differential pressure falls.
• Adjustment amount (LS differential pressure)
per turn of adjusting screw: 1.3 MPa {13.3
kg/cm²}
3 Lock nut: 49–64 Nm {5–7 kgm}
RKAD3760
2. After the adjustment, re-tighten lock nut (2), con-

firm that LS differential pressure is normal, fol-
lowing the steps for measurement explained 2
earlier. 3
RKZ10971
30-60 WB93R-8
TESTING OUTLET PRESSURE OF SOLENOID VALVE

• Testing tools for pressure of solenoid valve

1
Q
2 799-401-3100 Adapter 1 Size: 02
3 799-101-5160 Nipple 1 PT 1/8”
Before testing the solenoid valve outlet pressure, check that the control circuit oil pressure is normal.
TESTING SOLENOID OUTPUT PRESSURE

1. Remove the left front testing cover and discon-
nect outlet hoses (1) to (5) of the solenoid valves
to be tested. 1 2 3 4 5
No. Solenoid valve to be tested Port

1 Boom unlock solenoid valve A2
2 PPC solenoid valve UL
3 4 in 1 bucket curl solenoid valve A1
4 4 in 1 bucket dump solenoid valve B1
5 Eco/Power solenoid valve PM
RKA82810
2. Install adapter Q2 and connect the disconnected
hose again.
3. Install nipple Q3 of hydraulic tester Q1, and con-
nect them to oil pressure gauge.
kg/cm²}.
5. Run the engine at high idle, operate each control
lever and switch, turn the solenoid valve ON or
OFF, and measure the output pressure.
a The conditions for turning the solenoid valve
ON/OFF, see the operation table of each
solenoid valve.
a You can check the operating condition of the
solenoid valve with the monitoring function of
the machine monitor (For details, see SPE-
CIAL FUNCTIONS OF MACHINE MONI-
TOR).
WB93R-8 30-61
• Monitoring code available:

02431: Boom retain unlock switch
02426: PPC Lock Switch
02421: OUT PPC Lock Switch
02420: Out Eco-Power Solenoid
02447: Eco-Power Rocker Switch
02448: EcoPower Joystick Switch
• For standard values, see "Standard value
table for machine".
30-62 WB93R-8
TESTING PPC VALVE OUTLET PRESSURE

CONNECTING POINTS OF PPC PIPING
2
1
3 4
5 8 6
RKA82770
No. Port Circuit to be measured No. Port Circuit to be measured
1 Pa3 Loader bucket DUMP 2 Pb3 Loader bucket CURL

3 Pa8 Loader arm RAISE 4 Pb8 Loader arm LOWER
5 Pa9 L.H. outrigger LOWER 6 Pb9 L.H. outrigger RAISE
7 Pa10 R.H. outrigger LOWER 8 Pb10 R.H. outrigger RAISE

a The above figure shows the connecting points of PPC piping to the 11 spool control valve.
WB93R-8 30-63
• Testing tools for PPC valve outlet pressure

1
R
2 799-401-3100 Adapter 1 Size: 02
3 799-101-5160 Nipple 1 PT 1/8”
Before testing PPC valve output pressure, check that the control circuit source pressure is normal.
TESTING
1. Disconnect the hose (1) of PPC circuit to be
tested.
a For the hose to be disconnected, see "Con-
necting points of PPC piping".
2. Install adapter R2 and connect the disconnected
hose again.
3. Install nipple R3 of hydraulic tester R1 and con-
nect them to oil pressure gauge.
kg/cm²}.
4. Start the engine, and set the working mode to
power mode (P).
5. Run the engine at high idle, set the control levers 1
in NEUTRAL and travel end, and measure the oil
pressure at each position.
a For standard values, see "Standard value RKAD3691
table for machine".

30-64 WB93R-8
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVES
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVES

a If the right and left work equipment levers have large play, adjust them according to the following proce-
dure.
a The play of the lever measured at a position of 200 mm from the pivot must be 0.5 to 3 mm.
ADJUSTING
1. Remove boot (1).
2. Loosen lock nut (2) and tighten disc (3) until it 2 3
comes in contact with the heads of pistons (4) (4
pieces). 4
a At this time, do not move the pistons.
1
3. While fixing disc (3), tighten lock nut (2) to the
specified torque.
3 Locknut: 68 to 88 Nm (7 to 9 kgm)
RKA82470
4. Apply gear oil and grease (G2–L1) to the rocking

portions of the joint.
Apply gear oil and grease (G2–L1) to the rocking
portions of the joint.
(Portion J):
Apply grease (G2–L1) of 7 to 10 ml all around.
(Portion P):
Apply gear oil of 0.2 to 0.4 ml to the sliding parts
(4 places) of the joints and pins.
5. Install boot (1).
P
J
RKA82480
WB93R-8 30-65
TESTING TRANSMISSION OIL PRESSURE CIRCUIT

• Testing tools for transmission oil pressure circuit
1
R 790-261-1204 Digital hydraulic tester 1
2 799-101-5160 Nipple 1 PT 1/8”
• Transmission oil temperature: 75 to 85°C
TESTING
1. Testing Torque Converter Oil Pressure
1) Remove the plug (1) from P22 port on trans-
mission control valve and install nipple R2.
2) Connect oil pressure gauge of hydraulic
tester R1. 1
a Use the oil pressure gauges of 6.0 MPa {60
kg/cm²}.
3) Start the engine, set the working mode in the
power mode (P).
4) Set the travel direction control lever in NEU-
TRAL (N) and parking brake ON.
5) Run the engine at low idle and measure the
oil pressure in this condition.
a Standard value: minimum 0.05 MPa {0.5 RKAD3770
kg/cm²}
6) Run the engine at high idle using the acceler-
ator pedal and measure the oil pressure in
this condition.
a Standard value: maximum 0.9 MPa {9,2
kg/cm²}
7) Release the accelerator pedal and measure
the oil pressure in this condition.
a Standard value: minimum 0.05 MPa {0.5
kg/cm²}
a After releasing the accelerator pedal, if the
pressure drops below minimum value, the
transmission pump need to the replaced with
a new one.
30-66 WB93R-8
2. Testing Direction Clutch Oil Pressure Control

1) Remove the plug (2) from P18 FORWARD
clutch port or plug (3) P19 REVERSE clutch
on transmission body and install nipple R2.
2) Connect oil pressure gauge of hydraulic
tester R1. 2
3
a Use the oil pressure gauges of 6.0 MPa {60
kg/cm²}.
3) Start the engine, set the working mode in the
power mode (P).
4) Set the mechanical gear lever in NEUTRAL
(N).
5) Set the travel direction control lever in FOR-
WARD or REVERSE and release the parking RKAD3780
brake.
6) Run the engine at low idle and measure the
oil pressure in this condition.
a Standard value: maximum 0.03 MPa {0.3
kg/cm²}
7) Gradually increase the engine speed up to
high idle using the accelerator pedal and
measure the oil pressure in this condition.
a Standard value: maximum 1.1 to 1.3 MPa
{11,2 - 13.3 kg/cm²}
8) Release the accelerator pedal and measure
the oil pressure in this condition.
a Standard value: maximum 0.03 MPa {0.3
kg/cm²}
WORK AFTER FINISHING TEST

After finishing test, remove the testing tools and return
the removed parts.
3 Oil pressure pickup plug:
23 Nm {2.35 kgm}
WB93R-8 30-67
ISOLATING THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT
ISOLATING THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIP-

MENT
a If the work equipment (cylinder) drifts hydraulically, perform check to see if the problem is in the cylinder
seal or control valve according to the following procedure.
TESTING
1. Testing loader arm cylinders
1) Move the loader bucket in the posture
described in the picture and stop the engine.
1500 kg
2) Turn ON the starting switch without starting
the engine, and enable the work equipment
using the “Work Equipment Lock Switch”.
3) If the loader arm cylinders are equipped with
safety valve (lifting capability of the
machine), disable the function using the
“Lifter Mode selection switch”.
4) Move the loader arm control lever to "RAISE"
side for judgment.
• When the lowering speed is increased at
this time, the cylinder packing is defec- RKZ02630
tive.
• If the lowering speed does not change at
this time, the control valve is defective.
2. Testing loader bucket cylinders
1) Move the loader bucket in the posture
2) Turn ON the starting switch without starting
the engine, and enable the work equipment
using the “Work Equipment Lock Switch”.
3) If the loader arm cylinders are equipped with
safety valve (lifting capability of the
“Lifter Mode selection switch”.
4) Release the parking brake.
5) Move the loader bucket control lever to
"DUMP" side for judgment.
kWhen the control lever is moved the
RKA81860
machine might move backward.

this time, the cylinder packing is defec-
tive.
30-68 WB93R-8
3. Testing backhoe boom cylinder

1) Move the backhoe equipment in the posture
2) If the backhoe boom cylinder is equipped
with safety valve (lifting capability of the
“Overload switch”.
3) Move the backhoe boom control lever to
"LOWER" side for judgment.
tive.
this time, the control valve is defective. RKA82510
4. Testing backhoe arm cylinder

2) Move the backhoe arm control lever to
"CURL" side for judgment.
tive.
RKA81870
5. Testing backhoe bucket cylinder

2) Move the backhoe bucket control lever to
"CURL" side for judgment.
tive.
RKA81880
6. Testing boom swing cylinders

1) Stop the engine with the same posture as the
hydraulic drift measurement.
2) Move the boom swing control lever to "L.H.
SWING” for judgment if the boom has been
rotated completely to the left.
Move the boom swing control lever to "R.H.
SWING” for judgment if the boom has been
rotated completely to the right.
tive.
• If the lowering speed does not change at RKA81250
WB93R-8 30-69
[Reference]
Reasons why the lowering speed is increased by the above operation when the cylinder packing causes the
hydraulic drift:
1) When the machine is set in the above posture (where the holding pressure is applied to the bottom
side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less
than that on the bottom side by the volume of the rod, the pressure in the head side is increased by
the oil flowing in from the bottom side.
2) As the internal pressure on the head side increases, both pressures come to balance at a certain
level of pressure (depending on leakage), and the lowering speed becomes slower.
3) If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the
bottom side is closed by the check valve at this time), the oil in the head side flows in the drain cir-
cuit. As a result, the pressure is imbalanced and the lowering speed is increased.
30-70 WB93R-8
BLEEDING AIR FROM HYDRAULIC CIRCUIT
BLEEDING AIR FROM HYDRAULIC CIRCUIT

Steps for air bleeding
1 2 3 4
Air bleeding item Contents of Work Bleeding air Checking oil
Starting Bleeding air
from hydrau- level and
engine from cylInder
lic pump start work
Replacement of hydraulic oil
Cleaning of strainer
Replacement of return filter element
Replacement or repair of hydraulic pump
Removing suction piping
Replacement or repair of control valve
Removal of control valve piping
Replacement or repair of cylinder
Removal of cylinder piping
BLEEDING AIR FROM HYDRAULIC PUMP

1. Lightly pressurise the hydraulic tank (max 0.05 -
0.10 MPa) by inlet of compressed air from the oil
filler port.
1
a Pressurising the tank will force the hydraulic oil to
raise the oil level on the pump side.
2. Connect a transparent flexible hose (1) to the
bleeding screw (2) in order to collect the oil.
3. Loosen bleeding screw (2) by 1 turn.
4. After oil flows out of plug (2) without air, tighten
plug.
3 Plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
2
RKAD3790
STARTING THE ENGINE

1. Run the engine at low idle.
2. Leave the machine under the above condition for 10 minutes then stop the engine and check the oil level
in the hydraulic oil tank
a Ensure the work equipment are disabled “Work Equipment Lock Switch”..
a Do not operate the backhoe control lever by mistake.
BLEEDING AIR FROM CYLINDER

a If a cylinder was replaced, bleed air from it before connecting the work equipment.
1. Run the engine at low idle for about 5 minutes.
2. Running the engine at low idle, move the cylinder in both directions 4-5 times.
a Stop the piston rod about 100mm before each stroke end. Do not relieve the oil.
3. Running the engine at high idle, move the cylinder in both directions 4-5 times.
a Stop the piston rod about 100mm before each stroke end. Do not relieve the oil.
4. Running the engine at low idle, move the piston rod to the stroke end and relieve the oil.
5. Bleed air from all the backhoe and loader cylinders according to steps above.
WB93R-8 30-71
CHECK OF OIL LEVEL AND OPERATION

k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn
injury.
Wait for the temperature to go down, and then start the work.
• The oil may spray out when the oil filler cap is removed. Turn it slowly to release the internal
pressure, then remove it carefully.
1. Set the machine in the posture shown in the fig-

ure and stop the engine.
RKA81920
2. Check with the sight gauge (G).

If the oil level is below the level L, the hydraulic
oil is insufficient.
Perform the following procedure.
H
RKA82460
1) Loosen the cap of oil filler port (F) gradually

to release the internal pressure.
2) Remove the cap of oil filler port (F).
RKAD3520
30-72 WB93R-8
3) Add oil through the oil filler port (F) until the
oil level comes between the levels H and L of
sight gauge (G).
F
NOTICE
Do not add oil above mark H. This could
damage the hydraulic system and cause oil
spillage.
If the oil has been filled past level H. Wait for
the oil to cool down sufficiently, then drain the
excess oil through valve (P).
a The oil level will vary depending upon the oil
temperature. G
Depending on the temperature, refer to the
following guidelines:
• Before starting the operation: Around L level
(Oil temperature 10 to 30 °C)
• Normal operation: Around H Level
(Oil temperature 50 to 80 °C)
4) Install the cap of oil filler port (F).
RKA78960
WB93R-8 30-73
SET AND ADJUST EACH EQUIPMENT
ELECTRICAL SYSTEM
SET AND ADJUST EACH EQUIPMENT
Use the machine monitor to set or adjust as appropriate when replacement, disassembly, or additional instal-
lation of components shown in the table below is performed.
REMARK
To perform the works listed in "Required setting/adjustment", start from the work at the top of the list.
Detail of work Required setting or adjustment Reference page
Replacement of the monitor controller Machine model Selection
30-74 WB93R-8
SET AND OPERATE MACHINE MONITOR
1 6
2 7
3
8
4
9
5 10
RKA82000
CENTRAL PART OF MACHINE MONITOR

a: Multi-information display
When starting the engine, the battery voltage may suddenly drop depending on the temperature and the
battery condition. If this happens, the display on the machine monitor may momentarily go out, but this does
not indicate any abnormality.
SIDE PARTS OF MACHINE MONITOR (SWITCHES PART)
1: No Function (excepted for special operations)

6: Menu switch
7: UP switch
8: DOWN switch
9: RETURN switch
10: ENTER switch
The function of each function switch is indicated by the icon which is displayed on the left side of the function
switch on the screen of the multi-information display panel (a).
If the icon for a function switch is not displayed, that function switch is not working.
OPERATOR MODE AND SERVICE MODE OF MACHINE MONITOR

Machine monitor has operator mode and service mode. Various information is displayed on multi-information
display (a).
Some items are displayed automatically according to the configuration of the machine monitor whereas the
other items can be displayed only when the machine monitor is operated with switches.
• Operator mode
WB93R-8 30-75
The information items in this mode are ordinarily displayed. The operator can display and set them by the
operation with switches. (Display and setting of some items need special operation of switches.)
For details, see Operation and Maintenance Manual.
List of item and functions shown in Operator Mode:
• Display of KOMATSU logo
• Display of maintenance due time over
• Display of standard screen
• Display of DEF gauge low level warning
• Display of engine shutdown secondary switch operation
• Check of maintenance information
• Setting and display of user mode
• Display of energy saving guidance
• Operation of machine setting
• Display of caution lamp
• Display of aftertreatment devices regeneration and SCR information
• Display function of action level and failure code
The following functions become active by performing special operation:
• Method for fast checking failure code when no prompt are visible
• Method for setting usage limitation and changing maintenance password
• Service Mode
The information items in this mode are not ordinarily displayed. Technicians can change display and
settings by operating the switches specially.
This mode is used for testing, adjusting, or troubleshooting.
List of item and functions shown in Service Mode:
• Method for checking self-defined monitoring information
• Method for confirming abnormality record (mechanical systems)
• Method for confirming abnormality record (electrical systems)
• Method for confirming maintenance record
• Method for operating maintenance mode setting
• Method for operating phone number entry setting
• Method for setting with default setting menu (machine model select)
OPERATOR MODE
The following are items which needs specific switch operation in operator mode.
For details of contents and operations of each function and display, see STRUCTURE AND FUNCTION,
“MACHINE MONITOR”or the “OPERATION AND MAINTENANCE MANUAL”.
30-76 WB93R-8
METHOD FOR FAST CHECKING FAILURE CODE WHEN NO PROMPT ARE VISIBLE
1. Sometimes happens that an error occurs, but

there are no information available to the user
because the alarm is not a YELLOW or RED
NOT SHOWN
type, and thus the monitor do not change icon
10.
In order to check if there are such alarm, perform
the following procedure to easily check if there
are active alarm.
RKA82820
2. Press switch 6 and when the “Aftertreatment

System” screen is displayed, the “Current Abnor-
mality menu” can be shown pressing switch 3.
RKA84820
3. In this way it is possible to fast check any active

alarms recorded by the monitor.
RKA84830
WB93R-8 30-77
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD

On the machine monitor, a password can be set as a user limitation setting. If the password has been set, a
password enter screen is displayed for resetting of maintenance items.
For the operating method for “Operator ID Change” see Operation and Maintenance Manual
Perform the Usage Limitation Setting and Change Password functions according to the following procedure.
1. While the standard screen is displayed, perform

the following operation by using the numeral
input switches.
Switch operation (While pressing 4, press other
switches in order): 4 + 5 –> 5 –> 5 1 6
REMARK 2 7
This operation of the switches is not accepted 3 8
until 10 minutes elapsed after the starting switch 4 9
is turned to ON position.
5 10
RKA82010
2. After “Usage Limitation Password” screen is dis-

played, input the current password by using the
numeral input switches and confirm it by using
the function switch.
• NEXT switch (6): Switch to the next numeric
input box.
• UP switch (7): Increase the Number in the
selected box.
• DOWN switch (8): Decrease the number in the
selected box.
• RETURN switch (9): Clears an input numeric/ RKA84840
Return the screen to the standard screen.
• ENTER switch (10): Validates the inputted
password.
REMARK
• Default password: 000000
• When the input password is correct, the screen
changes to the next screen.
• When the input password is incorrect, the
screen displays message to request inputting
the password again.
30-78 WB93R-8
3. After “Usage Limitation Setting” screen is dis-

played use a switch on the switch panel to select
and validate "Usage Limitation ON or OFF“.
• UP switch (7): Moves the selection up by one
item
• DOWN switch (8): Moves the selection down
by one item
• RETURN switch (9): Cancels the selection and
returns the screen to the preceding screen
• ENTER switch (10): Validates the selection
RKA84850
4. After the "Usage Limitation ON or OFF" screen is

displayed, use a switch on the switch panel to
select and validate "Enable/Disable“.
• Disable: Password enter screen is not dis-
played.
• Enable: Displayed the password enter screen
for resetting of maintenance items.
item
by one item RKA84860

5. After the "Usage Limitation Setting" screen is dis-

played, use a switch on the switch panel to select
and validate "Change password“.
item
by one item
RKA84870
6. After the "Usage Limitation New Password Input"

screen is displayed, use a switch on the switch
panel to input and validate a new password.
input box.
selected box.
selected box.
• RETURN switch (9): Clears an input numeric/
Return the screen to the standard screen. RKA84890
WB93R-8 30-79

password.
REMARK
• Default password: 000000
• When the input password is correct, the screen
changes to the next screen.
• When the input password is incorrect, the
screen displays message to request inputting
the password again.
• Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it is
not accepted).
7. After "Usage Limitation New Password Input"
screen is displayed again, use a switch on the
switch panel to input and validate a new pass-
word.
input box
selected box.
selected box.
• RETURN switch (9): Clears an input RKA84900
numeric/Return the screen to the standard
screen.
password.
REMARK
• If the input password is different from the one
input before, the message to request inputting
again is displayed.
• If the standard screen is displayed after the
screen to notify completion of setting is dis-
played, the password is changed successfully.
RKA84910
30-80 WB93R-8
SERVICE MODE
METHOD FOR OPERATING SERVICE MODE
To change the mode of the machine monitor to the service mode from the operator mode, perform the
following operation.
This operation is always required when you use the service mode.
1. With the standard screen displayed, press the
numerical switches in order while pressing 4 as 4
+ 1 –>2 –>3.
REMARK
• This operation of the switches is accepted only 1 6
while the standard screen is displayed. 2 7
3 8
4 9
5 10
RKA82010
2. When "Service Menu" screen is displayed, the
service mode is selected. Select an item on ser-
vice menu with switches on the monitor panel.
item
by one item
RKA84890
SELECTABLE ITEMS IN SERVICE MENU
Cod
Item Reference
e
METHOD FOR CHECKING PRE-DEFINED MONITOR-
01 Self-define Monitoring
ING INFORMATION
Mechanical System METHOD FOR CONFIRMING ABNORMALITY RECORD
Abnormality Abnormality Record (MECHANICAL SYSTEMS)
02
Record Electrical System METHOD FOR CONFIRMING ABNORMALITY RECORD
Abnormality Record (ELECTRICAL SYSTEMS)
03 Maintenance Record METHOD FOR CONFIRMING MAINTENANCE RECORD
METHOD FOR OPERATING MAINTENANCE MODE
04 Maintenance Mode Setting
SETTING
METHOD FOR OPERATING PHONE NUMBER ENTRY
05 Phone Number Entry
SETTING
METHOD FOR SETTING WITH DEFAULT SETTING
06 Default Machine model select
MENU (MACHINE MODEL SELECT)
This menu is present for future implementation, no adjust-
07 Adjustment
ment available at the moment
WB93R-8 30-81
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION

The machine monitor monitors the condition of the machine in real time using signals from various switches,
sensors, actuators, and their controllers which are installed on various parts of the machine.
"Self-define Monitoring" is used to select a desired monitoring item.
1. Select “Pre-defined Monitoring” on the “Service

Menu” screen.
REMARK
For the selection method, see “METHOD FOR
OPERATING SERVICE MODE”.
RKA84920
2. When "Monitoring Selection Menu" screen is dis-

the item to be monitored.
• NEXT switch (6): Moves the selected item to
the right by one item
item
by one item
returns the screen to "Service Menu" screen RKA84930
• ENTER switch (10): Enters the selected items

REMARK
• Setting of the monitoring changes to "ENG" o
"SCR" o "MACHINE" o "MON" o "ENG" in
this or der wh en th e NE XT s witc h ( 6) is
pressed.
• Items can be selected while checking the mon-
itoring items. Select the component in charge
with NEXT switch (6), select the item with UP
Switch (7) or DOWN switch (8) and validate
your selection with ENTER switch (10).
• Only the entries of one component can be
shown.
• If the color of row showing the monitoring code
for the selected item changes yellow to red, the
selected item is entered.
• A maximum of 6 Monitoring items are selecta-
ble at a time.
30-82 WB93R-8
3. After selection of 6 monitoring items, the display

switch automatically to the "Monitoring" screen.
RKA84940
4. On "Monitoring" screen, perform the necessary

operation of the machine and check the a b
self-define monitoring information.
"Monitoring" screen displays the following infor-
mation:
a: Self-define monitoring information
b: Travel direction
REMARK
• The travel direction shows only the “N” (NEU-
TRAL”.
If “N” is not shown, the travel direction FOR- RKA84950
WARD or REVERSE has been selected.
• The self-define monitoring information is indi-
cated by value, ON/OFF, or special display.
• As a display unit can only be shown the “SI”
(International System).
5. A selected monitoring item can be saved or
deleted by using a switch on the switch panel.
• MEMORY switch (6): Saves a monitoring item.
• CLEAR switch (10): Clears a monitoring item.
RKA84960
REMARK
• When a monitoring item is saved, a confirma-
tion screen appears asking whether the saved
item should be displayed or not when
"Self-define Monitoring" is selected again.
• When an item is saved, it can be displayed as
many times as required unless it is cleared.
• The saved items will be cleared if another
monitoring items are selected.
RKA84970
WB93R-8 30-83
TABLE OF PRE-DEFINED MONITORING ITEMS

Pre-defined Monitoring Engine standard items
Applicable
ID Item Unit (SI)
component
01002 Engine Speed rpm ECU
03203 Battery Potential V ECU
04107 Coolant Temperature Engine degC ECU
14200 Fuel Temperature degC ECU
14300 Total Fuel Used L ECU
18100 EGR Valve Position % ECU
18101 EGR Valve Desired Position % ECU
18400 Intake Temperature degC ECU
18701 Engine Overtemperature status Level ECU
18800 Water In Fuel ON/OFF ECU
20217 Dataset Number ECU
31707 Throttle Valve Position % ECU
31708 Throttle Valve Desired Position % ECU
31709 Engine Speed requested rpm ECU
36400 Rail Pressure Bar ECU
36500 Turbo Pressure kPa ECU
37212 Engine Oil Pressure Low ON/OFF ECU
37300 Fuel Rate l/h ECU
37400 Barometric Pressure kPa ECU
48900 Engine Degradation status Level ECU
48901 ECU Operational status Level ECU
48902 Total Engine hours h ECU
48903 Total Engine revolutions revs ECU
60001 Fuel Prefilter Heater Status ON/OFF ECU
60002 Engine Overspeed ON/OFF ECU
60003 Engine Shut Down By HC Hi Lev ON/OFF ECU
62000 Engine Type ECU
30-84 WB93R-8
Pre-defined Monitoring Machine standard items

Applicable
ID Item Unit (SI)
component
02401 Fan Speed Frequency Hz MCH
02402 Fan Clutch Speed % % MCH
02403 Out 5V Fuel Trottle mV MCH
02404 Fuel Dial Trottle Signal mV MCH
02405 Fuel Pedal Trottle Signal mV MCH
02406 Ambient Temperature Resistance Ohm MCH
02407 Ambient Temperature °C MCH
02408 Transmission Oil Temperature Resistance Ohm MCH
02409 Transmission Oil Temperature °C RMT
02410 Fuel Level Resistance Ohm MCH
02411 Fuel Level % MCH
02412 Output Watchdog mV MCH
02413 Outputs Power Supply mV MCH
02414 Alternator Signal mV RMT
02415 Out PPC Lock Switch Lamp ON/OFF MCH
02416 Out RTD Float Power Supply ON/OFF MCH
02417 Out Differential Lock Solenoid ON/OFF MCH
02418 Out 4WD Solenoid ON/OFF MCH
02419 Out Transmission Declutch ON/OFF MCH
02420 Out Eco-Power Solenoid ON/OFF MCH
02421 Out PPC Lock Front Solenoid ON/OFF MCH
02422 Out PPC Lock Rear Solenoid ON/OFF MCH
02423 Out ECSS Solenoid ON/OFF MCH
02424 Seat Front or Rear Switch ON/OFF MCH
02425 Shifter N Switch ON/OFF MCH
02426 PPC Lock Switch ON/OFF MCH
02427 Both Brake Line Pressure Switch ON/OFF MCH
02428 4th Gear Engaged Switch ON/OFF MCH
02429 Pedal Low Idle Switch ON/OFF MCH
02430 Boom Sliding Unlock Switch ON/OFF RMT
02431 Boom Retain Unlock Switch ON/OFF RMT
02432 Boom Overload Signal ON/OFF RMT
02433 RH Stabilizer Down Sensor ON/OFF RMT
02434 LH Stabilizer Down Sesnor ON/OFF RMT
02435 Loader Lifter Mode Switch ON/OFF RMT
02436 ECSS Switch ON/OFF RMT
02437 Pattern Change Switch ON/OFF RMT
02438 Quick Coupler Front Switch ON/OFF RMT
02439 Quick Coupler Rear Switch ON/OFF RMT
02440 Input Machine Sel1 ON/OFF RMT
02441 Input Machine Sel2 ON/OFF RMT
WB93R-8 30-85
Applicable
ID Item Unit (SI)
component
02442 Seat Lateral/Rear Switch ON/OFF RMT
02443 A/C Compressor State ON/OFF RMT
02444 4WD Switch ON/OFF RMT
02445 Transmission Declutch Switch ON/OFF RMT
02446 Differential Lock Switch ON/OFF RMT
02447 Eco-Power Rocker Switch ON/OFF RMT
02448 EcoPower Joystick Switch ON/OFF RMT
02449 Air Filter Clogging Switch ON/OFF RMT
02450 Low Oil Brake Level Switch ON/OFF RMT
02451 Park Brake Switch ON/OFF RMT
02452 Out Low Oil Brake Level Lamp ON/OFF RMT
02453 Out ECSS Lamp ON/OFF RMT
02454 Out Differential Lock Lamp ON/OFF RMT
02455 Out 4WD Lamp ON/OFF RMT
02456 Out General Warning Lamp ON/OFF RMT
02457 Out Low Fuel Warning Lamp ON/OFF RMT
02458 Out Transm Oil Temp. Warning Lamp ON/OFF RMT
02459 Out Check Front Warning Lamp ON/OFF RMT
02460 Out Machine Buzzer ON/OFF RMT
10007 Fan Speed rpm MCH
10010 Fan Speed Command rpm MCH
10018 Fan Clutch Solenoid PWM Current mA MCH
10019 Fan Speed Deviation rpm MCH
20478 Machine Controller Program Version MCH
30-86 WB93R-8
Pre-defined Monitoring SCR standard items

Applicable
ID Item Unit (SI)
component
06004 Compliant ModStrong Inducement SCR
06005 Operator Inducement Severity SCR
06006 DEF Level Warning SCR
06007 DEF Quality Warning SCR
06008 DEF Technical Failure SCR
06009 Validation Count Down minutes SCR
06010 Validation Restart SCR
06011 Low Idle Increase Desired SCR
06012 Low Idle increase Status SCR
06013 Low Idle increase Inhibition SCR
19100 DEF Quality % SCR
19110 DEF Level % SCR
19115 DEF Temperature In Tank degC SCR
19120 DEF Injection Quantity g/h SCR
19202 NOx Concentration Upstream ppm SCR
19204 NH3 Concentration ppm SCR
19209 NOx Concentration Downstream ppm SCR
19300 SCR Upstream Temperature degC SCR
19302 SCR Downstream Temperature degC SCR
47300 DOC Upstream Temperature degC SCR
WB93R-8 30-87
Pre-defined Monitoring MONITOR standard items

Applicable
ID Item Unit (SI)
component
04500 Monitor Input 1
ENG Shutdown 2nd SW ON/OFF MON
Key ACC Signal ON/OFF MON
Parking Brake ON/OFF MON
TravelSpeed SW ON/OFF MON
Directional F Switch ON/OFF MON
Directional R Switch ON/OFF MON
04501 Monitor Input 2
Flasher Control Right ON/OFF MON
Flasher Control Left ON/OFF MON
Quick Coppler ON/OFF MON
Seatbelt Switch ON/OFF MON
Daylight SW ON/OFF MON
Light Switch ON/OFF MON
04503 Monitor Output
Buzzer ON/OFF MON
04504 Vehicle Identification Number
04505 Software Version-Monitor
• Listing order in table

This is the order to be displayed on the "Monitoring Selection Menu" screen.
• Applicable component
ECU: the engine controller detects the monitoring information.
SCR: the engine controller detects the monitoring information.
MCH: the vehicle controller detects the monitoring information.
RMT: the remote controller detects the monitoring information.
MON: the monitor detects the monitoring information.
• ON/OFF is also used for input signal unit but it is different from switch operation.
ON/OFF is described in the unit column of the monitoring items.
When there is an input signal to the controller "ON" is displayed, if there is no input signal, "OFF" is dis-
played on the monitor.
30-88 WB93R-8
ABNORMALITY RECORD MENU

METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYSTEMS)
The machine monitor logs the past and currently occurring failures classifying them into the mechanical
system abnormality and electrical system abnormality.
To check the mechanical system abnormality record, perform the following procedures.
For the failure code list, see “Failure code list”.
1. Select “Abnormality Record” on “Service Menu”

screen.
REMARK
RKA84980
2. After the "Abnormality Record" screen is dis-

"Mechanical Sys Abnormality Record".
item
by one item
• RETURN switch (9): Returns the screen to
"Service Menu" screen
RKA84990
3. After the "Mechanical Sys Abnormality Record"

screen is displayed, the following information are c
displayed.
a
a: Date of occurrence
&$
b: Detail of failure )XHO7HPSHUDWXUH6HQVRU/RZ6HQVRU2SHQ&LUFXLW
b %
c: Failure code 2YHUVSHHG
%
• UP switch (7): Moves the selection up by one /RZ3UHVVXUH)DXOW$ODUP
item
by one item
• RETURN switch (9): Return the screen to the RKA85000
"Abnormality Record" screen

REMARK
• If no abnormality is recorded, "There is no
abnormality record." Is displayed
• For all of the failure codes that the machine
monitor can record, see TROUBLESHOOT-
ING, "Failure code list"
WB93R-8 30-89
• If the characters in the failure are many, the

character strings display is scrolled.
• The contents of an abnormality record of the
mechanical system cannot be deleted.
METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS)

The machine monitor logs the failures that occurred in the past and is occurring currently and classifies them
into the mechanical system abnormality and electrical system abnormality.
To check “Electrical Sys Abnormality Record”, perform the following procedures.
To check the mechanical system abnormality record, perform the following procedures.
For the failure code list, see “Failure code list”.
1. Select “Abnormality Record” on “Service Menu”

screen.
REMARK
RKA84980
2. After the "Abnormality Record" screen is dis-

"Electrical Sys Abnormality Record“.
UP switch (7): Moves the selection up by one item
DOWN switch (8): Moves the selection down by
one item
RETURN switch (9): Returns the screen to
ENTER switch (10): Validates the selection
RKA85010
3. After the "Electrical Sys Abnormality Record"

screen is displayed, the following information are c
displayed.
a
a: Date of occurrence
%*
b: Detail of failure ,PPRELOL]HU&$16\VWHP(UURU
b %
c: Failure code ,QMHFWRU6KRUW&LUFXLW
%&
UP switch (7): Moves the selection up by one item 6XSSO\/RZ9ROWDJH
DOWN switch (8): Moves the selection down by

one item
RETURN switch (9): Return the screen to the
"Abnormality Record" screen RKA85020
REMARK
• If no abnormality is recorded, "There is no
abnormality record." is displayed.
30-90 WB93R-8
• For all of the failure codes that the machine

monitor can record, see TROUBLESHOOT-
ING, "Failure code list".
• If the characters in the failure are many, the
character strings display is scrolled.
• The contents of an abnormality record of the
electrical system cannot be deleted.
METHOD FOR CONFIRMING MAINTENANCE RECORD

The machine monitor records the maintenance information of the filters, oils, etc., which are displayed and
checked by the following operations.
If the data are reset in the operator mode when the maintenance is performed, the number of the times of
maintenance is recorded here.
1. Select "Maintenance Record" on "Service Menu"
screen.
REMARK
RKA85030
2. When "Maintenance Record" screen is dis-

the item to be changed
• UP switch (7): Moves the selected item up by one
item
• DOWN switch (8): Moves the selected item down
by one item
• RETURN switch (9): Returns the display to the
"Service Menu" screen.
RKA85040
WB93R-8 30-91
SELECTABLE ITEMS IN MAINTENANCE RECORD
Item
Air Cleaner Cleaning or Change
Coolant Change
Fuel Prefilter Change
Engine Oil Change
Engine Oil Filter Change
Fuel Main Filter Change
Differential Oil Change
T/M Oil Change
Axle Oil Change
Hydraulic Oil Change
Hydraulic Oil Filter Change
DEF Filter Change
DEF Tank Breather Change
DEF Tank Washing
Brake Oil Change
CCV Filter Change
General Machine Maintenance
Information displayed on the Maintenance Record
screen
a b c
a: Maintenance items
b: Number of replacements up to now
c: Service meter reading (SMR) at the last replace-
ment
RKA85050
METHOD FOR OPERATING MAINTENANCE MODE SETTING

The actuating condition of the maintenance function in the operator mode can be set and changed by this
menu.
• To enable or disable the function of maintenance items.
• To change the replacement interval setting of maintenance items (by item).
• To initialize all of the replacement interval setting of maintenance items.
30-92 WB93R-8
1. Select “Maintenance Mode Setting” on the “Ser-

vice Menu” screen.
REMARK
RKA85060
2. On "Maintenance Mode Setting" screen, select

an item to be changed with the switches.
• UP switch (7): Moves the selected item up by
one item
• DOWN switch (8): Moves the selected item
down by one item
• Enter switch (10): Enters the selected item
RKA85070
SELECTABLE ITEMS IN MAINTENANCE RECORD
Item
Air Cleaner Cleaning or Change
Coolant Change
Fuel Prefilter Change
Engine Oil Change
Engine Oil Filter Change
Fuel Main Filter Change
Differential Oil Change
T/M Oil Change
Axle Oil Change
Hydraulic Oil Change
Hydraulic Oil Filter Change
DEF Filter Change
DEF Tank Breather Change
DEF Tank Washing
Brake Oil Change
CCV Filter Change
General Machine Maintenance
WB93R-8 30-93
3. Select "Maintenance Mode Change". Select an

item to be changed with the switches.
one item
down by one item
returns the display to the "Maintenance Mode
Setting" screen
• ENTER switch (10): Enters the setting and
On or Off" screen RKA85090
4. Select "Mode On or Off Setting". Select an item

to be changed with the switches.
• "ON": Functions of all maintenance items
become enabled in operator mode
• "OFF": Functions of all maintenance items are
disabled in operator mode
one item
down by one item
RKA85100
Change" screen
• ENTER switch (10): Enters the selected item
and returns the display to "Maintenance
Mode Change" screen
REMARK
This setting overrides the ON/OFF setting of each
item after this change of setting is entered once.
30-94 WB93R-8
5. Select "Set". Select an item to be changed with

the switches.
• "Default": Maintenance notice time being set
on the machine monitor (Recommended by
the manufacturer and not changeable).
• "Set": Maintenance notice time that can be
freely set in the range from 10 to 200 hours.
M ain tenan ce r emin der fu nct ion wor ks
according to this set time in operator mode
(the time can be increased or decreased in
multiples of 10 hours)
• UP switch (7): Increases the set value RKA85110
• DOWN switch (8): Decreases the set value

• RETURN switch (9): Cancels the setting and
Change" screen
Change" screen
REMARK
• Enter the selected item with ENTER switch
(10). The setting is validated after the display
returns to "Set" screen with the RETURN
switch (9). RKA85120
• If the value of an item which is set to "ON" is

changed after one operating hour or more
from the setup, the change is recognized as
a reset operation.
6. When the screen of selected maintenance item is
displayed, select "ON/OFF" and change the set-
ting with switches on the switch panel.
one item
down by one item
Setting" screen
• ENTER switch (10): Enter the selected item
and switches to display to the individual set- RKA85130
ting screen
REMARK
• The image will be displayed when "Engine Oil
Change" is selected.
RKA85140
WB93R-8 30-95
7. When the oil change interval screen is displayed,

use a switch o the switch panel to select "ON" or
"OFF".
• "ON": Function of the particular maintenance
item becomes enabled on operator mode.
• "OFF": Function of the particular maintenance
item becomes ineffective in operator mode.
one item
down by one item
RKA85150
returns the display to the individual setting
screen
and switches the display to the individual set-
ting screen
REMARK
The image will be displayed when "Engine Oil
Change" is selected.
8. When the screen of selected maintenance item is
displayed, select "Set" and change the setting
with switches on the switch panel.
one item
down by one item
• RETURN switch (9): Chancels the selection
and returns the display to the "Maintenance
Mode Setting" screen
and switches the display to the individual RKA85160
screen
REMARK
The image will be displayed when "Engine Oil
Change Interval" is selected.
9. When "Set" screen is displayed, change a set
value with the switches on the switch panel.
• "Default": Maintenance set time set on the
machine monitor
• "Set": Maintenance notice time that can be
freely set. Maintenance reminder function
works according to this set time in operator
mode (the time can be increased or
decreased in multiples of 25 hours)
• UP switch (7): Increases the set value
• DOWN switch (8): Decreases the set value
RKA85170
• RETURN switch (9): Chancels the setting and
returns the display to the individual screen
switches the display to the individual screen
30-96 WB93R-8
REMARK
• Enter the selected item with ENTER switch
(10). The setting is validated after the display
returns to "Maintenance
• Mode Setting" screen with the RETURN switch
(9).
• If the value of an item which is set to "ON" is
changed after one operating hour or more
from the setup, the change is recognized as
a reset operation.
• The image will be displayed then "Engine Oil
Change Interval" is selected. RKA85180
RKA85190
NOTICE
Maintenance notice time cannot be set at "Set" in
"Air Cleaner Cleaning". Perform the cleaning or
replacement of the air cleaner element when "Air
cleaner clogging caution lamp" lights up.
RKA85200
WB93R-8 30-97
10. Select "Restore All to Default Value". Select an

item to be changed with the switches.
If this item is executed, the set values of all the
maintenance items return to the default values.
"Maintenance Mode Setting" screen
• ENTER switch (10): Executes the initialization
11. The initialization is completed when "Reset all!" is
appeared on the screen, followed by "Mainte-
nance Mode Setting" after pressing ENTER
switch (10).
RKA85210
RKA85220
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING

• The telephone number can be displayed together with “Current Abnormality” in the operator mode.
Phone number can be registered and changed according to the following procedure.
• Phone number must be registered in order to display the number while in operator mode.
1. Select “Phone Number Entry” from the “Service
Menu” screen.
REMARK
RKA85230
30-98 WB93R-8
2. After the "Phone Number Entry" screen is dis-

played, use a switch on the switch panel to regis-
ter the phone number or change it.
input box. Once reached the last numeric
input box, switch back to the first one
selected box
selected box
• RETURN switch (9): Returns the screen to the
"Service Menu" screen. RKA85240
If pressed before the ENTER Switch (10), the

operation is cancelled and the number is not
saved.
• ENTER switch (10): Validates the input and
returns the screen to the "Service Menu"
screen
REMARK
• Up to 14 digits can be inputted from the left.
Leave the surplus places without inputting
any digit.
• If you press ENTER switch (10) without input-
ting a digit, no phone number is displayed in RKA85250
operator mode since there is no phone

number information.
REMARK
• Up to 14 digits can be inputted from the left.
Leave the surplus places without inputting
any digit.
• If an inputted numeral is wrong, move the cur-
sor (orange background) to that digit and
overwrite it with the correct numeral.
• No telephone number is displayed in the oper-
ator mode when F6 is pressed without input-
ting any digit, since there is no information of
telephone number for it.
WB93R-8 30-99
DEFAULT MENU
METHOD FOR SETTING WITH DEFAULT SETTING MENU (MACHINE MODEL SELECT)
Default menu is used to check or change default values of the machine monitor and machine.
"Machine Model Selection" function is used to make the controller recognize the current machine model.
While "Machine Model Selection" screen is displayed, use switches on the switch panel to perform the
following operation.
Switch operation: While pressing DOWN switch (4), press
(1), (2) and (3) in this order on input switches.Default setting menu is used to check or change default values
of the machine monitor and the machine.
“Unit” function is used to select units of data displayed for monitoring, etc.
1. Select "Default" from the "Service Menu" screen.
REMARK
RKA85260
2. Select "Machine Model Selection" after "Default"

screen appears.
REMARK
RKA85270
3. While "Machine Model Selection" screen is dis-

played, use switches on the switch panel to per-
form the following operation.
• Switch operation: While pressing DOWN
switch (4), press (1), (2) and (3) in this order
on input switches.
RKA85280
30-100 WB93R-8
4. Select the machine model of the machine since

selecting the machine model is enabled.
one item
down by one item
returns the display to "Default" screen
and returns the display to "Default" screen
REMARK
RKA85280
Perform the machine model selection first. If the

monitoring controller is replaced when the
machine models has never been selected.
Default setting is "WB93R"
5. After the screen which promts you a key off is
displayed, turn the starting switch to OFF posi-
tion.
6. Turn the starting switch to ON position again.
RKA85290
WB93R-8 30-101
METHOD FOR STARTING UP KOMTRAX TERMINAL

METHOD FOR STARTING-UP KOMTRAX
Observe the following when using KOMTRAX.
1. KOMTRAX key person performs “Machine Registration” by using KOMTRAX client PC.
2. Perform “KOMTRAX Communication Inspection”.
• For operation procedures, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.
WHEN KOMTRAX TERMINAL IS REPLACED

Observe the following when replacing KOMTRAX terminal and using it again.
1. Our technician provides a new terminal, and records the part number and serial number.
2. Our technician replaces the terminal, and perform “KOMTRAX Communication Inspection”. Our techni-
cian notifies KOMTRAX key person of the completion of inspection work and new terminal information.
3. KOMTRAX key person performs “Terminal Replacement” by using KOMTRAX client PC.
4. KOMTRAX key person fills in required items on “Terminal Replacement Sheet”, and send it by email to
KOMTRAX support center via KOMTRAX administrator in the subsidiary.
• For details, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.
MACHINE SIDE INSPECTION FOR KOMTRAX COMMUNICATION OPENING

• KOMTRAX Communication Inspection must be done to check whether normal communication is availa-
ble from the terminal when the KOMTRAX terminal is replaced or started up.
• By performing this inspection, KOMTRAX starts communication.
• GPS and data communication are checked during the KOMTRAX Communication Inspection. Accord-
ingly, it is preferable to place the machine under the open sky where radio wave from the satellite is not
blocked. The opening inspection may not be completed when the machine is placed indoor where radio
wave from the satellite is blocked.
SIGN-UP TEST ON MACHINE SIDE

a Complete procedures 3 to 5 in 60 seconds.
1. Turn the starting switch OFF and wait for at least
5 seconds and then go to the next step.
2. Check visually that the test connectors under
KOMTRAX terminal (1) are connected.
a Test connectors: CK03, CK04 (male, female)
1
RKAD3810
30-102 WB93R-8
3. Turn the starting switch ON and keep that condi-

tion for 5 seconds.
• Check that the 7-segment indicator lamp indi-
cates a bar.
4. Disconnect test connectors CK03 and CK04 and

keep that condition for 5 seconds.
5. Reconnect test connectors CK03 and CK04 and
keep that condition for 5 seconds.
a If the KOMTRAX terminal detects disconnection
or reconnection of the connectors, the dot of the
7-segment indicator lamp blinks 2 – 3 times.
a If procedures 3 to 5 are not completed in 60 sec-
onds, repeat from procedure 1.
6. Check that the 7-segment indicator lamp of the

KOMTRAX terminal is displaying normally.
a b
RKA81970
WB93R-8 30-103
a If the indication is normal, the 7-segment indica-

tor lamp (a) is displayed for 30 seconds after pro-
cedure 5 is completed. (“d”, “0” and “–” are
displayed repeatedly.)
• Display of the 2nd letter “0” may be dif-
ferent from the first.
• Display of the 3rd letter “–” changes 30
seconds after the operation of procedure
5.
a Go to the next step if you can check that the dis-
play is “normal”.
a If the display is “abnormal”, repeat from proce-
dure 1 again. (“–” is displayed continuously.)
7. Turn the starting switch to the START position,
keep it more than 5 seconds, and check that the
engine does not start.
a If the engine starts, repeat from procedure 1.
a If the engine starts again, the engine start lock
function does not work normally. Stop the inspec-
tion and check of the relays and wiring harnesses
for trouble.
8. Return the starting switch to the ON position and
keep it there for 5 seconds.
a Do not return the starting switch to the OFF posi-
tion.
9. Turn the starting switch to the START position
again and ensure that the engine starts.
10. Check that the 7-segment indicator lamp of the
KOMTRAX terminal is indicating normally without
stopping the engine.
a Go to the next step if you ensured that the display
is [normal]. (It takes from 90 seconds to 15 min-
utes before the display turns normal.)
a If [GPS position data detection trouble] is indi-
cated, check if there is any external abnormality
on the GPS antenna or cable. If there is any
abnormality, repair it and repeat from procedure 1
again.
a If [Reception trouble] is indicated, check if there
is any external abnormality on the appearance of
the communication antenna or cable. If there is
any abnormality, repair it then repeat from proce-
dure 1) again.
a If [GPS position data detection trouble and recep-
tion trouble] is indicated, check if there is any
external abnormality on the GPS antenna or
cable and communication antenna or cable. If
there is any abnormality, repair it and repeat from
procedure 1 again.
30-104 WB93R-8
a If [Network trouble] is indicated, check the display

of [LED-4] referring to “Lamp display of KOMT-
RAX terminal”. (If CAN is not recognized, check
the CAN harness of the KOMTRAX terminal, and
then if there is any abnormality, repair it and
repeat from procedure 1 again.)
[A]: Normal finish (It takes at least 90 seconds for

the system to display this)
[B]: GPS position data detection trouble “Check
the GPS antenna and cable for external abnor-
mality.” (It takes 90 seconds – 5 minutes)
[C]: Incomplete receiving “Check the communica-
tion antenna and cable for external abnormality.”
(It takes 30 seconds – 1 minute)
[D]: Network trouble or wiring harness trouble
“The network type selection input does not agree
with the obtained network data.” “Check the
machine wiring for an error.”
a If the display is not any of the above, call Cus-
tomer Support Division.
a It takes 90 seconds – 5 minutes for the system to
display “Normal finish” after the operation of 5
11. Turn the starting switch OFF.
12. Check that the 7-segment indicator lamp is indi-

cating normally in 10 seconds.
a If you checked that the display is [Normal], that is
the end of the signup test.
a If the display shows [Abnormal], repeat from pro-
cedure 1) again because the sign-up test has not
been completed successfully.
WB93R-8 30-105
APPLICATION FOR THE START OF USE

a Application for the start of use must be made only
after the sign-up test is finished.
1. Notify to the KOMTRAX operations administrator Serial No.
of the following information concerning the
machine whose sign-up test on the machine side
is completed.
1) Information on the machine whose sign-up
test on the machine side is completed
(Model, model number and serial number)
2) Part number and serial number of the
KOMTRAX terminal
3) Reading of the service meter when the
KOMTRAX terminal was installed (0.1h unit)
a If you checked that the display is [Normal], that is
the end of the signup test.
Part No.
RKA81980
30-106 WB93R-8
LAMP DISPLAY OF KOMTRAX TERMINAL
1 2 3 4 5
6 7
RKA81990
CPU LED
1. LED-1 (R signal and ACC signal)
2. LED-2 (Starting output status)
3. LED-3 (S-NET status and C signal status)
4. LED-4 (Fuel sensor and CAN connection status)
5. LED-5 (Downloading and writing status)
7-segment and dot for CPU

6. 7-segment (Sign-up test status and operation status)
7. Dot (GPS positioning status and test connector disconnection/connection status))
WB93R-8 30-107
In the KOMTRAX system, various information and processing details are displayed on the LED of the upper
surface of the KOMTRAX terminal. Therefore, if a defect is suspected in the system, perform the following
checks.
• Check of antennas
• Check of terminal LED displays
Application for the start of use and sign-up test on the machine side must be completed in advance in order
to use KOMTRAX system.
Check of antennas
• Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
• The communication antenna must not be off or damaged.
• The communication antenna cable must not be broken and must be connected to the KOMTRAX termi-
nal normally.
• The GPS antenna must not be off or damaged.
• The GPS antenna cable must not be broken and must be connected to the KOMTRAX terminal normally.
CONTENTS OF CPU LED, 7-SEGMENT AND DOT DISPLAYS

a The LED displays must be checked with the starting switch in the ON or START position or with the
engine started.
No. LED (Color) Name/Function Display (*1) Contents of display
ON Starting switch ACC signal: ON, alternator R signal: ON
Starting switch ACC signal: OFF, alternator R signal:
Fast blinking
Starting switch ON
LED-1
1 ACC signal and Starting switch ACC signal: ON, alternator R signal:
(Green)
alternator R signal Slow blinking OFF
Starting switch ACC signal: OFF, alternator R signal:
OFF
OFF
LED-2 Starting output ON Engine control signal: ON
2
(Red) status OFF Engine control signal: OFF
S-NET connection Fast blinking Starting switch C signal: ON
LED-3 status and starting ON Starting switch C signal: OFF, S-NET: Connected
3
(Yellow) switch C signal
status OFF Starting switch C signal: OFF, S-NET: Disconnected
ON CAN: Connected, (Fuel sensor: Disconnected)
Fuel sensor and Fast blinking CAN: Connected, (Fuel sensor: Connected)
LED-4
4 CAN connection
(Green) Slow blinking CAN: Disconnected, (Fuel sensor: Connected)
status
OFF CAN: Disconnected, (Fuel sensor: Disconnected)
LED-5 Downloading and ON Downloading and writing mode: ON
5
(Red) writing status OFF Downloading and writing mode: OFF (Normal mode)
30-108 WB93R-8
No. LED (Color) Name/Function Display (*1) Contents of display

Before execution of sign-up test
When sign-up test is not completed, “–” (bar) is always
Sign-up status [–]
displayed.
During sign-up test
Sign-up progress *For display during sign-up test, see “How to start oper-
*
status ation of KOMTRAX terminal”.
After completion of sign-up test
If server initialization communication is not completed,
[C]
[C] is displayed.
Initialization com-
7-segment munication incom- “ON” indicates that machine is within communication
6 ON
(Red) range.
pletion status Fast blinking
“Fast blinking” indicates that machine is out of commu-
nication range.
Operation status
[0 – 9] Figure indicates number of mails waiting for to be sent
(9 is displayed when number is 9 or larger).
Number of unsent ON “ON” indicates that terminal is capturing satellite.
mails or within/out
of communication Figure indicates number of mails waiting for to be sent
[0 – 9]
range status (9 is displayed when number is 9 or larger).
Fast blinking indicates that terminal has not captured
Fast blinking
satellite.
GPS connector ON GPS positioning has been executed. See *2.
positioning/ OFF GPS positioning has not been executed. See *2.
Dot
7 Test connector
(Red) If sign-up test connector is disconnected or connected,
disconnection and Fast blinking
connection status dot blinks 2 – 3 times.
*1 Types and periods of blinking

Fast blinking: Blinking at cycles of about 1 second (ON for 0.5 seconds o OFF for 0.5 seconds)
Slow blinking: Blinking at cycles of about 4 seconds (ON for 2 seconds o OFF for 2 seconds)
*2 It may take more than 1 minute from turning on the starting switch to the completion of positioning even in
an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of radio waves.
WB93R-8 30-109
ADJUST FRONT PANEL SETTINGS

Germany or Military specification
METHOD FOR ADJUSTING FRONT PANEL SETTINGS
1. Remove front panel (For details, see “50 DISAS-

SEMBLY AND ASSEMBLY - REMOVE AND
INSTALL FRONT PANEL”)
2. Remove the plug (1).
3. Set dipswitch (2) using the below parameters.

Settings valid for km/h
Dipswitch
Tyre size
1 2 3 4
16.9x28 OFF OFF OFF OFF
440/80 R28 OFF OFF OFF OFF
480/80 R26 OFF OFF OFF OFF
18.4X26 OFF OFF OFF OFF
Settings valid for mph

Dipswitch
Tyre size
1 2 3 4
16.9x28 ON OFF OFF OFF
440/80 R28 ON OFF OFF OFF
480/80 R26 ON OFF OFF OFF
18.4X26 ON OFF OFF OFF
30-110 WB93R-8
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM

a When carrying out troubleshooting of an electric
circuit related to the KOMTRAX terminal, expose
the related connectors according to the following
procedure.
a The KOMTRAX terminal is installed under the
right side switch panel.
1. Turn the battery disconnecting switch to the OFF
position (for detail see “HANDLING BATTERY
DISCONNECT SWITCH”).
2. Remove the screw covers (1) by unscrewing
them half to 1 turn. 1
RKAD3820
3. Remove switch panel (2) fixing screws (3) and

move the switch panel aside.
2
3
RKAD3830
4. Insert or connect a troubleshooting T-adapter to

connector CK02 of KOMTRAX terminal (1). 1
a Cable (2) is for the communication antenna 2
(system 1).
a Cable (3) is for the GPS antenna.
CK02
RKAD3840
WB93R-8 30-111
HANDLING BATTERY DISCONNECT SWITCH
HANDLING BATTERY DISCONNECT SWITCH

1. When the battery disconnect switch is turned to
"OFF (O)" position, be sure to remove switch key
(1).
k A hazard can result if an unauthorized per-
son turns switch key (1) to ON position care-
1
lessly.
a The battery disconnect switch is installed
inside the rear left cover of the machine.
2. The operating condition of each controller can be
checked with the system operating lamp (2) to 2
prevent the abnormal end of the disconnection of
the battery power supply circuit while the control- RKAD3540
lers are in operation.
1) Before shutting off the battery power supply circuit, turn the starting switch to "OFF" position, and
check that system operating lamp (2) goes off, then turn the battery disconnect switch to "OFF (O)"
position.
2) If the battery disconnect switch is turned to "OFF (O)" position (battery power supply circuit is OFF)
while system operating lamp (2) is lit, data loss error of controller may occur. Never operate the bat-
tery disconnect switch while system operating lamp (2) is lit.
3) System operating lamp (2) goes off in 2 minutes after the starting switch is turned to "OFF" position.
4) System operating lamp (2) may sometimes light up while the starting switch is turned to "OFF" posi-
tion because KOMTRAX terminal may maintain its communication under this condition.
5) System operating lamp (2) may look slightly luminous in the dark after it is turned off. It is due to the
minute leakage of current and not an abnormal phenomenon.
• After the starting switch is turned to "OFF" position, KOMTRAX terminal repeats the start and
stop to maintain the periodic communication.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors
including the communication state and machine stop time. So the lamp can be lit as long as
approximately 1 hour.
6) When you want to cut off the battery circuit for maintenance but the system operating lamp (2) is
kept lit, turn the starting switch to "ON" position once and then turn it to "OFF (O)" position. Lamp (2)
goes out in max. 2 minutes. After system operating lamp (2) goes out, turn the battery disconnect
switch immediately to "OFF (O)" position.
30-112 WB93R-8
TESTING DIODES
TESTING DIODES
a Test the diode array (8-pin) and the single diode
(2-pin) according to the following procedure.
a The continuity directions of the diode array are as 1
follows.
1
1 5 2 2
a The continuity direction of the single diode is indi- 3 3
cated on the surface of the diode. 2 6 4
4
3 7 5
6
4 8 7
8
BWP10582
TESTING
1. When using a digital tester
1) Select the diode range screen to check the
displayed values.
a When an ordinary circuit tester is used,
the voltage of the internal battery is indi-
cated.
2) Apply the red (+) lead of the multimeter to the
anode (P) side of the diode and apply the
black (-) lead to the cathode (N) side and
check the indicated value.
3) Evaluate the condition of the diode by the
indicated value.
• Indicated value does not change: No
continuity (defective)
• Indicated value changes: Continuity (nor-
mal) (note)
Note: In the case of a silicon diode, a value in
the range from 460 to 600 mV is indicated.
• The indicated value is 0 or approxi-
mate 0: The diode has internal short
circuit (defective).
2. When using analog tester
1) Selects the resistance range screen.
2) Check the movement of the pointer when
performing the following connection.
1] Apply the red (+) lead of the multimeter to P N
the anode (P) side of the diode and apply the
black (-) lead to the cathode (N) side.
2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and apply
the black (-) lead to the anode (P) side.
3) Evaluate the condition of the diode by the
movement of the pointer. RKA82500
• The pointer does not move by the above
1] connection, but it does by the 2] con-
nection: Normal (however, the movement
of the pointer (resistance) varies by type
of tester, or selection of measuring
range).
WB93R-8 30-113
TESTING DIODES
• The pointer moves by either connection

of the above 1], and 2]:
• Defective (internal short circuit)
• The pointer moves by neither connection
the above 1], nor 2]: Defective (internal
open circuit)
30-114 WB93R-8
OUTRIGGER SENSOR AND SAFETY SYSTEM
WORK EQUIPMENT
k Place the machine on a level ground, lower the work equipment to the ground and fully raise the
outrigger the stop the engine.
METHOD FOR CHECKING AND ADJUSTING THE OUTRIGGER SENSOR
1. Disconnect the cable (1) from sensor (2).
1
X151
2
RKA94490
2. Remove bolt (3) and protection (4).
RKA94500
3. Loosen nut (5) and remove sensor (6).
6
5
RKA94560
WB93R-8 30-115
4. Measure the total length A of the sensor (6).
RKA94300
5. Install sensor (6) until and screw it in until quote

C is reached.
NOTICE
Calculate quote C with the following formula:
6
B = A - 16 mm
C = B - 1 mm max
RKA94570
RKA94310
6. Tighten nut (5) to lock the position.
RKA94561
30-116 WB93R-8
7. Install the protection (4) and lock bolt (3).
RKA94500
8. Connect the cable (1) to the sensor (2).
1
X151
2
RKA94490
METHOD FOR TESTING CORRECT FUNCTIONALITY OUTRIGGER SAFETY SYSTEM

2. Lower the outriggers until it reaches 100 mm
from the ground.
3. Select the forward or reverse direction without
selecting any mechanical speed.
4. The outrigger safety system is working correctly
if the outriggers warning lamp light up on the
machine monitor and the buzzer sounds.
5. Fully raise the outriggers
6. The outrigger safety system is working correctly
if the outriggers warning lamp and the buzzer
turn off.
WB93R-8 30-117
RETURN TO DIG SENSOR ADJUSTMENT
RETURN TO DIG SENSOR ADJUSTMENT

k Place the machine on a level ground, lower the front work equipment with then loader bucket
fully curled and then stop the engine.
METHOD FOR ADJUSTING RETURN TO DIG SENSOR
1. With the loader bucket cylinders fully retracted,

remove cover (1).
1
RKA84780
2. Loose bolts (2) and move sensor (3) forward or

backward until it reaches quote “A”.
a Quote “A” with Komatsu buckets: 257 mm
A
3. Tighten bolts (2) and install cover (1).
RKA84790
4. Adjust the distance between sensor (3) and bar

(4) at 10±1 mm.
5. Check that the distance between sensor (3) and
bar (4) is within the limit during all the bar (4) A
travel “A”.
4 3
RKA84800
30-118 WB93R-8
TELESCOPIC ARM GUIDE SLACK ADJUSTMENT

Use the telescopic arm guide slack adjustment when disassembly or replacement of components shown in
the table below is performed.
Detail of work
Replacement of the fixed arm
Replacement of the movable arm
Replacement of the lower guide
METHOD FOR ADJUSTING GUIDE SLACK

PREPARATION FOR ADJUSTING GUIDE SLACK
1. Move the backhoe work equipment in the posture
Work equipment posture:
• Backhoe bucket fully curled
• Outrigger fully extended
• Telescopic arm fully extended
• Telescopic arm guide vertical with the movable
arm not forcing on guides
RKA82050
GUIDE SLACK REGISTRATION

1. Verify which is the side where the adjusting dow-
els (1) are more unscrewed. This is the side
where the slack has to be registered. 2
2. Loosen the four lock nuts (2) and tighten all the
adjusting dowels (1) until the slack is completely
removed.
1 1
RKAD3550
WB93R-8 30-119
a The guides (3) need to be replaced evenif only

one of the adjusting dowels (1) are screwed in
the locking nut (2) of 5.0 mm or more.
1
5 mm
3
RKA82760
3. Loose adjusting dowels (1) by 270° (3/4 turn) and

tighten the lock nuts (2) following the order
“a-b-c-d”.
4. Start the machine, extend and retract the tele-
scopic arm and verify it slides correctly.
5. Fully retract the movable arm and stop the
engine.
6. Verify that the movable arm is correctly centred

in the fixed arm.
a Maximum difference between distance on left
and right side: D1 D2
• Front side: D1 - D2 = max 2.5 mm
• Rear side: D3 - D4 = max 3.0 mm
150
RKAD3560
D3 D4
RKAD3570
30-120 WB93R-8
7. Tighten locknuts (2) to the prescribed torque.

3 Locknut(2): 200 Nm 2
8. Lubricate the guides with grease.
2 Guides (3): NLGI1
RKAD3580
WB93R-8 30-121
30-122 WB93R-8
WB93R-8
HYDRAULIC EXCAVATOR
WB93R-8

40 TROUBLESHOOTING 01-
WB93R-8 40-1
40 TROUBLESHOOTING
CONTENTS
CONTENTS
CONTENTS .............................................................................................................................................. 40-2
ABBREVIATION LIST ............................................................................................................................. 40-12

LIST OF ABBREVIATIONS USED IN THE TEXT ............................................................................ 40-12
LIST OF ABBREVIATIONS USED IN THE CIRCUIT DIAGRAMS ................................................... 40-18
RELATED INFORMATION ON TROUBLESHOOTING.......................................................................... 40-19

GENERAL TROUBLESHOOTING POINTS ........................................................................................ 40-19
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM............................................................... 40-20
CHECKS BEFORE TROUBLESHOOTING ............................................................................................ 40-21
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ............................................................. 40-23

WALK-AROUND CHECK..................................................................................................................... 40-23
TESTING IN ACCORDANCE WITH TESTING PROCEDURE............................................................... 40-25

CHECK OF FUEL LEVEL AND TYPE ................................................................................................. 40-25
METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDIMENT .............. 40-26
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE .......................................................... 40-28
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE ....................................................... 40-30
METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT ..................................................................... 40-31
METHOD FOR CHECKING DEF LEVEL AND TYPE.......................................................................... 40-32
METHOD FOR ADDING DEF.............................................................................................................. 40-33
METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL..................................... 40-36
METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT ................................................ 40-38
METHOD FOR CHECKING AIR CLEANER ........................................................................................ 40-39
METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT ......................................................... 40-40
METHOD FOR CHANGING AIR CLEANER ELEMENT...................................................................... 40-43
CHECK AND REPLACE VACUATOR VALVE..................................................................................... 40-44
METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL .................................. 40-44
METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER......
40-45
BLEED AIR FROM HYDRAULIC SYSTEM ......................................................................................... 40-47
METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT ................................................... 40-48
METHOD FOR CHECKING THE OIL LEVELS IN THE TRANSMISSION .......................................... 40-50
METHOD FOR CHECKING THE FRONT AXLE OIL LEVEL .............................................................. 40-51
METHOD FOR CHECKING THE REAR AXLE OIL LEVEL................................................................. 40-52
FAILURE CODES TABLE....................................................................................................................... 40-52
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)....................................................... 40-71

TROUBLESHOOTING OF ENGINE FAILURE .................................................................................... 40-71
FAILURE CODE [#T0001] ................................................................................................................ 40-71
40-2 WB93R-8
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [#T0002] ................................................................................................................ 40-71

FAILURE CODE [#T0003] ................................................................................................................ 40-71
FAILURE CODE [#T0004] ................................................................................................................ 40-72
FAILURE CODE [#T0005] ................................................................................................................ 40-72
FAILURE CODE [#T0006] ................................................................................................................ 40-72
FAILURE CODE [#T0007] ................................................................................................................ 40-73
FAILURE CODE [#T0008] ................................................................................................................ 40-73
FAILURE CODE [#T0009] ................................................................................................................ 40-74
FAILURE CODE [#T0010] ................................................................................................................ 40-74
FAILURE CODE [#T0011] ................................................................................................................ 40-74
FAILURE CODE [#T0012] ................................................................................................................ 40-75
FAILURE CODE [#T0013] ................................................................................................................ 40-75
FAILURE CODE [#T0014] ................................................................................................................ 40-76
FAILURE CODE [#T0015] ................................................................................................................ 40-76
FAILURE CODE [#T0016] ................................................................................................................ 40-76
FAILURE CODE [#T0017] ................................................................................................................ 40-77
FAILURE CODE [#T0018] ................................................................................................................ 40-77
FAILURE CODE [#T0019] ................................................................................................................ 40-78
FAILURE CODE [#T0020] ................................................................................................................ 40-78
FAILURE CODE [#T0021] ................................................................................................................ 40-79
FAILURE CODE [#T0022] ................................................................................................................ 40-79
FAILURE CODE [#T0023] ................................................................................................................ 40-79
FAILURE CODE [#T0024] ................................................................................................................ 40-80
FAILURE CODE [#T0025] ................................................................................................................ 40-80
FAILURE CODE [#T0026] ................................................................................................................ 40-80
FAILURE CODE [#T0027] ................................................................................................................ 40-81
FAILURE CODE [#T0028] ................................................................................................................ 40-81
FAILURE CODE [#T0029] ................................................................................................................ 40-81
FAILURE CODE [#T0030] ................................................................................................................ 40-82
FAILURE CODE [#T0031] ................................................................................................................ 40-82
FAILURE CODE [#T0032] ................................................................................................................ 40-82
FAILURE CODE [#T0033] ................................................................................................................ 40-83
FAILURE CODE [#T0034] ................................................................................................................ 40-83
FAILURE CODE [#T0035] ................................................................................................................ 40-83
FAILURE CODE [#T0036] ................................................................................................................ 40-84
FAILURE CODE [#T0037] ................................................................................................................ 40-84
FAILURE CODE [#T0038] ................................................................................................................ 40-84
FAILURE CODE [#T0039] ................................................................................................................ 40-85
FAILURE CODE [#T0040] ................................................................................................................ 40-85
FAILURE CODE [#T0041] ................................................................................................................ 40-85
FAILURE CODE [#T0042] ................................................................................................................ 40-86
FAILURE CODE [#T0043] ................................................................................................................ 40-86
FAILURE CODE [#T0044] ................................................................................................................ 40-86
FAILURE CODE [#T0045] ................................................................................................................ 40-87
WB93R-8 40-3
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [#T0046] ................................................................................................................ 40-87

FAILURE CODE [#T0047] ................................................................................................................ 40-87
FAILURE CODE [#T0048] ................................................................................................................ 40-88
FAILURE CODE [#T0049] ................................................................................................................ 40-88
FAILURE CODE [#T0050] ................................................................................................................ 40-89
FAILURE CODE [#T0051] ................................................................................................................ 40-89
FAILURE CODE [#T0052] ................................................................................................................ 40-89
FAILURE CODE [#T0053] ................................................................................................................ 40-90
FAILURE CODE [#T0054] ................................................................................................................ 40-90
FAILURE CODE [#T0055] ................................................................................................................ 40-90
FAILURE CODE [#T0056] ................................................................................................................ 40-91
FAILURE CODE [#T0057] ................................................................................................................ 40-91
FAILURE CODE [#T0058] ................................................................................................................ 40-92
FAILURE CODE [#T0059] ................................................................................................................ 40-93
FAILURE CODE [#T0060] ................................................................................................................ 40-94
FAILURE CODE [#T0061] ................................................................................................................ 40-95
FAILURE CODE [#T0062] ................................................................................................................ 40-95
FAILURE CODE [#T0063] ................................................................................................................ 40-96
FAILURE CODE [#T0064] ................................................................................................................ 40-96
FAILURE CODE [#T0065] ................................................................................................................ 40-96
FAILURE CODE [#T0066] ................................................................................................................ 40-97
FAILURE CODE [#T0067] ................................................................................................................ 40-97
FAILURE CODE [#T0068] ................................................................................................................ 40-97
FAILURE CODE [#T0069] ................................................................................................................ 40-98
FAILURE CODE [#T0070] ................................................................................................................ 40-98
FAILURE CODE [#T0071] ................................................................................................................ 40-99
FAILURE CODE [#T0072] ................................................................................................................ 40-99
FAILURE CODE [#T0073] .............................................................................................................. 40-100
FAILURE CODE [#T0074] .............................................................................................................. 40-100
FAILURE CODE [#T0075] .............................................................................................................. 40-100
FAILURE CODE [#T0076] .............................................................................................................. 40-101
FAILURE CODE [#T0077] .............................................................................................................. 40-101
FAILURE CODE [#T0078] .............................................................................................................. 40-102
FAILURE CODE [#T0079] .............................................................................................................. 40-102
FAILURE CODE [#T0080] .............................................................................................................. 40-103
FAILURE CODE [#T0081] .............................................................................................................. 40-103
FAILURE CODE [#T0082] .............................................................................................................. 40-103
FAILURE CODE [#T0083] .............................................................................................................. 40-104
FAILURE CODE [#T0084] .............................................................................................................. 40-104
FAILURE CODE [#T0085] .............................................................................................................. 40-105
FAILURE CODE [#T0086] .............................................................................................................. 40-105
FAILURE CODE [#T0087] .............................................................................................................. 40-105
FAILURE CODE [#T0088] .............................................................................................................. 40-106
FAILURE CODE [#T0089] .............................................................................................................. 40-106
40-4 WB93R-8
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [#T0090] .............................................................................................................. 40-106

FAILURE CODE [#T0091] .............................................................................................................. 40-107
FAILURE CODE [#T0092] .............................................................................................................. 40-107
FAILURE CODE [#T0093] .............................................................................................................. 40-108
FAILURE CODE [#T0094] .............................................................................................................. 40-108
FAILURE CODE [#T0095] .............................................................................................................. 40-109
FAILURE CODE [#T0096] .............................................................................................................. 40-109
FAILURE CODE [#T0099] .............................................................................................................. 40-109
FAILURE CODE [#T0100] .............................................................................................................. 40-110
FAILURE CODE [#T0101] .............................................................................................................. 40-110
FAILURE CODE [#T0102] .............................................................................................................. 40-110
FAILURE CODE [#T0103] .............................................................................................................. 40-111
FAILURE CODE [#T0104] .............................................................................................................. 40-111
FAILURE CODE [#T0105] .............................................................................................................. 40-112
FAILURE CODE [#T0106] .............................................................................................................. 40-112
FAILURE CODE [#T0107] .............................................................................................................. 40-112
FAILURE CODE [#T0108] .............................................................................................................. 40-113
FAILURE CODE [#T0109] .............................................................................................................. 40-113
FAILURE CODE [#T0110] .............................................................................................................. 40-113
FAILURE CODE [#T0111] .............................................................................................................. 40-114
FAILURE CODE [#T0112] .............................................................................................................. 40-114
FAILURE CODE [#T0113] .............................................................................................................. 40-114
FAILURE CODE [#T0114] .............................................................................................................. 40-115
FAILURE CODE [#T0115] .............................................................................................................. 40-115
FAILURE CODE [#T0116] .............................................................................................................. 40-115
FAILURE CODE [#T0117] .............................................................................................................. 40-116
FAILURE CODE [#T0118] .............................................................................................................. 40-116
FAILURE CODE [#T0119] .............................................................................................................. 40-116
FAILURE CODE [#T0120] .............................................................................................................. 40-117
FAILURE CODE [#T0121] .............................................................................................................. 40-117
FAILURE CODE [#T0122] .............................................................................................................. 40-117
FAILURE CODE [#T0123] .............................................................................................................. 40-118
FAILURE CODE [#T0124] .............................................................................................................. 40-118
FAILURE CODE [#T0125] .............................................................................................................. 40-119
FAILURE CODE [#T0126] .............................................................................................................. 40-119
FAILURE CODE [#T0127] .............................................................................................................. 40-120
FAILURE CODE [#T0128] .............................................................................................................. 40-120
FAILURE CODE [#T0129] .............................................................................................................. 40-121
FAILURE CODE [#T0130] .............................................................................................................. 40-121
FAILURE CODE [#T0131] .............................................................................................................. 40-122
FAILURE CODE [#T0132] .............................................................................................................. 40-122
FAILURE CODE [#T0133] .............................................................................................................. 40-122
FAILURE CODE [#T0134] .............................................................................................................. 40-123
FAILURE CODE [#T0135] .............................................................................................................. 40-123
WB93R-8 40-5
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [#T0136] .............................................................................................................. 40-123

FAILURE CODE [#T0137] .............................................................................................................. 40-124
FAILURE CODE [#T0138] .............................................................................................................. 40-124
FAILURE CODE [#T0139] .............................................................................................................. 40-124
FAILURE CODE [#T0140] .............................................................................................................. 40-125
FAILURE CODE [#T0141] .............................................................................................................. 40-125
FAILURE CODE [#T0142] .............................................................................................................. 40-125
FAILURE CODE [#T0143] .............................................................................................................. 40-126
FAILURE CODE [#T0144] .............................................................................................................. 40-126
FAILURE CODE [#T0145] .............................................................................................................. 40-126
FAILURE CODE [#T0146] .............................................................................................................. 40-127
FAILURE CODE [#T0147] .............................................................................................................. 40-127
FAILURE CODE [#T0148] .............................................................................................................. 40-127
FAILURE CODE [#T0149] .............................................................................................................. 40-128
FAILURE CODE [#T0150] .............................................................................................................. 40-128
FAILURE CODE [#T0151] .............................................................................................................. 40-128
FAILURE CODE [#T0152] .............................................................................................................. 40-129
FAILURE CODE [#T0153] .............................................................................................................. 40-129
FAILURE CODE [#T0154] .............................................................................................................. 40-129
FAILURE CODE [#T0155] .............................................................................................................. 40-130
FAILURE CODE [#T0156] .............................................................................................................. 40-130
FAILURE CODE [#T0157] .............................................................................................................. 40-130
FAILURE CODE [#T0158] .............................................................................................................. 40-131
FAILURE CODE [#T0159] .............................................................................................................. 40-131
FAILURE CODE [#T0160] .............................................................................................................. 40-131
FAILURE CODE [#T0161] .............................................................................................................. 40-132
FAILURE CODE [#T0162] .............................................................................................................. 40-132
FAILURE CODE [#T0163] .............................................................................................................. 40-132
FAILURE CODE [#T0164] .............................................................................................................. 40-133
FAILURE CODE [#T0165] .............................................................................................................. 40-133
FAILURE CODE [#T0166] .............................................................................................................. 40-133
FAILURE CODE [#T0167] .............................................................................................................. 40-134
FAILURE CODE [#T0168] .............................................................................................................. 40-134
FAILURE CODE [#T0169] .............................................................................................................. 40-134
FAILURE CODE [#T0170] .............................................................................................................. 40-135
FAILURE CODE [#T0171] .............................................................................................................. 40-135
FAILURE CODE [#T0172] .............................................................................................................. 40-135
FAILURE CODE [#T0173] .............................................................................................................. 40-136
FAILURE CODE [#T0174] .............................................................................................................. 40-137
FAILURE CODE [#T0175] .............................................................................................................. 40-137
FAILURE CODE [#T0176] .............................................................................................................. 40-137
FAILURE CODE [#T0177] .............................................................................................................. 40-138
FAILURE CODE [#T0178] .............................................................................................................. 40-138
FAILURE CODE [#T0179] .............................................................................................................. 40-138
40-6 WB93R-8
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [#T0180] .............................................................................................................. 40-139

FAILURE CODE [#T0181] .............................................................................................................. 40-139
FAILURE CODE [#T0182] .............................................................................................................. 40-140
FAILURE CODE [#T0183] .............................................................................................................. 40-140
FAILURE CODE [#T0184] .............................................................................................................. 40-140
FAILURE CODE [#T0185] .............................................................................................................. 40-141
FAILURE CODE [#T0186] .............................................................................................................. 40-141
FAILURE CODE [#T0187] .............................................................................................................. 40-141
FAILURE CODE [#T0188] .............................................................................................................. 40-142
FAILURE CODE [#T0189] .............................................................................................................. 40-142
FAILURE CODE [#T0190] .............................................................................................................. 40-143
FAILURE CODE [#T0191] .............................................................................................................. 40-143
FAILURE CODE [#T0192] .............................................................................................................. 40-143
FAILURE CODE [#T0193] .............................................................................................................. 40-144
FAILURE CODE [#T0194] .............................................................................................................. 40-144
FAILURE CODE [#T0195] .............................................................................................................. 40-144
FAILURE CODE [#T0196] .............................................................................................................. 40-145
FAILURE CODE [#T0197] .............................................................................................................. 40-145
FAILURE CODE [#T0198] .............................................................................................................. 40-146
FAILURE CODE [#T0199] .............................................................................................................. 40-146
FAILURE CODE [#T0200] .............................................................................................................. 40-146
FAILURE CODE [#T0201] .............................................................................................................. 40-147
FAILURE CODE [#T0202] .............................................................................................................. 40-147
FAILURE CODE [#T0203] .............................................................................................................. 40-147
FAILURE CODE [#T0204] .............................................................................................................. 40-148
FAILURE CODE [#T0205] .............................................................................................................. 40-149
FAILURE CODE [#T0206] .............................................................................................................. 40-150
FAILURE CODE [#T0207] .............................................................................................................. 40-151
FAILURE CODE [#T0208] .............................................................................................................. 40-152
FAILURE CODE [#T0209] .............................................................................................................. 40-152
FAILURE CODE [#T0210] .............................................................................................................. 40-153
FAILURE CODE [#T0211] .............................................................................................................. 40-153
FAILURE CODE [#T0212] .............................................................................................................. 40-154
FAILURE CODE [#T0213] .............................................................................................................. 40-154
FAILURE CODE [#T0214] .............................................................................................................. 40-154
FAILURE CODE [#T0215] .............................................................................................................. 40-155
FAILURE CODE [#T0216] .............................................................................................................. 40-155
FAILURE CODE [#T0217] .............................................................................................................. 40-156
FAILURE CODE [#T0218] .............................................................................................................. 40-157
FAILURE CODE [#T0219] .............................................................................................................. 40-157
FAILURE CODE [#T0220] .............................................................................................................. 40-158
FAILURE CODE [#T0221] .............................................................................................................. 40-159
FAILURE CODE [#T0222] .............................................................................................................. 40-160
FAILURE CODE [#T0223] .............................................................................................................. 40-161
WB93R-8 40-7
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [#T0224] .............................................................................................................. 40-162

FAILURE CODE [#T0225] .............................................................................................................. 40-162
FAILURE CODE [#T0226] .............................................................................................................. 40-162
FAILURE CODE [#T0227] .............................................................................................................. 40-163
FAILURE CODE [#T0228] .............................................................................................................. 40-163
FAILURE CODE [#T0229] .............................................................................................................. 40-164
FAILURE CODE [#T0230] .............................................................................................................. 40-164
FAILURE CODE [#T0231] .............................................................................................................. 40-165
FAILURE CODE [#T0232] .............................................................................................................. 40-165
FAILURE CODE [#T0233] .............................................................................................................. 40-165
FAILURE CODE [#T0234] .............................................................................................................. 40-166
FAILURE CODE [#T0235] .............................................................................................................. 40-166
FAILURE CODE [#T0236] .............................................................................................................. 40-166
FAILURE CODE [#T0237] .............................................................................................................. 40-167
FAILURE CODE [#T0238] .............................................................................................................. 40-167
FAILURE CODE [#T0239] .............................................................................................................. 40-167
FAILURE CODE [#T0240] .............................................................................................................. 40-168
FAILURE CODE [#T0241] .............................................................................................................. 40-168
FAILURE CODE [#T0242] .............................................................................................................. 40-168
FAILURE CODE [#T0243] .............................................................................................................. 40-169
FAILURE CODE [#T0244] .............................................................................................................. 40-169
FAILURE CODE [#T0245] .............................................................................................................. 40-169
FAILURE CODE [#T0246] .............................................................................................................. 40-170
FAILURE CODE [#T0247] .............................................................................................................. 40-170
FAILURE CODE [#T0248] .............................................................................................................. 40-170
FAILURE CODE [#T0249] .............................................................................................................. 40-171
FAILURE CODE [#T0250] .............................................................................................................. 40-171
FAILURE CODE [#T0251] .............................................................................................................. 40-171
FAILURE CODE [#T0252] .............................................................................................................. 40-172
FAILURE CODE [#T0253] .............................................................................................................. 40-172
FAILURE CODE [#T0254] .............................................................................................................. 40-172
FAILURE CODE [#T0255] .............................................................................................................. 40-173
FAILURE CODE [#T0256] .............................................................................................................. 40-173
FAILURE CODE [#T0257] .............................................................................................................. 40-173
FAILURE CODE [#T0258] .............................................................................................................. 40-174
FAILURE CODE [#T0260] .............................................................................................................. 40-174
FAILURE CODE [#T0259] .............................................................................................................. 40-174
FAILURE CODE [#T0261] .............................................................................................................. 40-175
FAILURE CODE [#T0262] .............................................................................................................. 40-175
FAILURE CODE [#T0263] .............................................................................................................. 40-176
FAILURE CODE [#T0264] .............................................................................................................. 40-176
FAILURE CODE [#T0265] .............................................................................................................. 40-176
FAILURE CODE [#T0266] .............................................................................................................. 40-177
FAILURE CODE [#T0267] .............................................................................................................. 40-177
40-8 WB93R-8
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [#T0268] .............................................................................................................. 40-178

FAILURE CODE [#T0269] .............................................................................................................. 40-178
FAILURE CODE [#T0270] .............................................................................................................. 40-179
FAILURE CODE [#T0271] .............................................................................................................. 40-179
FAILURE CODE [#T0272] .............................................................................................................. 40-179
FAILURE CODE [#T0273] .............................................................................................................. 40-180
FAILURE CODE [#T0274] .............................................................................................................. 40-180
FAILURE CODE [#T0275] .............................................................................................................. 40-180
FAILURE CODE [#T0276] .............................................................................................................. 40-181
FAILURE CODE [#T0277] .............................................................................................................. 40-181
FAILURE CODE [#T0278] .............................................................................................................. 40-182
FAILURE CODE [#T0279] .............................................................................................................. 40-182
FAILURE CODE [#T0280] .............................................................................................................. 40-182
FAILURE CODE [#T0281] .............................................................................................................. 40-183
FAILURE CODE [#T0282] .............................................................................................................. 40-183
FAILURE CODE [#T0283] .............................................................................................................. 40-183
FAILURE CODE [#T0284] .............................................................................................................. 40-184
FAILURE CODE [#T0285] .............................................................................................................. 40-184
FAILURE CODE [#T0286] .............................................................................................................. 40-184
FAILURE CODE [#T0287] .............................................................................................................. 40-185
FAILURE CODE [#T0288] .............................................................................................................. 40-185
FAILURE CODE [#T0289] .............................................................................................................. 40-185
FAILURE CODE [#T0290] .............................................................................................................. 40-186
FAILURE CODE [#T0291] .............................................................................................................. 40-186
FAILURE CODE [#T0292] .............................................................................................................. 40-186
FAILURE CODE [#T0293] .............................................................................................................. 40-187
FAILURE CODE [#T0294] .............................................................................................................. 40-187
FAILURE CODE [#T0295] .............................................................................................................. 40-187
FAILURE CODE [#T0296] .............................................................................................................. 40-188
FAILURE CODE [#T0297] .............................................................................................................. 40-188
FAILURE CODE [#T0298] .............................................................................................................. 40-188
FAILURE CODE [#T0299] .............................................................................................................. 40-189
FAILURE CODE [#T0300] .............................................................................................................. 40-189
FAILURE CODE [#T0301] .............................................................................................................. 40-189
FAILURE CODE [#T0302] .............................................................................................................. 40-190
FAILURE CODE [#T0303] .............................................................................................................. 40-190
FAILURE CODE [#T0304] .............................................................................................................. 40-190
FAILURE CODE [#T0305] .............................................................................................................. 40-191
FAILURE CODE [#T0306] .............................................................................................................. 40-191
FAILURE CODE [#T0307] .............................................................................................................. 40-192
FAILURE CODE [#T0308] .............................................................................................................. 40-192
FAILURE CODE [#T0309] .............................................................................................................. 40-192
FAILURE CODE [#T0310] .............................................................................................................. 40-193
FAILURE CODE [#T0311] .............................................................................................................. 40-193
WB93R-8 40-9
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [#T0312] .............................................................................................................. 40-193

FAILURE CODE [#T0313] .............................................................................................................. 40-194
FAILURE CODE [#T0314] .............................................................................................................. 40-194
FAILURE CODE [#T0315] .............................................................................................................. 40-194
FAILURE CODE [#T0316] .............................................................................................................. 40-195
FAILURE CODE [#T0317] .............................................................................................................. 40-195
FAILURE CODE [#T0318] .............................................................................................................. 40-195
FAILURE CODE [#T0319] .............................................................................................................. 40-196
FAILURE CODE [#T0320] .............................................................................................................. 40-196
FAILURE CODE [#T0321] .............................................................................................................. 40-196
FAILURE CODE [#T0322] .............................................................................................................. 40-197
FAILURE CODE [#T0323] .............................................................................................................. 40-197
FAILURE CODE [#T0324] .............................................................................................................. 40-197
FAILURE CODE [#T0325] .............................................................................................................. 40-198
FAILURE CODE [#T0326] .............................................................................................................. 40-198
FAILURE CODE [#T0327] .............................................................................................................. 40-199
FAILURE CODE [#T0328] .............................................................................................................. 40-199
FAILURE CODE [#T0329] .............................................................................................................. 40-199
FAILURE CODE [#T0330] .............................................................................................................. 40-200
FAILURE CODE [#T0331] .............................................................................................................. 40-200
FAILURE CODE [#T0332] .............................................................................................................. 40-200
FAILURE CODE [#T0333] .............................................................................................................. 40-201
FAILURE CODE [#T0334] .............................................................................................................. 40-201
FAILURE CODE [#T0335] .............................................................................................................. 40-201
FAILURE CODE [#T0336] .............................................................................................................. 40-202
FAILURE CODE [#T0337] .............................................................................................................. 40-202
FAILURE CODE [#T0338] .............................................................................................................. 40-202
FAILURE CODE [#T0339] .............................................................................................................. 40-203
FAILURE CODE [#T0340] .............................................................................................................. 40-203
FAILURE CODE [#T0341] .............................................................................................................. 40-203
FAILURE CODE [#T0342] .............................................................................................................. 40-204
FAILURE CODE [#T0343] .............................................................................................................. 40-204
FAILURE CODE [#T0344] .............................................................................................................. 40-204
FAILURE CODE [#T0345] .............................................................................................................. 40-205
FAILURE CODE [#T0346] .............................................................................................................. 40-205
FAILURE CODE [#T0347] .............................................................................................................. 40-205
FAILURE CODE [#T0348] .............................................................................................................. 40-206
FAILURE CODE [#T0349] .............................................................................................................. 40-206
FAILURE CODE [#T0350] .............................................................................................................. 40-206
FAILURE CODE [#T0351] .............................................................................................................. 40-207
FAILURE CODE [#T0352] .............................................................................................................. 40-207
FAILURE CODE [#T0353] .............................................................................................................. 40-207
FAILURE CODE [#T0354] .............................................................................................................. 40-208
FAILURE CODE [#T0355] .............................................................................................................. 40-208
40-10 WB93R-8
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [#T0356] .............................................................................................................. 40-208

FAILURE CODE [#T0357] .............................................................................................................. 40-209
WB93R-8 40-11
40 TROUBLESHOOTING
ABBREVIATION LIST
ABBREVIATION LIST
of the meaning.
LIST OF ABBREVIATIONS USED IN THE TEXT

Abbrevia-
tion
the tires rotate.
AISS Engine
reverse direction.
ARAC
ASR
BCV
not being used.
work tronic control
machine.
Crankcase Depres-
sion Regulator
40-12 WB93R-8
40 TROUBLESHOOTING
ABBREVIATION LIST

Abbrevia-
tion
than OLSS).
Electronic Control
Module
ECMV
Electronically Con-
System
EGR Engine
failure history).
portional Control
tive Structure
3449.
Forward-Neu-
tral-Reverse
WB93R-8 40-13
40 TROUBLESHOOTING
ABBREVIATION LIST

Abbrevia-
tion
Communication
Plus)
Communication
Plus)
System (D Series)
HST
(Same as IMV)
Unit
KCCV Engine
Komatsu Catalyzed
KCSF Engine gas.
Soot Filter
KDOC Engine
muffler.
ulate Filter
muffler.
40-14 WB93R-8
40 TROUBLESHOOTING
ABBREVIATION LIST

Abbrevia-
tion
KTCS
soft ground.
direction.
work tronic control
machine.
machine.
MMS Communication
NC Normally Closed
actuated.
NO Normally Open
actuated.
Open-center Load
Sensing System
less of the load.
PC Hydraulic system
tion sure.
PCCS
WB93R-8 40-15
40 TROUBLESHOOTING
ABBREVIATION LIST

Abbrevia-
tion
Pre-stroke Control
Valve

Motor (D, PC, etc)
ROPS Cab and canopy
structure)
3471 or ISO 12117-2.
SCR Urea SCR system
Le Systeme Interna-
principle applied.
energized.
TOPS Cab and canopy
12117.
direction of flow.
bocharger
is variable.
40-16 WB93R-8
40 TROUBLESHOOTING
ABBREVIATION LIST

Abbrevia-
tion
VHPC Engine control

HD: Dump truck
WA: Wheel loader
WB93R-8 40-17
40 TROUBLESHOOTING
ABBREVIATION LIST
LIST OF ABBREVIATIONS USED IN THE CIRCUIT DIAGRAMS

A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
40-18 WB93R-8
40 TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS

k If you remove the radiator cap while the engine is still hot, hot coolant may spout out and can
scald you. Wait until the engine cools down.
k Take extreme care not to touch a hot portion or not to be wound in a turning portion.
k Before removing a plug or a cap of a portion where oil pressure, hydraulic pressure, or air pres-
sure is applied, release the internal pressure first, then connect the measuring tool securely.
k When disconnecting wiring, remove the key and turn the battery disconnect switch to OFF posi-
tion.
k Park the machine on a level place and check the frame lock bar, chocks, parking brake, etc.
k When working in a group, make signs and allow only the persons concerned to approach the
machine.
• Troubleshooting means to investigate the root cause of a failure, repair immediately, and prevent recur-
rence of the failure.
• One important thing when you perform troubleshooting is to understand the structure and operation.
• It is important to have an interview with the operator and set up an aim of failure cause for performing a
troubleshooting effectively.
• If you disassembly the machine hastily when it has a failure, you may disassemble unrelated portions
and may not be able to find the cause. As a result, the costs of the man-hours, parts, oil, or grease may
increase, and you may lose the confidence of the users and operators. Accordingly, sufficient advance
check and proper procedure are necessary for troubleshooting.
1. Ask users or operators the following questions.
1) Have any other problems occurred apart from the problem that has been reported?
2) Is there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
2. Perform the following checks before troubleshooting.
1) Check the machine for a symptom of abnormality.
2) Perform the Check before starting items.
3) Check the other check items.
4) Check other maintenance matters which can be checked externally and are considered to be neces-
sary.
3. Check the degree of the trouble by yourself and judge if it is a real failure or it is a problem of handling or
operation.
When reproducing the trouble phenomenon by operating the machine, do not perform check or meas-
urement that can increase the failure.
4. Use the results of the investigation and inspection to narrow down the probable causes of the failure,
then use the troubleshooting flow chart (matrix) to locate the failure exactly.
The basic troubleshooting procedure is as follows.
• Start from the simple points.
• Start from the most likely points.
• Investigate other related parts or information.
5. If the root cause is not corrected, a similar failure may occur again even if the apparent failure has been
repaired. Always find out the cause of a failure first and remove the root cause of each failure.
WB93R-8 40-19
40 TROUBLESHOOTING
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM

The following is the description of precautions and changes for the troubleshooting related to the engine
accompanied with the addition of urea SCR system.
Shutting down of the engine controller

• When the starting switch is turned to OFF position, engine controller performs ending operation. After
the engine controller has completed the ending operation, the power supply of engine controller is turned
off. This is called “Shut down of engine controller”.
• For the machine equipped with the urea SCR system, DEF purging is added in the ending operation of
engine controller. With this addition, it takes 2 to 6 minutes normally and 7 minutes maximum to com-
plete the ending operation which has been 2 minutes in the past. (It is written as 2 to 6 minutes in the text
of troubleshooting.)
• When the starting switch is turned to ON position from OFF position while the engine controller power
supply is not turned off, the error information of engine controller may not be reset (which should be
reset), and the troubleshooting for the function of corresponding device may not be performed again. In
that case, shutting down operation of the engine controller is required. Shut down of engine controller
can be checked with that system operating lamp goes out.
40-20 WB93R-8
40 TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

ENGINE, LUBRICATING OIL, AND COOLANT
No. Item Criteria Remedy
1 Check for unusual noise and smell - Repair
2 Check around engine for dirt - Remove
3 Check around engine for water leakage - Repair
4 Check around engine for oil leakage - Repair
5 Check fuel line for leakage - Repair
6 Check radiator for clogging - Remove
7 Check fuel level and type - Refill with oil
8 Check foreign material in fuel - Clean and drain
9 Check fuel prefilter - Replace
10 Check fuel main filter - Replace
11 Check of engine oil level (in oil pan) and type Between H and L Refilling with oil
12 Check of coolant level (reservoir tank) Between H and L Refilling with coolant
Air cleaner clogging
caution lamp is not dis-
13 Check air cleaner for clogging Clean or replace
played on machine
monitor.
14 Check around KDOC for dirt - Remove
15 Check around KDOC for gas leakage - Repair
HYDRAULIC AND MECHANICAL EQUIPMENT

1 Check for unusual noise and smell - Repair
2 Check for oil leakage - Repair
3 Check hydraulic oil level Between H and L Refilling with oil
4 Check hydraulic oil strainer - Clean and drain
5 Check hydraulic oil filter - Replace
6 Check oil level in transmission gear - Refill with oil
Check oil level in axle (differential and finel reduction
7 - Refill with oil
gear)
8 Bleeding air from cylinder - Bleeding air
9 Bleeding air from brake line - Bleeding air
10 Check of toe-in - Adjust
WB93R-8 40-21
40 TROUBLESHOOTING
ELECTRIC EQUIPMENT
1 Check battery terminal for looseness and corrosion - Retighten or replace
Check battery disconnect switch terminal for loose-
2 - Retighten or replace
ness and corrosion
Check alternator terminal for looseness and corro-
sion
Check starting motor terminal for looseness and cor-
rosion
5 Check battery voltage (with engine stopped) 20 to 30 V Charge or replace
6 Check battery electrolyte level Between H and L Refill or replace
Check wiring harness for discoloration, burnt areas
7 - Repair or replace
and cover peeling
Check for coming off of wiring harness clamp and
8 - Repair
sagging of wiring harness
9 Check grounding - Repair
10 Check for loose connector and damaged lock - Repair or replace
Check connector pin for corrosion, bends and defor-
11 - Repair or replace
mation
Check connector for entering of water and foreign
12 - Dry, clean or replace
material
13 Check wiring harness for open or short circuit - Repair or replace
14 Check fuse for blowing out and corrosion - Replace
After few minutes of
Check alternator voltage (when engine speed is
15 operation Replace
medium or higher)
13.5 to 14.5 V
Check battery relay operation sound (when starting
16 - Replace
switch is turned to ON or OFF position)
EXTERIOR
1 Check of wheel nuts - Retighten or replace
2 Check of tyres and wheel rims condition - Replace
3 Check handrails and steps - Repair
4 Check mirrors - Clean or repair
INTERIOR
1 Check gauges and monitors - Clean or replace
2 Check seat belt - Replace
3 Check brake pedals - Clean
40-22 WB93R-8
40 TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING

WALK-AROUND CHECK
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, wiring harnesses for play, and accumulation of dust in places that reach
high temperatures.
k Accumulated combustibles and fuel or oil leakages around hot engine parts such as engine,
aftertreatment devices, turbocharger, etc. may cause a machine fire. Be sure to check thoroughly
and repair any failures.
• Check of unusual noise and smell
If the machine is operated under the unusual noise or smell, the cause of it may damage the machine,
so stop the operation immediately once you recognize it.
• Check around engine and removal of dirt
Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs,
etc.) on hot engine parts such as the aftertreatment devices, turbocharger, etc.
• Check around engine for water leakage
• Check around engine for oil leakage
Check for oil leakage from engine and coolant leakage from cooling system. If any abnormality is found,
repair it.
• Check of fuel line for leakage
Check for fuel leakage, check hoses and pipes for damage. If any abnormality is found, repair it.
• Check of radiator and removal of dirt
Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the radia-
tor. If any, remove them.
For removal of dirt from the radiator, see Operation and Maintenance Manual, “METHOD FOR CHECK-
ING AND CLEANING RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND FUEL
COOLER FINS”.
• Check around the aftertreatment devices and removal of dirt
Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the after-
treatment devices. If any, remove them.
• Check around the aftertreatment device for gas leakage
Check the pipe between the turbocharger and KDOC, and also the aftertreatment devices connection for
leakage of exhaust gas (or sticking of soot, etc.). If any abnormality is found, repair it.
• Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage, and hoses for breakage, wear, and clearance. If any
abnormality is found, repair it.
• Check of hydraulic equipment, hydraulic tank, hoses, and joints for oil leakage Check for oil leaks. If any
abnormality is found, repair it.
• Air bleeding
For the bleeding air from the fuel system, see 30 TESTING AND ADJUSTING, “BLEEDING AIR FROM
HYDRAULIC CIRCUIT”.
• Check the components of the chassis and, in particular, perform an accurate check on the condition of
the tires and rims.
Deflate the tires before removing the wheels.
• Check of handrails and steps for abnormality and looseness of bolts
If any abnormality is found, repair it and tighten any loose bolts.
• Check and clean of rearview mirrors
Check rearview mirror for abnormality. If any, repair it.
Clean the mirror surface and adjust the mirror angle so that the rear of the machine can be seen from
the operator's seat.
WB93R-8 40-23
40 TROUBLESHOOTING
• Check of gauges and monitors for abnormality

Check gauges and monitors in the operator's cab for abnormality. If any abnormality is found, replace it
with a new one.
Clean up the surfaces.
• Check of seat belt and mounting hardware
Check the hook, the lock, and hook mounting part for damage. If any abnormality is found, repair it.
• Check and clean the brake pedal area.
Check the area around the brake pedal and remove and clean any dirt or mud that could prevent correct
operation.
40-24 WB93R-8
40 TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE

CHECK OF FUEL LEVEL AND TYPE
k Fuel is highly flammable and dangerous. Never bring open flames near fuel.
k When adding fuel, never spill it or let it overflow.
k Wipe off any spilled fuel. If fuel spills over soil or sand, remove all the fuel and soil or sand
together.
1. Turn the ignition switch to position ON.

2. When the fuel level caution lamps (2) on front
panel and on machine motor light up in red,
check the fuel level with fuel level gauge on the
machine monitor.
When the fuel gauge pointer indicates the red
range, the fuel quantity is 17ℓ or less
Since the fuel level is low, add fuel.
3. After checking, return the starting switch to OFF
position.
2
RKA83090
1
rpm
RKA83100
4. Open fuel filler cap (G) of the fuel tank.

5. Add fuel.
G
RKAD3860
WB93R-8 40-25
40 TROUBLESHOOTING
METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND

SEDIMENT
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn
injury. Accordingly, wait until all parts have cooled down before starting the work.
k High pressure is generated inside the engine fuel piping system when the engine is running.
Stop the engine and wait at least 30 seconds until the inner pressure is released and then replace
the filter.
k Keep open flame away.
NOTICE
• Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filtering proper-
ties. Be sure to use Komatsu genuine parts when replacing.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu gen-
uine fuel filter cartridge is used, foreign materials may enter and problem may occur in the injec-
tion system. Do not use substitute parts.
• During testing or maintenance of the fuel system, be sure that any foreign material does not
enter the fuel system. If any dust or other material sticks to any part, wash the part thoroughly
with clean fuel.
• Prepare a container to receive the drained fuel.
• Prepare a filter wrench.
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT

1. Turn the ignition switch to position ON.
2. When the water separator caution lamp (1) on
machine motor light up in red, drain the water
1
accumulated in the water separator.
rpm
RKA83110
3. Water separator (2) is integrated with the fuel

prefilter and located in the lower part.
RKAD3870
4. Open engine hood.

5. Check for water and sediment.
40-26 WB93R-8
40 TROUBLESHOOTING
6. It is possible to judge the water level and amount

of sediment by looking through transparent cup
(3). 6
7. Place a container under drain hose (4) to receive
the water.
8. Loosen drain valve (5).
3
9. Push manually the pump (6) to drain the water.
10. When fuel starts to be drained from drain hose 5
(4), tighten drain valve (5) to stop draining.
NOTICE 4
If the water inside transparent cup (2) freezes,
RKA83120
wait until the frozen water has melted
completely, then follow the procedure to drain
the water.
REMARK
• If the transparent cap (3) is dirty or it is difficult
to see the inside, clean transparent cap when
replacing fuel prefilter cartridge (1).
• When the drain valve (5) has been removed
during the cleaning operation, coat O-ring with
grease and tighten until it contacts the bottom.
REMARK
• If drain plug (5) is hard to turn, apply grease
to O-ring (7) of plug (5) according to the fol-
lowing procedure.
1) Place a container under the drain hose (4) to
catch the fuel.
2) Loosen drain valve (5) and drain all the fuel
and sediment through drain hose (4).
3) Check that nothing more comes out from
drain hose (4), then remove plug (5).
4) Apply a suitable amount of grease to O-ring 7 a
5 4
(7). RKAD3880
At this time, take care that grease will not
stick to water drain port (a) and threaded por-
tion of the plug.
5) Tighten plug (5) by hand until it stops.
6) Remove the container to catch the drained
fuel.
• If the transparent cup (3) is so dirty that
the inside cannot be seen, clean the
transparent cup (3) when replacing the
filter.
• In the case that the plug (5) has been
removed during the cleaning work, apply
grease to O-Ring (7) and tighten with
your fingers until it stops.
WB93R-8 40-27
40 TROUBLESHOOTING
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE

k WARNING
• After the engine stops, all parts are still very hot, so do not replace the filter immediately. Wait for
all of parts to cool down before starting the work.
• High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.
• Do not bring any open flame close.
NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing the parts, Komatsu recommends using Komatsu genuine parts.
uine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Never use a substitute.
• When performing the inspection and maintenance of the fuel system, be careful not to let any dirt
or dust get in, more than ever before. If dust sticks to the fuel system, wash it off thoroughly with
fuel.
Items to be prepared
• Filter wrench
• Fuel catchment container
1. Open engine hood (1).
2. Place a container under the fuel prefilter car-
tridge to receive the fuel. 1
RKAD3890
3. Loosen the plug (2) and drain the water and sed-
iments from transparent cup (3), and also drain
all the fuel from filter cartridge (4).
10
4. Disconnect drain hose (5) and connectors (6)
and (7) (if present).
5. Wrap the connectors (6) and (7) (if present) with
a plastic bag, etc. so that fuel, oil and water do 4
not get onto the disconnected connector.
6. Turn the transparent cup (3) by using the filter
wrench, and remove it.
Transparent cup (3) is used again.
7. Turn the filter cartridge (4) by using the filter 3
wrench, and remove it. 2
8. Install the currently removed transparent cup (3)
to the bottom of the new filter cartridge (4). 7
At this time, be sure to replace the O-ring (8) with
a new one.
6 5
RKA83140
40-28 WB93R-8
40 TROUBLESHOOTING
NOTICE
• When installing the transparent cup, thinly apply fuel to the packing surface, contact it to the
sealing surface of filter cartridge (4), and then tighten it 1/4 to 1/2 turn.
• If the transparent cup is tightened too much, O-ring may be damaged, and this will cause the
leakage of fuel. If it is not tightened enough, fuel will leak through the gap at O-ring. Be sure to
observe the tightening angle.
9. Clean the filter head (9).
10. Thinly apply fuel to the packing surface of the
new filter cartridge, then install the filter cartridge 10
to the filter head (9).
9
11. Tighten the filter cartridge (4) to the following
torque.
3 Filter cartridge: 18 Nm
NOTICE
• When tightening with a filter wrench, be
extremely careful not to dent or damage the
filter.
RKAD3871
12. Connect drain hose (5) and check that the plug
(2) is tightened securely.
13. Remove the plastic bag wrapping the connectors
(6) and (7) (if present), then connect them.
REMARK
• If water gets on the connector (6), the sensor
may malfunction and the water separator cau-
tion lamp may flash. When removing the con-
nector (5), be extremely careful not to let water
get on the connector.
• If water gets on the connector (6), dry it com-
pletely before connecting it.
14. Push manually pump (10) to fill the filter cartridge 9JD01860
with fuel.
WB93R-8 40-29
40 TROUBLESHOOTING
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE

k WARNING
NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing the parts, Komatsu recommends using Komatsu genuine parts.
uine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Never use a substitute.
• When performing the inspection or maintenance of the fuel system, pay more attention than nor-
mal to the entry of dirt. If dirt sticks to any part, use fuel to wash it off completely.
• Filter wrench

2. Place a container under the fuel prefilter car-
tridge to receive the fuel.
RKAD3890
3. Turn the filter cartridge (1), and remove it

together the gasket (2).
4. Thinly apply fuel to the new gasket surface of the 3
new filter cartridge, then install the filter cartridge 2
to the filter head (3).
NOTICE
1
• Fill the fuel filter cartridge (1) with fuel. This
will help when bleeding air from the fuel cir-
cuit.
5. Tighten the filter cartridge (1) to the following
torque.
3 Filter cartridge: 17 to 23 Nm RKA83150
6. After completing the replacement of filter car-

tridge (3), bleed air from the fuel system.
40-30 WB93R-8
40 TROUBLESHOOTING
METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT

k WARNING
NOTICE
• When performing the inspection or maintenance of the fuel system, pay more attention than nor-
mal to the entry of dirt. If dirt sticks to any part, use fuel to wash it off completely.

2. Place a container under the fuel filter cartridge to
receive the fuel.
RKAD3890
3. Loose the breather screw (2) of the fuel filter.
RKAD3900
4. Push the manual fuel prefilter pump (3) until the

fuel leaving the breather screw flows without air
bubbles. 3
5. Tighten the breather screw (2).
6. Start the engine and let it run idle for a few min-
utes to removal any residual air.
RKAD3872
WB93R-8 40-31
40 TROUBLESHOOTING
METHOD FOR CHECKING DEF LEVEL AND TYPE

k WARNING
• Do not put anything than DEF into DEF tank. If diesel oil or gasoline is put in, it can cause fires.
Also, toxic gas may develop by putting in additive.
• Keep your face away from the filler port during opening the cap of DEF tank or refilling to avoid
the ammonia vapor. It is toxic.
• Foreign material mixed in DEF can shorten the service life of DEF injector and DEF pump.
Clean foreign matter around the cap before removing the filler port cap. Refilling nozzle also
needs to be cleaned before the refilling.
• Wipe and wash the area with water immediately if DEF is spilled. If spilled DEF is left, toxic gas or
corrosive substance may be produced by chemical reactions.
• DEF may cause inflammation if it touches your skin. Contaminated clothing or shoes must be
removed immediately and to wash off with water or warm water.
Use a soap and rinse your skin. Consult your doctor immediately if you have pain or change in
your skin.
• Do not force yourself to vomit if you have swallowed DEF accidentally. Wash your mouth out and
consult your doctor immediately.
• If DEF splashes in the eyes, immediately flash your eye with clean water for a few minutes and
consult your doctor.
1. Turn the starting switch to “ON” position, and
check DEF level with level gauge (1) on the mon-
itor panel.
After checking, turn the switch back to “OFF”
1
position.
2. If the level is low, add DEF from refilling port until
it reaches the necessary level for check.
rpm
RKA83170
40-32 WB93R-8
40 TROUBLESHOOTING
METHOD FOR ADDING DEF

k WARNING
• Do not put fluid other than DEF into DEF tank.
• When opening the cap of DEF tank of the
machine, the ammonia vapor may escape.
Keep your face away from the filler port.
09632-62800
• Foreign materials in the DEF system or urea

deposits caused by precipitation of urea may
hinder operation of the devices. Before
removing the filler cap, wipe off the dirt from
around the filler port. Before inserting the
filler nozzle into the filler port, wipe off dirt
from it.
• If DEF is spilled, immediately wipe and wash
the area with water. If spilled DEF is left unat-
tended an d the area is no t washed and
cleaned, it can cause corrosion to the con-
09632-62800
taminated area and emit toxic gas.
NOTICE
• Do not add DEF more than line F of sight gauge (5). DEF may leak through the breather. When the
ambient temperature is low and DEF may freeze, do not add it more than line (9) of sight gauge
(5).
Be careful of the DEF level when performing operations on a slope or traveling on a rough
ground.
When the remaining DEF level is low, if DEF pump sucks air or if DEF level suddenly lowers
causing a drop of DEF level to the warning level, the engine power may be derated.
• If DEF is stored in unspecified container, foreign material may mix in it and toxic gas or corrosive
substance may be produced by chemical reactions. When adding DEF, do not transfer it to
another container.
• Do not use a funnel when to add DEF. The strainer may be broken.
• When using a portable DEF refill container, use up DEF each time. If any of DEF is left, remove
foreign material, if there is any.
• Do not wash the adding nozzle in city water. Minerals may clog the devices.
• Do not dilute DEF with water.
• If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution
lamp lights up and the audible alert sounds to warn the abnormality. In this case, ask your
Komatsu distributor for draining of the wrong fluid and for inspection. DEF injector and/or DEF
pump may need to be replaced.
WB93R-8 40-33
40 TROUBLESHOOTING
1. Turn the starting switch to ON position (B).
D
A
RKA83180
2. Check the DEF level gauge (1) on the machine

monitor.
rpm
RKA83170
3. After checking, turn the starting switch back to

OFF position (A).
RKA83190
4. Open cover at the left side of the machine, clean

blue DEF tank filler cap (2) and surrounding area.
5. Turn the cap (2) counterclockwise.
The caps of DEF tanks are blue, as required by
emission regulations. 5
6. By sight gauge (3), add DEF through the filler 4
port until float (4) reaches line F (5). 6
3
Line (6) in the sight gauge indicates approxi- 8
mately 5 . below line F, and line (7) indicates 7
approximately 10.
Line (8) is the max adding line when DEF may 2
freeze in cold weather.
RKAD3910
40-34 WB93R-8
40 TROUBLESHOOTING
7. After adding, align claw (9) of the cap with groove

(10) of the filler port and close the cap securely
by turning it clockwise by 90°.
9
RKA83200
10
RKA83210
REMARK
• It is recommended to use a nozzle having a diameter and a length specified by ISO 22241-4 and
an auto stop function to add DEF. When the specified nozzle is used, the magnet installed inside
the filler port of the tank cancels the wrong fluid addition prevention device, and you can add
DEF. This mechanism prevents addition of DEF into the fuel tank, addition of fuel into DEF tank,
and spill of DEF from the filler port.
• When using a nozzle which is not conformed to ISO 22241-4, hold it in your hand and add DEF
carefully while checking the sight gauge.
• Add only DEF in clearly marked DEF tanks that have the blue cap.
WB93R-8 40-35
40 TROUBLESHOOTING
METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL
k WARNING
Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Consequently, wait until they have cooled down before starting the work.
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the
engine before checking.
If the machine is inclining, make it level before checking.
1. Open the engine hood (1).
RKAD3890
2. Pull out dipstick (G) and wipe the oil off with a
cloth.
3. Fully insert the dipstick (G) into the dipstick pipe,
then pull it out.
F
G
RKAD3920
4. If the oil level is between marks H and L, it is cor-

rect.
If the oil level is below L mark, add oil through oil
filler port (F).
40-36 WB93R-8
40 TROUBLESHOOTING
5. If the oil level is higher than H, decrease it to a

proper level according to the following procedure.
1) Place the oil container under the drain plug
(P) at the bottom of the machine to catch the
drained oil. P
2) Drain excess engine oil through drain plug
(P).
3) Check the oil level again.
6. If the oil level is proper, tighten the oil filler cap
(F) securely.
7. Close the engine hood (1).
RKAD3930
WB93R-8 40-37
40 TROUBLESHOOTING
METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT

k WARNING
• Do not open the radiator cap unless it is necessary. When checking the coolant, check it with the
reservoir tank when the engine is cold.
• Immediately after the engine is stopped, the coolant is still hot and the pressure is accumulated
in the radiator. There is a risk of severe burns if the cap is removed in these conditions to check
the coolant level. Always wait for the temperature to decrease, turn the cap slowly to release the
pressure, then remove the cap with care.
1. Open the engine hood (1).
RKAD3890
2. Check the reservoir tank (2).

If the coolant level is within the range between
FULL and LOW, the coolant amount is at a
proper level.
3. If the coolant is insufficient, add the coolant to 2
MAX. level through the filler port of the reservoir
tank (2).
4. Tighten the cap securely after the refilling.
NOTICE
If reservoir tank (2) is empty, leakage of
coolant should be suspected. After checking,
repair any abnormality immediately. If no RKAD3940
abnormality is found, check the level of the
coolant in the radiator. If it is low, add coolant
of the same density in radiator, then add
coolant to reservoir tank (2).
5. Close the engine hood (1).
RKA83220
40-38 WB93R-8
40 TROUBLESHOOTING
METHOD FOR CHECKING AIR CLEANER

The air cleaner clogging caution lamp informs when the air cleaner element should be checked.
If the air cleaner clogging caution lamp (1) lights up,
clean the air cleaner element.
rpm
RKA83230
WB93R-8 40-39
40 TROUBLESHOOTING
METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT

k WARNING
• Place the machine on a level ground, lift the loader arm and engage it with safety lock.
• Never remove the inner element. If it is removed, dirt will enter and can cause an engine trouble.
• Do not use a screwdriver or other tool.
• When cleaning the element, do not hit it or hit anything with the element.
• Before and after cleaning the element, do not leave or keep it under direct sunlight.
1. Open engine hood. (1).
RKAD3890
2. Pull the yellow lock (2) of the air filter and unlock
it.
3. Loosen the cover (3) by turning it counterclock-
wise. 2
RKAD3950
4. Hold the outer element (5), rock it lightly up and

down and to the right and left, and pull it out while
turning it to the right or left. 6
5. When outer element (5) is removed, check that 5
the inner element does not come out of position
and is not at an angle.
If it is at an angle, push it straight to the bottom
with your hand.
6. After removing outer element (5), cover the inner
element (6) with a clean cloth or tape to prevent 7
dirt or dust from entering.
7. Clean dust sticking inside air cleaner body (7) RKA83240
and on cover (3) by using a clean cloth or brush.
40-40 WB93R-8
40 TROUBLESHOOTING
8. If any dust is attached to vacuator valve (4)

installed to cover (3), remove it.
9. When the outer element has been cleaned 6 3
times or used for 1 year, replace it.
• When the element needs to be replaced
Replace the inner and outer elements with new
ones.
For details, see METHOD FOR REPLACING
4
ELEMENT.
• When the element does not need to be
replaced clean the outer element. Continue the
cleaning procedure. RKA83250
10. Blow dry compressed air (Max. 0.2 MPa {2.1

kg/cm 2 }) from the inside of the outer element
along the pleats.
11. Blow along the pleats from the outside, then blow
again from the inside.
RKA83260
12. Peel off a seal every time after the cleaning of the
element.
RKA83270
13. After cleaning, illuminate the inside of the ele-

ment with an electric bulb to check.
If any holes or thin places are found, replace the
inner and outer elements.
14. Remove the cover of cloth or tape attached to
inner element (6).
NOTICE
• Do not use the element with damaged
pleats or a damaged gasket or seal.
• If the element and O-ring are cleaned and
used again after they are used for more
than one year, it will cause problems. Do RKA83280
not use them again.

15. Check the seal of the cleaned or new element for
sticking of dusts and oil and wipe them off, if any.
WB93R-8 40-41
40 TROUBLESHOOTING
NOTICE
• Be sure to install the air cleaner element
facing in the correct direction. Install so that
the bottom of the air cleaner element (face
where no hole is drilled) (B), (C) comes to
cover (3) end. If it is installed in wrong direc-
tion, it may cause breakage of the air cleaner
element or serious damage to the engine.
C
When inserting the element into the body, if
the rubber at the tip is swollen or the outer
element is not pushed in straight, and cover
(3) is installed by force with hook (2), there is B
a danger that the hook and air cleaner body
may be damaged, so be careful when RKA83290
installing.
16. Push the outer element in straight with your hand
when installing it to the air cleaner body.
Hold the outer element, and rock it lightly up and
down and to the right and left while pushing it in,
the outer element can be inserted easily.
17. Install the cover (3) and fix it with yellow lock (2).
18. Close the engine hood.
19. Check the air cleaner clogging caution lamp (1)
on the machine monitor.
If it light up just after cleaning of the elements has
been finished, replace the inner and outer ele-
ments.
40-42 WB93R-8
40 TROUBLESHOOTING
METHOD FOR CHANGING AIR CLEANER ELEMENT

NOTICE
• Do not clean and reuse the secondary element. When replacing the primary element, replace the
secondary element with a new one at the same time.
• If the primary element and cover are installed while the secondary element is not installed prop-
erly, the primary element may be damaged.
• The sealing portion of the improper part lacks precision, and allows the entry of dust, which
leads to damage of the engine. Do not use such improper part.
RKAD3890
2. Pull the yellow lock (2) of the air filter and unlock
it.
3. Loosen the cover (3) by turning it counterclock-
wise. 2
RKAD3950
4. Hold the outer element (5), rock it lightly up and

down and to the right and left, and pull it out while
turning it to the right or left. 6
NOTICE 5
• Do not remove inner element (6) at this
time.
5. When outer element (5) is removed, check that
the inner element does not come out of position
and is not at an angle. 7
If it is at an angle, push it straight to the bottom
with your hand.
RKA83240
WB93R-8 40-43
40 TROUBLESHOOTING
6. Clean dust sticking inside air cleaner body (7)

and on cover (3) by using a clean cloth or brush.
7. If any dust is attached to vacuator valve (4) 3
installed to cover (3), remove it.
8. Remove the inner element (6), then quickly
install the new inner element.
Install the inner element securely so that it does
not move.
4
9. Push new outer element (5) in straight with your
hand into the air cleaner body.
Hold the element, and rock it lightly up and down
and to the right and left while pushing it in, the RKA83250
element can be inserted easily.
10. Install the cover (3) and fix it with yellow lock (2).
REMARK
• Check that the vacuator valve (4) is in verti-
cal position.
11. Close the engine hood.
CHECK AND REPLACE VACUATOR VALVE

1. Check vacuator valve (4) for damage and defor-
mation of its rubber portion.
2. If the vacuator is damaged or its rubber part is
deformed, replace it with a new one.
METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL

For checking oil level in hydraulic tank , see “30 TESTING AND ADJUSTING”, “BLEEDING AIR FROM
40-44 WB93R-8
40 TROUBLESHOOTING
METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING

HYDRAULIC TANK STRAINER
k WARNING
• Do not mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when
the temperature increases insoluble compounds are generated, which deposit on the filters and
clog them. The maximum concentration of ordinary oil must not exceed 1% of the total quantity
of oil in the hydraulic system.
NOTICE
• If the machine is equipped with a hydraulic breaker, the oil deteriorates faster than when per-
forming normal operations with the bucket.
Refill capacity: 41.5 l
• Container to catch the drained oil
• Oil drain hose (supplied)
1. Place the machine on level ground and in the

posture shown in figure.
2. Stop the engine.
RKA83300
3. Remove R.H. lateral cover (1).

4. Loosen the cap (F) of oil filler port and gradually
discharge the internal pressure.
5. Remove the cap of oil filler port (F).Remove the
screws (1) and remove the cover (2). F
RKAD3960
WB93R-8 40-45
40 TROUBLESHOOTING
6. Place a container of sufficient capacity under the

valve (P) to collect the oil contained in the tank.
7. After draining the oil, remove the hose and fit the
cap the drain valve (P).
8. Disconnect the hose (2) from the hydraulic pump.
9. Loosen the bolts (3) (4 pieces) and remove the
strainer assembly (4).
10. Remove all dirt from strainer (4) and wash it in
clean diesel fuel or oil.
If the strainer (4) is damaged, replace it with a 4
new one.
11. Insert the strainer (4) and install it with bolts (3).
Check seal fitted to cover. If it is damaged,
replace it with a new one.
2
P 3
RKA83310
12. Fill the hydraulic oil tank to the proper level

through the oil filler port (F)
F
RKA78960
40-46 WB93R-8
40 TROUBLESHOOTING
13. Check that the oil level is between the H and L

lines on sight gauge (G).
14. Tighten the cap of oil filler port (F) securely.
15. Bleed air from the hydraulic circuit.
For the air bleeding procedure of hydraulic cir- H
cuit, see “METHOD FOR BLEEDING AIR FROM
16. After bleeding the air, check the level again in the
tank. L
17. For the method to check the oil level, see
“METHOD FOR CHECKING OIL LEVEL IN
HYDRAULIC TANK, ADDING OIL”. RKA82460
BLEED AIR FROM HYDRAULIC SYSTEM

1. For bleeding air from the hydraulic system, see “30 TESTING AND ADJUSTING”, “BLEEDING AIR
FROM HYDRAULIC CIRCUIT”.
WB93R-8 40-47
40 TROUBLESHOOTING
METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT

k WARNING
NOTICE
If the machine is equipped with a hydraulic breaker, the oil deteriorates faster than when performing normal
operations.
1. Remove R.H. lateral cover (1).
2. Remove the cap of oil filler port (F) gradually to
release the internal pressure.
Release the internal pressure.
F
RKAD3960
3. Remove the cover mounting bolt (2), and remove

the cover (3).
The cover (3) may be jumped out by spring (5).
While pressing down the cover (3), remove the
cover mounting bolt (2).
4. After removing the spring (5) and spring seat (6),
take out the element (7).
5. Remove all dirt from the parts taken out, then
wash it in clean diesel fuel or flushing oil.
6. Install the new element in the place where the old
element has been installed.
7. Check the O-ring (4) to be fit between the 2
hydraulic tank and cover (3).
If the O-ring is damaged, replace it with a new 3
O-ring. 4
8. Place the seat spring (6) and spring (5) on top of
5
the element.
9. While pressing the cover (3) by hand, install the
6
cover (3) with the cover mounting bolts (2).
3 Mounting bolts (2): 30 Nm
7
RKAD3970

11. Operate the work equipment control levers, and
extend all cylinders to their stroke end.
12. Stop the engine.
13. Tighten the cap of oil filler port (F) on the hydrau-
lic tank securely.
By doing so, the hydraulic tank is pressurized.
NOTICE
• If the hydraulic tank is not pressurized, air is sucked in the pump and it affects the components
badly.
40-48 WB93R-8
40 TROUBLESHOOTING
14. Bleed air from hydraulic system.

15. Stop the engine.
NOTICE
• Leave the engine stopped for at least 5 minutes, and then start it. This will remove the air bubbles
in the oil inside the tank.
16. Check that there is no leakage of oil and wipe off
any oil that is spilled.
WB93R-8 40-49
40 TROUBLESHOOTING
METHOD FOR CHECKING THE OIL LEVELS IN THE TRANSMISSION

k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn
injury. Consequently, wait until they have cooled down before starting the work.
Prepare a container to receive the oil.
RKAD3890
2. Pull out the dipstick (1) and check the oil level.
3. If the oil level is near MAX., it is correct.
4. If the oil level is below, add oil through oil filler
port.
REMARK
• The oil filler port is the same using for dip-
stick (1). 1
RKAD3921
40-50 WB93R-8
40 TROUBLESHOOTING
METHOD FOR CHECKING THE FRONT AXLE OIL LEVEL

k WARNING
For the control, position the machine on solid and flat ground, place the equipment on the ground and stop the
engine.
Differential
1. Visually check that the oil level is up to the hole
(1).
2. If necessary, top-up through the level hole (1).
Use a 17 mm wrench.
RKAD3980
Final reduction gears

The inspection must be performed on each reduction gear.
1. Position the reduction gear so that the cap (2) is
positioned on the horizontal axis.
If necessary, for precise control, perform small
movements with the machine to the correct posi-
tion.
2. Visually check that the oil level is up to the hole 2
(2).
Use a 17 mm wrench.
RKAD3990
WB93R-8 40-51
40 TROUBLESHOOTING
FAILURE CODES TABLE
METHOD FOR CHECKING THE REAR AXLE OIL LEVEL

k WARNING
For the control, position the machine on solid and flat ground, place the equipment on the ground and stop the
engine.
Differential
1. Visually check that the oil level is up to the hole
(1).
Use a 1/2” square wrench.
RKAD4010
FAILURE CODES TABLE

Engine ECU failure code
Applica-
Failure Action Category of
DTCM Failure (as displayed on screen) ble com-
code level history
ponent
#T0001 7402-1F EEPROM: Error during Write/Read EEPROM operation ECU L01 Electrical
#T0002 A800-10 Battery voltage: High Battery Voltage indication ECU L03 Electrical
#T0003 A800-12 Battery voltage: Low Battery voltage indication ECU L03 Electrical
Battery voltage: Signal Range Check high for battery volt-
#T0004 A800-0 ECU L03 Electrical
age sensor
Battery voltage: Signal Range Check low for battery voltage

sensor
#T0006 7F02-2 CAN Bus: Bus off of CAN node A ECU L01 Electrical
#T0007 CF04-2 CAN Bus: Error passive CAN Bus Node B ECU L03 Electrical
#T0008 7F02-1F CAN Bus: Bus Off error CAN A ECU L03 Electrical
#T0009 CF04-1F CAN Bus: Error CAN Bus Node B ECU L03 Electrical
Coolant temperature: SRC High for Engine coolant temper-
#T0010 EC0F-0 ECU L03 Electrical
ature (down stream)
Coolant temperature: SRC low for Engine coolant tempera-

#T0011 EC0F-1 ECU L03 Electrical
ture (down stream)
#T0012 160E-E Idle shutdown error ECU L01 Electrical
Torque limitation, Engine protection: Torque limitation
#T0013 6006-E Info L00 Electrical
caused by turbo charger protection
Torque limitation, Engine protection: Strong torque limitation

#T0014 2106-E Info L00 Electrical
from engine protection active
Torque limitation, Engine protection: Strong torque limitation

#T0015 2106-1F Info L00 Electrical
from injection system active
40-52 WB93R-8
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
Torque limitation, Engine protection: General report of the
#T0016 A9EE-FF Info L00 Electrical
event of torque limitations

#T0017 750E-1F Info L00 Electrical
caused by particulate filter

#T0018 D616-1F Info L00 Electrical
caused by performance limiter

#T0019 E604-E Info L00 Electrical
caused by smoke limitation
CAN Bus: Timeout Error of CAN-Receive-Frame CRI1

#T0020 C10D-9 DEF L03 Electrical
(Catalyst reagent information)
#T0021 1A11-2 EMF Signal Plausibility for NH3 Sensor DEF L03 Electrical
#T0022 5BEA-E9 Timeout error of CAN receive frame HCUData DEF L01 Electrical
#T0023 5CEA-E9 Timeout error of CAN receive frame HCUData DEF L01 Electrical
Timeout Error of CAN-Receive-Frame NH3Fact from NH3

#T0024 1A11-9 DEF L03 Electrical
sensor
NH3 sensor: Internal open load or short circuit error on
#T0025 1A11-C DEF L03 Electrical
measuring cell line
NH3 sensor: Internal open load or short circuit error on
#T0026 1C11-4 DEF L03 Electrical
ground line
NH3 sensor: Internal Short circuit on heater line (over-
#T0027 1E11-3 DEF L03 Electrical
heated Sensor)
NH3 sensor: Internal Short circuit on heater line (under-
#T0028 1E11-4 DEF L03 Electrical
heated Sensor)
NH3 sensor: Internal Short circuit or open load error on tem-
#T0029 1F11-4 DEF L03 Electrical
perature cell input line
NH3 sensor: Internal Short circuit or open load error on trim
#T0030 1C11-C DEF L03 Electrical
resistor line
#T0031 1F11-1F NH3 sensor: Internal sensor heater control failure DEF L03 Electrical
#T0032 1E11-7 Heater Performance Error for NH3 Sensor DEF L03 Electrical
#T0033 1911-1F Signal Plausibility for NH3 Sensor DEF L03 Electrical
#T0034 1F11-C NH3 sensor: Internal sensor heater supply failure DEF L03 Electrical
#T0035 1911-C NH3 sensor: Electrical problem DEF L03 Electrical

CAN Bus: Timeout Error of CAN-Receive-Frame NH3Sens
#T0036 1911-9 DEF L03 Electrical
from NH3 Sensor
#T0037 A00C-5 CAN NOx Sensor: Open Circuit Error for Nox Sensor DEF L03 Electrical
#T0038 A00C-6 CAN NOx Sensor: Short Circuit Error for Nox Sensor DEF L03 Electrical
#T0039 A00C-C NOx Sensor (CAN): Sensor Heater performance insufficient DEF L03 Electrical
WB93R-8 40-53
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
#T0040 A20C-5 NOx Sensor (CAN): Open circuit error detected by sensor DEF L03 Electrical
#T0041 A20C-6 NOx Sensor (CAN): Short circuit error detected by sensor DEF L03 Electrical
CAN NOx Sensor Upstream: Open Circuit Error for Nox

#T0042 970C-5 ATS L03 Electrical
Sensor upstream
CAN NOx Sensor Upstream: Short Circuit Error for Nox

Sensor upstream
NOx Sensor Upstream (CAN): Sensor Heater performance

#T0044 960C-C ATS L03 Electrical
insufficient
NOx Sensor Upstream (CAN): Open Wire error detected by

sensor
NOx Sensor Upstream (CAN): Short circuit error detected

by sensor
CAN Bus Received frames: CAN-Receive-Frame

#T0047 F5E9-E9 ECU L03 Electrical
BC2EDC2
CAN NOx Sensor: Timeout Error of CAN-Receive-Frame

#T0048 5316-9 NOX sensor (NOxSens: NOX concentration,Lambda func- DEF L03 Electrical
tion,Oxygen function, sensor status, sensor error)
CAN NOx Sensor Upstream: Timeout Error of

CAN-Receive-Frame NOX sensor upstream (NOxSens:
NOX concentration,Lambda function,Oxygen function, sen-
sor status, sensor error)
CAN Bus Received frames: CAN-Receive-Frame Torque /

#T0050 9EE8-FF Speed control from PE to EDC through TSC1_PE Message ECU L03 Electrical
active
#T0051 9EE8-E9 Speed control from PE to EDC through TSC1_PE Message ECU L03 Electrical
passive
#T0052 6F10-1F Speed control from VE to EDC through TSC1_VE Message ECU L03 Electrical
active
CAN Bus: Passive Time out for Torque Speed Control
#T0053 6F10-9 ECU L03 Electrical
TSC1VE message
CAN Urea Level: Timeout Error of CAN-Receive-Frame

#T0054 86EB-E9 DEF L03 Electrical
Urea Tank Level (UreaLvl)
CAN Bus Received frames: CAN-Receive-Frame from the

#T0055 69E8-E9 ECU L03 Electrical
Vehicle Control Module to EDC (VM2EDC)
Info: Torque Limitation active: OBD performance limiter is

#T0056 B3EE-E0 Info L00 Electrical
active.
Battery voltage: Power stage diagnosis could be disabled

#T0057 9E00-10 ECU L01 Electrical
due to high Battery voltage
40-54 WB93R-8
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
Battery voltage: Power stage diagnosis could be disabled
due to low Battery voltage
#T0059 8110-10 Catalyst efficiency fault path DEF L03 Electrical
#T0060 8110-1F SCR Control: Too high efficiency of the catalyst system DEF L01 Electrical
NOx Sensor: Lambda value measurement from NOx sensor

#T0061 A20C-2 DEF L03 Electrical
incorrect
#T0062 980C-2 Upstream Lambda NOx sensor monitoring DEF L03 Electrical
#T0063 9A0C-A NOx sensor: measured value stuck DEF L03 Electrical
#T0064 C6EA-E2 Upstream NOx sensor plausibility monitoring DEF L03 Electrical
#T0065 7602-1F EEPROM: EEP Erase Error ECU L03 Electrical

EEPROM: EEP Read Error based on the error for more
#T0066 7602-13 ECU L03 Electrical
blocks
#T0067 7602-E EEPROM: EEP Write Error based on the error for one block ECU L03 Electrical
#T0068 630A-12 EGR OBD Monitoring error ECU L03 Electrical
#T0069 E70A-1F EGR Valve: Current limited ECU L03 Electrical
#T0070 1B00-F Permanent governor deviation for valve ECU L03 Electrical
#T0071 1B00-11 Permanent governor deviation for valve ECU L03 Electrical
#T0072 1DEC-E5 Open load error for power stage ECU L03 Electrical
#T0073 1EEC-E6 Over temperature error for H-bridge ECU L03 Electrical
#T0074 1DEC-E3 Short circuit to battery on Out1 error for H-bridge ECU L03 Electrical
#T0075 1EEC-E3 Short circuit to battery on Out2 error for H-bridge ECU L03 Electrical
#T0076 1DEC-E4 Short circuit to ground on Out1 error for H-bridge ECU L03 Electrical
#T0077 1EEC-E4 Short circuit to ground on Out1 error for H-bridge ECU L03 Electrical
#T0078 1FEC-E6 Short circuit over load error for H-bridge ECU L03 Electrical
#T0079 1FEC-E5 EGR Valve: Under voltage of H-bridge ECU L03 Electrical
#T0080 E70A-0 DFC for valve position sensor voltage SRC high ECU L03 Electrical
#T0081 E70A-1 DFC for valve position sensor voltage SRC low ECU L03 Electrical
Engine Protection: Engine temperature reaches prewarning
#T0082 6E00-10 Info L00 NONE
level
Engine Protection: Engine temperature reaches warning
#T0083 6E00-0 Info L02 Mechanical
level
Injection cut off: Injection cut off demand (ICO) for shut off
#T0084 170E-E ECU L03 Electrical
coordinator
ECU
Engine Protection: Over speed detection in component
#T0085 BE00-0 Over- L02 Mechanical
engine protection
speed
#T0086 6C00-0 Ambient pressure sensor: Signal Range Check High failure ECU L03 Electrical
WB93R-8 40-55
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
#T0087 6C00-1 Ambient pressure sensor: Signal Range Check low failure ECU L03 Electrical
#T0088 AB00-0 Ambient temperature sensor: Signal Range Check High ECU L03 Electrical
#T0089 AB00-1 Ambient temperature sensor: Signal range check low ECU L03 Electrical
Camshaft Sensor: Camshaft signal diagnose - disturbed
#T0090 7C02-2 ECU L01 Electrical
signal
#T0091 7C02-9 Camshaft Sensor: Camshaft signal diagnose - no signal ECU L03 Electrical
#T0092 7C02-1F Camshaft Sensor: Camshaft offset angle exceeded ECU L01 Electrical
Crankshaft Sensor: Crankshaft signal diagnose - disturbed
#T0093 7D02-2 ECU L03 Electrical
signal
#T0094 7D02-9 Crankshaft Sensor: Crankshaft signal diagnose - no signal ECU L03 Electrical
#T0095 BE14-12 Liquid HC in the exhaust system DEF L02 Electrical
#T0096 BE14-1 Accumulated HC in the exhaust system DEF L01 Electrical
Fuel filter heater: No load error in power stage of fuel filter
#T0099 A90F-5 ECU L03 Electrical
heating
Fuel filter heater: Over Temperature error at ECM power
stage
ECU Power stages: Short circuit to battery error in power
stage of fuel filter heating
ECU Power stages: Short circuit to ground error in power

stage of fuel filter heating
ECU
Water sensor in the fuel filter: Water in fuel level sensor
#T0103 6100-1F Water in L01 Electrical
defect detection
Fuel
#T0104 9A0C-1F NOx Sensor (CAN): NOx Sensor detects incorrect supply DEF L03 Electrical
NOx Sensor Upstream (CAN): NOx Sensor detects incor-

#T0105 900C-1F DEF L03 Electrical
rect supply
Fuel temperature Sensor: Signal Range check high for fuel

#T0106 AE00-0 ECU L03 Electrical
temperature sensor
Fuel temperature Sensor: Signal Range check low for fuel

#T0107 AE00-1 ECU L03 Electrical
temperature sensor
#T0108 64E9-F3 DFC for faulty diagnostic data transmission or protocol error ECU L03 Electrical
Glow Plug: Open Load error of low voltage glow system

power stage
Over temperature error on ECU power stage for Glow plug

Low Voltage System
#T0111 A402-3 Short circuit to battery error for Low Voltage System ECU L03 Electrical
Glow Plug: Short Circuit to Ground error of low voltage glow
system power stage
#T0113 CC14-4 Array of DFCs for short circuit in 1th Glow Plug ECU L03 Electrical
#T0114 CD14-4 Array of DFCs for short circuit in 3th Glow Plug ECU L03 Electrical
#T0115 CE14-4 Array of DFCs for short circuit in 4th Glow Plug ECU L03 Electrical
#T0116 CF14-4 Array of DFCs for short circuit in 2th Glow Plug ECU L03 Electrical
40-56 WB93R-8
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
EEPROM: Error in EEPROM block EEPData1. SD correc-
tion can not be calculated
Hydraulic Load Deactivation: Open load error on the power-

#T0118 E2EC-E5 ECU L01 Electrical
stage
Hydraulic Load Deactivation: Over temperature error on the

powerstage
Hydraulic Load Deactivation: Short circuit to battery error on

the powerstage
Hydraulic Load Deactivation: Short circuit to ground error on

the powerstage
#T0122 9D00-1 Injection control: check of minimum rail pressure ECU L01 Electrical
#T0123 8B02-9 Measured injection closing time exceeds a limit 1 ECU L01 Electrical
#T0124 8C02-9 Measured injection closing time exceeds a limit 3 ECU L01 Electrical
#T0125 8D02-9 Measured injection closing time exceeds a limit 4 ECU L01 Electrical
#T0126 8E02-9 Measured injection closing time exceeds a limit 2 ECU L01 Electrical
Injector Adjustment programming: check of missing injector
#T0127 8B02-1F ECU L03 Electrical
adjustment value programming (IMA codes): injector %

#T0128 8E02-1F ECU L03 Electrical

#T0129 8C02-1F ECU L03 Electrical

#T0130 9002-1F ECU L03 Electrical
Injector Adjustment: IMA programming not compatible to

#T0131 8B02-2 ECU L01 Electrical
software for injector cyl 1


#T0133 8D02-2 ECU L01 Electrical

Injector, solenoid: Short circuit in an injection bank 1 (all

#T0135 ED0A-3 ECU L03 Electrical
injectors of the same bank can be affected)
Injector, solenoid: Short circuit in an injection bank 2 (all

#T0136 EE0A-3 ECU L03 Electrical
injectors of the same bank can be affected)
Injector: ECM internal failure of Injector actuation (chip
#T0137 6102-C ECU L03 Electrical
error)
Injector, solenoid: Open load error of an injector 1 (interrup-
tion of an electric connection)



#T0142 8B02-3 Injector, solenoid Power stage: Short circuit in the injector 1 ECU L03 Electrical
WB93R-8 40-57
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
#T0143 8E02-3 Injector, solenoid Power stage: Short circuit in the injector 3 ECU L03 Electrical
#T0144 8C02-3 Injector, solenoid Power stage: Short circuit in the injector 4 ECU L03 Electrical
#T0145 9002-3 Injector, solenoid Power stage: Short circuit in the injector 2 ECU L03 Electrical
Fuel Metering Unit: Intermittent contact between ECU and
MeUn
#T0147 A205-5 Fuel metering unit: open load of metering unit output ECU L03 Electrical
Fuel metering unit: over temperature of device driver of
metering unit
#T0149 A305-3 Fuel Metering Unit: short circuit to battery ECU L03 Electrical
#T0150 A305-4 Fuel Metering Unit: short circuit to ground ECU L03 Electrical
Analog Digital Converter (ADC): Diagnostic fault check to
#T0151 C415-E ECU L03 Electrical
report the NTP error in ADC monitoring

#T0152 C415-1F ECU L03 Electrical
report the ADC test error

#T0153 C415-2 ECU L03 Electrical
report the error in Voltage ratio in ADC monitoring

#T0154 E8-FF ECU L03 Electrical
report errors in query-/response-communication

#T0155 1E8-FF ECU L03 Electrical
report errors in SPI-communication
#T0156 7402-E report multiple error while checking the complete ECU L03 Electrical
ROM-memory
Power stages, Injector: Loss of synchronization sending
bytes to the MM from CPU
Power stages, Injector: DFC to set a torque limitation once

#T0158 7502-E ECU L03 Electrical
an error is detected before MoCSOP's error reaction is set
#T0159 2E8-E9 Power stages, Injector: Wrong set response time ECU L03 Electrical
Power stages, Injector: Too many SPI errors during MoC-

SOP execution
Power stages, Injector: Diagnostic fault check to report the

#T0161 8E13-1F ECU L03 Electrical
error in under voltage monitoring
Power stages, Injector: Diagnostic fault check to report that

WDA is not working correct
Power stages, Injector: OS timeout in the shut off path test.

Failure setting the alarm task period
Power stages, Injector: Diagnostic fault check to report that

the positive test failed

timeout in the shut off path test

#T0166 8E13-E ECU L03 Electrical
error in overvoltage monitoring
ECU Internal: Diagnostic fault check to report the accelera-

#T0167 5B00-1F ECU L04 Electrical
tor pedal position error
40-58 WB93R-8
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
Engine speed: Diagnostic fault check to report the engine
#T0168 E8-EE ECU L04 Electrical
speed error
Injection control: Error in the plausibility of the injection

energizing time
Injection control: Error in the plausibility of the start of ener-

#T0170 4115-1F ECU L04 Electrical
gizing angles
Level 2 Monitoring: Error in the plausibility of the energizing

times of the zero fuel quantity calibration
Level 2 Monitoring: Diagnostic fault check to report the error

due to Over Run

#T0173 5C04-1F ECU L04 Electrical
due to injection quantity correction
Level 2 Monitoring: Diagnostic fault check to report the

plausibility error in rail pressure monitoring

#T0175 BE8-FF ECU L04 Electrical
due to torque comparison
Level 2 Monitoring: Diagnosis of curr path limitation forced

by ECU monitoring level 2
Level 2 Monitoring: Diagnosis air path limitation due to a

#T0177 AE8-FF functional control unit monitoring forced by ECU monitoring ECU L04 Electrical
level 2
Level 2 Monitoring: Diagnosis quantity path limitation due to

#T0178 CE8-FF ECU L04 Electrical
a functional control unit monitoring (level 2)
#T0179 D0E-3 Level 2 Monitoring: Reported Overvoltage of Supply ECU L03 Electrical
#T0180 D0E-4 Level 2 Monitoring: Reported Under Voltage of Supply ECU L03 Electrical
#T0181 CD05-D Main Relay: Early opening defect of main relay ECU L03 Electrical
#T0182 CD05-7 Main Relay: DFC for stuck main relay error ECU L03 Electrical
ECU internal: Diagnostic fault check to report 'WDA active'
due to errors in query-/response communication
ECU internal: Diagnostic fault check to report 'ABE active'

due to under voltage detection
ECU internal: Diagnostic fault check to report 'ABE active'

due to overvoltage detection
ECU internal: Diagnostic fault check to report 'WDA/ABE

#T0186 7006-B ECU L03 Electrical
active' due to unknown reason
ECU Oil
Oil pressure sensing: Diagnostic fault check for oil pressure
#T0187 6400-12 Pressure L03 Mechanical
below minimum limit
Low
Oil pressure sensing: Plausibility check for oil pressure sen-
sor
Turbocharger: Over boost deviation at P2 too high in Pres-
sure charger regulator
Turbocharger: Under boost detected in Pressure charger

regulator
WB93R-8 40-59
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
Strategy to detect the inefficiency of the SCR catalyst

#T0191 C50D-0 DEF L01 Electrical
DeSox regeneration (too much time regeneration)
Intake air pressure sensor: Plausibility Check for air pres-

#T0192 6600-F ECU L03 Electrical
sure at the upstream of intake valve sensor
Intake air pressure sensor: Plausibility Check for air pres-

sure at the upstream of intake valve sensor
Intake air pressure sensor: Diagnostic fault check for SRC

high in air pressure upstream of intake valve sensor
Intake air pressure sensor: Diagnostic fault check for SRC

low in air pressure upstream of intake valve sensor
Pressure Relief valve: pressure relief valve reached maxi-

#T0196 C315-F ECU L03 Electrical
mum allowed opening count
Pressure Relief valve: pressure relief valve is forced to

open, perform pressure increase
Pressure Relief valve: pressure relief valve is forced to

#T0198 C315-A ECU L03 Electrical
open, perform pressure shock
#T0199 C315-B Pressure Relief valve: pressure relief valve is open ECU L04 Electrical
Pressure Relief valve: Averaged rail pressure is outside the
expected tolerance range
Pressure Relief valve: pressure relief valve reached maxi-

mum allowed open time
Turbine upstream pressure sensor: SRC High for Turbine

#T0202 B904-0 ECU L03 Electrical
upstream pressure sensor
Turbine upstream pressure sensor: SRC low for Turbine

#T0203 B904-1 ECU L03 Electrical
upstream pressure sensor
Fuel Metering Unit: maximum positive deviation of rail pres-

#T0204 40EE-F2 ECU L04 Electrical
sure exceeded
Fuel Metering Unit: leakage is detected based on fuel quan-

#T0205 D804-1F ECU L04 Electrical
tity balance
Fuel Metering Unit: maximum negative rail pressure devia-

#T0206 40EE-EF ECU L04 Electrical
tion with metering unit on lower limit is exceeded
#T0207 41EE-F1 Fuel Metering Unit: minimum rail pressure exceeded ECU L04 Electrical
#T0208 A205-0 Fuel Metering Unit: maximum rail pressure exceeded ECU L04 Electrical
#T0209 D804-B Error detection by metering unit set value in overrun ECU L04 Electrical
Fuel pressure control Metering unit: Leakage in high pres-
#T0210 D804-E ECU L04 Electrical
sure system detected at idle
#T0211 9D00-2 Rail pressure Sensor: rail pressure raw value is intermittent ECU L01 Electrical
#T0212 C315-1F Rail pressure sensor: maximum rail pressure exceeded ECU L04 Electrical
#T0213 9D00-B Rail pressure Sensor: Sensor voltage above upper limit ECU L04 Electrical
#T0214 9D00-C Rail pressure Sensor: Sensor voltage below lower limit ECU L04 Electrical
40-60 WB93R-8
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
Induce-
Info: SCR reagent tank level below first warning level, DFC
ment Low
#T0215 E106-11 for triggering warning action dependent on filling level of L00 NONE
DEF
reducing agent
Warning
Induce-
ment Low
Info: SCR reagent tank level below second warning level,
DEF Mod-
#T0216 E106-B DFC for triggering warning action dependent on filling level L03 Electrical
erate
of reducing agent
Induce-
ment
#T0217 1811-2 SCR monitoring: general backflow line plausibility error DEF L03 Electrical
#T0218 86EB-EE SCR monitoring: general pressure check error DEF L03 Electrical
#T0219 EE10-A SCR monitoring: pressure stabilization error DEF L03 Electrical
#T0220 EE10-F SCR Reagent Feeding: UREA pressure too high DEF L03 Electrical
#T0221 EE10-11 SCR Reagent Feeding: UREA pressure too low DEF L03 Electrical
#T0222 EE10-10 SCR Reagent Feeding: UREA pressure too high (2nd level) DEF L03 Electrical
SCR Reagent Feeding: Pressurisation after start not possi-

ble
#T0224 31F1-E7 DeNOX relay stuck closed DEF L01 Electrical
#T0225 32F1-E7 DeNOX relay stuck open DEF L01 Electrical
#T0226 31F1-FF Filter Clog reached warning level DEF L03 Electrical
Voltage Plausibility: backflow and suction line heater power

#T0227 30F1-E2 DEF L03 Electrical
stage
#T0228 31F1-E2 Voltage Plausibility: pressure line power stage DEF L01 Electrical
#T0229 32F1-E2 Voltage Plausibility: supply module heater power stage DEF L01 Electrical
#T0230 EB10-C Reporting the leakage in the system during no dosing DEF L03 Electrical
#T0231 D70B-6 Urea Tank temperature: overheating of the tank DEF L03 Electrical
#T0232 1215-7 SCR Dosing valve: Dosing Valve is Blocked closed DEF L03 Electrical
#T0233 1215-F Error in dosing valve plausibility at low voltage DEF L03 Electrical
#T0234 91EB-F3 Defective pressure reduction DEF L03 Electrical
WB93R-8 40-61
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
Error urea supply module heater temperature sensor
#T0235 7FEC-E2 DEF L03 Electrical
dynamic plausibility
Error urea supply module temperature sensor dynamic

#T0236 F110-2 DEF L03 Electrical
plausibility
#T0237 230D-C SCR Tank heater: Urea tank heater is faulty DEF L03 Electrical
#T0238 33F1-E5 SCR Relay: Open load error DEF L03 Electrical
#T0239 33F1-E6 SCR Relay: Overtemperature error DEF L01 Electrical
#T0240 33F1-E3 SCR Relay: Short circuit to battery error DEF L03 Electrical
#T0241 33F1-E4 SCR Relay: Short circuit to ground DEF L03 Electrical
#T0242 E106-13 Diagnostic fault check for signal error from CAN DEF L03 Electrical
SCR Reagent Pump: SRC high for Urea Pump Module

#T0243 220D-0 DEF L03 Electrical
Pressure Sensor
SCR Reagent Tank Level Sensor: Signal above maximum

#T0244 E106-10 DEF L03 Electrical
limit.
SCR Reagent Pump: SRC low for Urea Pump Module Pres-
sure Sensor
SCR Reagent Tank Level Sensor: Signal below minimum

#T0246 E106-12 DEF L03 Electrical
limit.
ECU Sensor Supply Monitor: ECU internal: Error Sensor

#T0247 B50D-C ECU L03 Electrical
supplies 1

supplies 2

supplies 3
#T0250 8B06-E ECU Internal: Stop Counter Timer accuracy ECU L01 Electrical
ECU Power stages: Starter relay HS power stage output
short circuit to battery
#T0252 A502-4 Starter Relay HS: power stage output short circuit to ground ECU L03 Electrical
#T0253 2905-5 Starter Relay LS: power stage output No Load error ECU L03 Electrical
ECU Power stages: Starter relay HS power stage over tem-
perature
#T0255 2905-3 Starter Relay LS: power stage output short circuit to battery. ECU L03 Electrical
ECU Power stages: Starter relay power stage: Short circuit
to ground error for the Low side
#T0257 9800-E ECU internal: Visibility of Software Resets in DSM ECU L01 Electrical
#T0258 9800-1F ECU internal: Visibility of Software Resets in DSM ECU L01 Electrical
EGR
#T0259 DDED-E0 EGR Inducement - first step of engine derating Induce- L01 Electrical
ment 1
40-62 WB93R-8
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
EGR
Induce-
#T0260 DDED-F0 EGR Inducement - second step of engine derating L03 Electrical
ment
Warning
SCR Dos-
ing
#T0261 D016-10 SCR Inducement - second step of engine derating L03 Electrical
Induce-
ment 1
SCR Dos-
SCR Inducement - Last step of engine derating most ing
#T0262 D016-0 L04 Electrical
severe derating Induce-
ment 2
SCR Dos-
ing
#T0263 D016-F SCR Inducement - First step of engine derating Induce- L03 Electrical
ment
Warning
DEF Qual-
SCR Inducement - second step of engine derating, trig-
#T0264 D116-10 ity Induce- L03 Electrical
gered by Reagent quality fault
ment 1
DEF Qual-
SCR Inducement - Last step of engine derating triggered by
#T0265 D116-1F ity Induce- L04 Electrical
Reagent Quality fault
ment 2
DEF Qual-
SCR Inducement warning, triggered by Reagent Quality ity Induce-
#T0266 D116-F L01 Electrical
fault ment
Warning
SCR
Technical
SCR Inducement less severe derating level, triggered by
#T0267 7E14-10 Failure L03 Electrical
Tampering fault
Induce-
ment 1
SCR
Technical
SCR Inducement most severe derating level, triggered by
#T0268 7E14-0 Failure L04 Electrical
Tampering fault
Induce-
ment 2
SCR
Technical
Failure
#T0269 7E14-F SCR Inducement warning, triggered by Tampering fault L03 Electrical
Induce-
ment
Warning
Induce-
#T0270 A31A-1F Activation of Repeated Offenders logic L00 Electrical
ment
Induce-
#T0271 DEED-FF Severe inducement for several times within a timeframe L00 Electrical
ment
Tempo-
rary
Validation mode activated: full power restart in case of
#T0272 DCED-FF Recovery L00 Electrical
inducement activation
of Induce-
ment
#T0273 8B06-1F Terminal 50 switch: Defective T50 switch ECU L03 Electrical
#T0274 B721-E Cold start detected ECU Info L00 NONE
WB93R-8 40-63
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
ECU temperature sensor: SPI Error ECU temperature sen-
sor (LM71)
#T0276 2F0-E0 Permanent governor deviation for valve ECU L03 Electrical
#T0277 2F0-E1 Permanent governor deviation for valve ECU L03 Electrical
#T0278 3F0-E5 Open load error for power stage ECU L03 Electrical
#T0279 3F0-EF Over temperature error for H-bridge ECU L03 Electrical
#T0280 3F0-E3 Short circuit to battery on Out1 error for H-bridge ECU L03 Electrical
#T0281 2F0-E3 Short circuit to battery on Out2 error for H-bridge ECU L03 Electrical
#T0282 3F0-E4 Short circuit to ground on Out1 error for H-bridge ECU L03 Electrical
#T0283 2F0-E4 Short circuit to ground on Out2 error for H-bridge ECU L03 Electrical
#T0284 2F0-EF Short circuit over load error for H-bridge ECU L03 Electrical
#T0285 2F0-E5 Under voltage error for H-bridge ECU L03 Electrical
ECU Power stages: Throttle valve actuator power stage:

SRC High
ECU Power stages: Throttle valve actuator power stage:
SRC low
Intake air temperature sensor: Diagnostic fault check for
#T0288 6900-0 SRC high in engine inlet valve air temperature upstream ECU L03 Electrical
sensor
Intake air temperature sensor: Diagnostic fault check for
#T0289 6900-1 SRC low in engine inlet valve air temperature upstream ECU L03 Electrical
sensor
OxiCat upstream temperature sensor: Diagnostic fault
#T0290 9D12-0 check for SRC high in Oxidation Catalyst upstream temper- ATS L03 Electrical
ature
OxiCat upstream temperature sensor: Diagnostic fault
#T0291 9D12-1 check for SRC low in Oxidation Catalyst upstream tempera- ATS L03 Electrical
ture
#T0292 8102-5 Turbocharger control: Open load of VTG actuator ECU L04 Electrical
#T0293 B7EB-E6 Turbocharger control: Over temperature of VTG actuator ECU L01 Electrical
Turbocharger control: Short circuit to battery of VTG actua-

tor
Turbocharger control: Short circuit to ground of VTG actua-
tor
J1939 Network #1, Primary Vehicle Network Special
#T0296 B2E8-F3 ECU L03 Electrical
Instruction
SCR Catalyst Temperature sensing: SRC high for Catalyst

#T0297 B11-0 DEF L03 Electrical
temperature downstream
40-64 WB93R-8
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
SCR Catalyst Temperature sensing: SRC low for Catalyst
#T0298 B11-1 DEF L03 Electrical
temperature downstream
SCR Catalyst Temperature sensing: SRC high for Catalyst

temperature upstream
SCR Catalyst Temperature sensing: SRC low for Catalyst

temperature upstream
Induce-
ment Low
#T0301 E106-1F SCR Reagent Tank Level: Empty Urea Tank L04 Electrical
DEF Final
Step
#T0302 210D-5 SCR Dosing valve: Diagnostic error check for open load. DEF L03 Electrical
SCR Dosing valve: Diagnostic error check for overtempera-

ture.
SCR Dosing valve: Diagnostic error check for short circuit to

battery.

#T0305 8AEB-E3 DEF L03 Electrical
battery on the high side switch.

ground.

#T0307 8AEB-E4 DEF L03 Electrical
ground on the high side switch.
Pressure line heater error and temperature condition to per-

#T0308 211-E DEF L03 Electrical
form an afterrun
#T0309 311-1F Urea Backflow Line Heater Actuator power stage: FET error DEF L01 Electrical
Urea Backflow Line Heater Actuator power stage: Open

Load error
Urea Backflow Line Heater Actuator power stage: Short Cir-

cuit to Battery
Urea Backflow Line Heater Actuator power stage: Short Cir-

cuit to Ground
#T0313 211-C Urea Pressure Line Heater: FET error DEF L03 Electrical
#T0314 211-5 Urea Pressure Line Heater: No load error DEF L03 Electrical
#T0315 211-3 Urea Pressure Line Heater: Short circuit to battery error DEF L03 Electrical
#T0316 211-4 Urea Pressure Line Heater: Short circuit to ground error DEF L03 Electrical
#T0317 7EEC-FF FET error DEF L01 Electrical
Urea Supply Module Heater Actuator power stage: Open

#T0318 7EEC-E5 DEF L03 Electrical
Load error
WB93R-8 40-65
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
Urea Supply Module Heater Actuator power stage: Short
Circuit to Battery
Urea Supply Module Heater Actuator power stage: Short

Circuit to ground
#T0321 230D-5 Urea Tank Heater: No load error (Reagent Tank Heater) DEF L03 Electrical
#T0322 230D-6 Urea Tank Heater: Over Temperature error DEF L03 Electrical
#T0323 230D-3 Urea Tank Heater: Short circuit to battery error DEF L03 Electrical
#T0324 230D-4 Urea Tank Heater: Short circuit to ground error DEF L03 Electrical
#T0325 1611-9 SCR Reagent Pump: Communication Receive Fail DEF L03 Electrical
#T0326 1611-10 SCR Reagent Pump: Pump motor speed deviation DEF L01 Electrical
SCR Reagent Pump: Permanent Pump Motor Speed Devia-

tion
SCR Reagent Pump: No load error on power stage for urea

#T0328 3B15-5 DEF L03 Electrical
pump motor
SCR Reagent Pump: Over temperature error on power

stage for urea pump motor
Urea Pump motor internal Duty cycle above the maximum

#T0330 32E0-E0 DEF L03 Electrical
range value
Urea Pump motor internal Duty cycle below minimum range

value
Urea Pump Supply Heater Module temperature Duty cycle

above the maximum range value
Urea Pump Supply Heater Module temperature Duty cycle

below minimum range value
Urea Pump motor speed Duty cycle above the maximum

range value
Urea Pump motor speed Duty cycle below minimum range

value
Urea Pump Supply Module temperature Duty cycle above

the maximum range value
Urea Pump Supply Module temperature Duty cycle below

minimum range value
SCR Reagent Pump: Short circuit to battery error on power

SCR Reagent Pump: Short circuit to ground error on power

40-66 WB93R-8
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applica-
code level history
ponent
#T0340 96EB-E5 No load error on low powerstage for Urea back flow pump DEF L03 Electrical
Over temperature error on low powerstage for Urea back

flow pump
Short circuit to battery error on low powerstage for Urea

back flow pump
Short circuit to ground error on low powerstage for Urea

back flow pump
#T0344 200D-E HCU: Missing Power Supply voltage DEF L03 Electrical
#T0345 200D-1F HCU: NVM (internal memory) error DEF L01 Electrical
#T0346 200D-6 HCU: Over temperature error DEF L01 Electrical
#T0347 200D-3 HCU: Power Supply Overvoltage error DEF L01 Electrical
#T0348 200D-4 HCU: Power Supply Undervoltage error DEF L03 Electrical
Urea Quality Sensor: Shortcut to Battery error, via Catalyst

Reagent Properties Preliminary FMI
Urea Quality Sensor: Shortcut to Ground error, via Catalyst

Reagent Properties Preliminary FMI
Urea Quality Sensor: sensor system error detected, via Cat-

#T0351 64E0-FF DEF L01 Electrical
alyst Reagent Properties Preliminary FMI
Urea Quality Sensor: Shortcut to Battery error, via Catalyst

#T0352 20EC-E3 DEF L01 Electrical
Reagent Temperature 2 Preliminary FMI
Urea Quality Sensor: Shortcut to Ground error, via Catalyst

#T0353 20EC-E4 DEF L01 Electrical
Reagent Temperature 2 Preliminary FMI
Urea Quality Sensor: sensor system error detected, via Cat-

#T0354 20EC-FF DEF L01 Electrical
alyst Reagent Temperature 2 Preliminary FMI
Urea Quality Sensor: Reducing agent concentration outside

#T0355 BC0D-1F DEF L01 Mechanical
range
#T0356 C10D-1F Urea Quality Sensor: critical fluid identified DEF L03 Mechanical
SCR Reagent Tank Level: Diagnostic Fault Check for signal

#T0357 E106-E DEF L01 Electrical
error from CAN
Machine ECU failure code
Failure Applicable Action Category of

Failure (As displayed on screen)
code component level history
#V0001 Pedal Throttle Idle Switch Open Circuit or Ground Fault MACHINE CU L03 Electrical
#V0002 Pedal Throttle Idle Switch +12V Hot Short Circuit MACHINE CU L03 Electrical
#V0003 Dial Throttle Sensor Open Circuit or Ground Fault MACHINE CU L03 Electrical
WB93R-8 40-67
40 TROUBLESHOOTING
FAILURE CODES TABLE

#V0004 Dial Throttle Sensor Hot Short Circuit MACHINE CU L03 Electrical
#V0005 Dial Throttle Sensor Low Error MACHINE CU L03 Electrical
#V0006 Dial Throttle Sensor High Error MACHINE CU L03 Electrical
#V0007 Pedal Throttle Sensor Open Circuit or Ground Fault MACHINE CU L03 Electrical
#V0008 Pedal Throttle Sensor Hot Short Circuit MACHINE CU L03 Electrical
#V0009 Pedal Throttle Sensor Low Error MACHINE CU L03 Electrical
#V0010 Pedal Throttle Sensor High Error MACHINE CU L03 Electrical
#V0011 Seat F/R Switch Input Malfunction MACHINE CU L01 Electrical
#V0012 Travel Neutral Switch Input Malfunction MACHINE CU L01 Electrical
#V0013 PPC Lock Switch Input Malfunction MACHINE CU L03 Electrical
#V0014 Brake both pushed Pressure Switches Input Hardware Fault MACHINE CU L01 Electrical
#V0015 4th Gear Switch Input Hardware Fault MACHINE CU L01 Electrical
#V0016 Fan Speed Sensor Input Hardware Fault MACHINE CU L01 Electrical
#V0017 Ambient Temperature Sensor Ground Fault MACHINE CU L01 Electrical
#V0018 Transmission Oil Temperature Sensor Ground Fault MACHINE CU L01 Electrical
#V0019 Fuel Level Sensor Ground Fault MACHINE CU L01 Electrical
#V0020 Fuel Level Sensor Open Circuit or Hot Short Circuit MACHINE CU L01 Electrical
#V0021 Fan Clutch Solenoid Ground Fault MACHINE CU L01 Electrical
#V0022 Fan Clutch Solenoid Hot Short Circuit MACHINE CU L01 Electrical
#V0023 Fan Clutch Solenoid Open Circuit MACHINE CU L01 Electrical
#V0024 Fan Clutch Solenoid Output Malfunction MACHINE CU L01 Electrical
#V0025 Lamp PPC lock Switch Ground Fault MACHINE CU L01 Electrical
#V0026 Lamp PPC lock Switch Hot Short Circuit MACHINE CU L01 Electrical
#V0028 Lamp PPC lock Switch Input Malfunction MACHINE CU L01 Electrical
#V0029 Differential Lock Solenoid Ground Fault MACHINE CU L01 Electrical
#V0030 Differential Lock Solenoid Hot Short Circuit MACHINE CU L01 Electrical
#V0031 Differential Lock Solenoid Open Circuit MACHINE CU L01 Electrical
#V0032 Differential Lock Solenoid Output Malfunction MACHINE CU L01 Electrical
#V0033 Return to Dig - Float Magnet Ground Fault MACHINE CU L01 Electrical
#V0034 Return to Dig - Float Magnet Hot Short Circuit MACHINE CU L01 Electrical
#V0035 Return to Dig - Float Magnet Open Circuit MACHINE CU L01 Electrical
#V0036 Return to Dig - Float Magnet Output Malfunction MACHINE CU L01 Electrical
#V0037 4WD Solenoid Ground Fault MACHINE CU L03 Electrical

#V0038 4WD Solenoid Hot Short Circuit MACHINE CU L01 Electrical
#V0039 4WD Solenoid Output Malfunction MACHINE CU L03 Electrical
#V0040 Transmission Declutch Solenoid Ground Fault MACHINE CU L03 Electrical
#V0041 Transmission Declutch Solenoid Hot Short Circuit MACHINE CU L01 Electrical
#V0042 Transmission Declutch Solenoid Output Malfunction MACHINE CU L03 Electrical
40-68 WB93R-8
40 TROUBLESHOOTING
FAILURE CODES TABLE

#V0043 Power Mode Selection Solenoid Ground Fault MACHINE CU L01 Electrical
#V0044 Power Mode Selection Solenoid Hot Short Circuit MACHINE CU L01 Electrical
#V0045 Power Mode Selection Solenoid Output Malfunction MACHINE CU L01 Electrical
#V0046 PPC Lock Front Solenoid Ground Fault MACHINE CU L01 Electrical
#V0047 PPC Lock Front Solenoid Hot Short Circuit MACHINE CU L03 Electrical
#V0048 PPC Lock Front Solenoid Output Malfunction MACHINE CU L03 Electrical
#V0049 PPC Lock Rear Solenoid Ground Fault MACHINE CU L01 Electrical
#V0050 PPC Lock Rear Solenoid Hot Short Circuit MACHINE CU L03 Electrical
#V0051 PPC Lock Rear Solenoid Output Malfunction MACHINE CU L03 Electrical
#V0052 ECSS Solenoid Ground Fault MACHINE CU L01 Electrical

#V0053 ECSS Lock Rear Solenoid Hot Short Circuit MACHINE CU L01 Electrical
#V0054 ECSS Lock Rear Solenoid Output Malfunction MACHINE CU L01 Electrical
#V0055 Sensors +5V Supply Voltage Ground Fault MACHINE CU L03 Electrical
#V0056 Sensors +5V Supply Voltage Hot Short Circuit MACHINE CU L03 Electrical
#V0057 Machine Ground Connection Malfunction MACHINE CU L03 Electrical
#V0058 CAN 3 Defective Communication (I/O Remote Controller) MACHINE CU L03 Electrical
#V0059 I/O Remote Controller Internal Failure MACHINE CU L03 Electrical

#V0060 Lamp Fuel Low Indicator Ground Fault MACHINE CU L01 Electrical
#V0061 Lamp Fuel Low Indicator Hot Short Circuit MACHINE CU L01 Electrical
Lamp Hi Trasmission Temperature Indicator Ground Fault or open
#V0062 MACHINE CU L01 Electrical
Circuit
#V0063 Lamp Hi Trasmission Temperature Indicator Hot Short Circuit MACHINE CU L01 Electrical
#V0064 Lamp Check output Ground Fault or Open Circuit MACHINE CU L01 Electrical
#V0065 Alternator D+ Terminal Open Circuit MACHINE CU L03 Electrical

#V0066 Buzzer Ground Fault or Open Circuit MACHINE CU L01 Electrical
#V0067 Buzzer Hot Short Circuit MACHINE CU L01 Electrical
#V0068 Lamp Differential Lock Ground Fault MACHINE CU L01 Electrical
#V0069 Lamp Differential Lock Hot Short Circuit MACHINE CU L01 Electrical
#V0070 Lamp Centralized Warning Ground Fault or Open Load MACHINE CU L01 Electrical
#V0071 Lamp Centralized Warning Hot Short Circuit MACHINE CU L01 Electrical
#V0072 Lamp ECSS Ground Fault MACHINE CU L01 Electrical

#V0073 Lamp ECSS Hot Short Circuit MACHINE CU L01 Electrical
#V0074 Lamp 4WD Ground Fault MACHINE CU L01 Electrical
WB93R-8 40-69
40 TROUBLESHOOTING
FAILURE CODES TABLE

#V0075 Lamp 4WD Hot Short Circuit MACHINE CU L01 Electrical
#V0076 Lamp Low Oil Brake Level Ground Fault or Open Load MACHINE CU L01 Electrical
#V0077 Lamp Low Brake Level Hot Short Circuit MACHINE CU L01 Electrical
#V0078 Transmission Oil Overheat MACHINE CU L02 Mechanical
#V0079 Charge Voltage Low MACHINE CU L03 Mechanical
#V0080 Machine Controller Software Validation Process Error MACHINE CU L03 Electrical
#V0081 Machine Controller Internal Failure MACHINE CU L03 Electrical

#V0082 Air Cleaner Clogging MACHINE CU L01 Mechanical
#V0083 Low Brake Oil Level MACHINE CU L03 Mechanical
#V0084 Fan Clutch Speed Target Not Reached MACHINE CU L03 Mechanical
#V0085 Idle Validation Process Error MACHINE CU L03 Electrical
Monitor ECU failure code
Applica-
SPN-FMI DTCM Failure (As displayed on screen) ble com-
code level history
ponent
#W8800 Electrical
#W8801 Electrical
• In this table, failure codes are arranged in alphabetical order.

• The failure codes that do not have numbers in the action level columns are not displayed on the stand-
ard screen even when a failure related to them occurs. They are simply recorded in the abnormality
record (electrical system or mechanical system) of the service menu.
• History category means the classification of either electrical system or mechanical system which is used
for storage in the Failure History of the service menu.
40-70 WB93R-8
40 TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)

TROUBLESHOOTING OF ENGINE FAILURE
FAILURE CODE [#T0001]
Failure code Action level DTCM Code
#T0001 L01 7402-1F

Failure EEPROM : Error during Write/Read EEPROM operation
Fault component ECU EEPROM
Failure detection Calibrated parameters for baud rate cannot be read from EEPROM
Failure cause Wrong programming or EEPROM defective.
Failure repair Reprogram ECM or replace ECM.
#T0002 L03 A800-10
Failure Battery voltage: High Battery Voltage indication
Fault component Battery voltage
Failure detection The sensor raw signal BattU_uRaw (voltage) is above 5,00V
Failure cause Alternator voltage governor defect

Failure repair Replace alternator governor device or alternator

#T0003 L03 A800-12
Failure Battery voltage: Low Battery voltage indication
Failure detection The sensor raw signal BattU_uRaw (voltage) is below 1,59V
Battery defect, alternator defect, wiring problems (too high resistance) or ECU defect.
Failure cause
Occurence possible during cold start.
Failure repair Replace battery or alternator. Check ECU and wiring.
WB93R-8 40-71
40 TROUBLESHOOTING
#T0004 L03 A800-0
Failure Battery voltage: Signal Range Check high for battery voltage sensor

The sensor raw signal BattU_uRaw (voltage) is above 3,39V due to defective voltage
Failure detection
divider circuit inside the ECU.
Failure cause Alternator voltage governor defect.
Failure repair Replace alternator governor device or alternator.
#T0005 L03 A800-1

Failure Battery voltage: Signal Range Check low for battery voltage sensor
Failure detection The sensor raw signal BattU_uRaw (voltage) is below 980,00mV.
Battery defect, alternator defect, wiring problems (too high resistance) or ECU defect.
Failure cause
Occurrence possible during cold start.
Failure repair Replace battery or alternator. Check ECU and wiring.

#T0006 L01 7F02-2
Failure CAN Bus : Bus off of CAN node A
Fault component CAN Bus
Failure detection First thershold for Bus Off at node A is detected
CAN bus not correctly terminated, or

Failure cause Burst of error frames on the bus casued by other ECU(s), or
Excessive bus load.
Check termination resistors and network connection and contacts. Monitor CAN
Failure repair
communication for erroneous behaviour of a participant.
40-72 WB93R-8
40 TROUBLESHOOTING
#T0007 L03 CF04-2

Failure CAN Bus: Error passive CAN Bus Node B
Failure detection Bus Off at node B is detected

Wrong configuration of CAN timing (Prescaler, synchronization jump width, sampling,
Failure cause propagation and phase segments), bad termination resistors, defective network con-
nection and contacts or defective CAN controller with erroneous messages.
Check timing configuration with hardware compatibility, check termination resistors

and network connection and contacts. Short circuits to external source, ground or
Failure repair
CAN High to Low.Monitor CAN communication for erroneous behaviour of a partici-
pant.

#T0008 L03 7F02-1F
Failure CAN Bus : Bus Off error CAN A
Failure detection Bus Off at node A is detected
CAN bus not correctly terminated, or

ECM disconnession from CAN Bus, or
Failure cause Short circuit to external sources, to ground ot between H and L lines, or
Continuous error frames on the bus casued by other ECU(s) or
Excessive bus load.
Check termination resistors and network connection and contacts. Short circuits to
Failure repair external source, ground or CAN High to Low. Monitor CAN communication for erro-
neous behaviour of a participant.
WB93R-8 40-73
40 TROUBLESHOOTING
#T0009 L03 CF04-1F

Failure CAN Bus: Error CAN Bus Node B
Failure detection Bus Off at node B is detected

Wrong configuration of CAN timing (Prescaler, synchronization jump width, sampling,
Failure cause propagation and phase segments), bad termination resistors, defective network con-
nection and contacts or defective CAN controller with erroneous messages.
Check timing configuration with hardware compatibility, check termination resistors

and network connection and contacts. Short circuits to external source, ground or
Failure repair
CAN High to Low.Monitor CAN communication for erroneous behaviour of a partici-
pant.

#T0010 L03 EC0F-0
Failure Coolant temperature : SRC High for Engine coolant temperature (down stream)
Fault component Coolant temp sensor
Failure detection The sensor raw signal > 4,93V.
Failure cause Sensor defective or short circuit to external source
Failure repair Check wiring or replace sensor
#T0011 L03 EC0F-1
Failure Coolant temperature : SRC low for Engine coolant temperature (down stream)
Fault component Coolant temp sensor
Failure detection The sensed signal < 198,00mV
Failure cause Sensor defective or short circuit to ground
40-74 WB93R-8
40 TROUBLESHOOTING
#T0012 L01 160E-E

Failure Idle shutdown error
Fault component Engine stop
DFC shows that the Idle shutdown is already in the driver alert or in the shutdown
phase.
Failure detection Fault is set If CoEng_tiIdlShDwnRemain1_mp < (5,00min- 5,00min): in this moment
DSM_FAULT_PERCENT_50 is set and the driver shall be informed.
When CoEng_tiIdlShDwnRemain1_mp = 0 DSM_FAULT_PERCENT_100 is set and
the shutdown takes place.
Failure cause Engine shutdown after a calibratable time at low idle.
Failure repair INFO failure: no intervention necessary.

#T0013 L00 6006-E
Torque limitation, Engine protection : Torque limitation caused by turbo charger pro-
Failure
tection
Fault component Info: Torque Limitation active
A Power reduction > 25,00% or an engine speed limitation > 25,00% is asked by the
Failure detection
VGT to protect it against overspeed at high altitude.
Failure cause Active power reduction > 120,00s due to turbo charger protection
No actions necessary due to this failure alone. If power reduction occurred due to
Failure repair actual defect, the failure triggering the torque limitation should also be in the failure
memory. Follow troubleshooting of this root error.
WB93R-8 40-75
40 TROUBLESHOOTING
#T0014 L00 2106-E

Torque limitation, Engine protection: Strong torque limitation from engine protection
Failure
active
A Power reduction > 25,00% or an engine speed limitation > 25,00% is asked by the
Failure detection
engine to protect it against overload depending on engine speed.
Failure cause Active power reduction > 120,00s due to engine protection mechanics
#T0015 L00 2106-1F
Torque limitation, Engine protection : Strong torque limitation from injection system
Failure
active
A Power reduction > 25,00% or an engine speed limitation > 25,00% is asked by
Failure detection
High pressure fuel pump depending on engine speed and actual fuel pressure.
Failure cause Active power reduction > 120,00s due to high pressure fuel pump protection
#T0016 L00 A9EE-FF
Failure Torque limitation, Engine protection : General report of the event of torque limitations
Failure detection CoETS_stLimInfo reports limitation.
Failure cause One or more torque reductions are present

No actions necessary due to this failure alone. If powerreduction occurred due to
40-76 WB93R-8
40 TROUBLESHOOTING
#T0017 L00 750E-1F

Failure Torque limitation, Engine protection : Torque limitation caused by particulate filter
A Power reduction > 25,00% or an engine speed limitation > 25,00% due to particu-
late filter protection.
Failure detection
The particulate filter protection limits the calculated pressure drop over filter (= Flow
resistance * Exhaust gas flow), which is depending on collected soot mass, by curve
EngDem_trqLimPDiff.
Active power reduction > 120,00s due to torque limitation for pressure drop limitation
Failure cause
over particulate filter.
#T0018 L00 D616-1F
Failure Torque limitation, Engine protection : Torque limitation caused by performance limiter

A Power reduction > 25,00% or an engine speed limitation > 25,00% due to OBD
performance limitation.
The OBD performance limitation is activated it there is a failure active, which causes
high NOx emissions for a certain time (1,00s, 1,00s , 1,00s or 1,00s depending on
the failure).
Failure detection The performance limiter is activated immediately within 25,13min or 39,95min
(depending on limitation).
If the failure which caused the high NOx disappears, the performance limiter is
released within 10,00s or 10,00s (depending on limitation) only, after the engine
speed was in idle condition (engine speed < 1,00rpm resp. not more than 15,00rpm
above idle speed asked by external access (e.g. body computer))
Active power reduction due to the OBD performance limiter because of too high NOx
Failure cause
emissions
No actions necessary due to this failure alone. If powerreduction occurred due to

WB93R-8 40-77
40 TROUBLESHOOTING
#T0019 L00 E604-E

Failure Torque limitation, Engine protection : Torque limitation caused by smoke limitation
A Power reduction > 25,00% or an engine speed limitation > 25,00% due to smoke
limitation.
Failure detection
Depending on engine speed and actual air mass flow a minimal lambda is calculated
by a map. The actual fuel mass is limited to this minimal allowed lambda. The limited
fuel mass is calculated as maximum possible torque.
Active power reduction due to smoke limitation with unexpected long duration >
120,00s
If no other failure stored concerning EGR or Boost pressure control:

Failure cause
operation in extreme high altitude (>1800 m, i.e ambient pressure < 780mbar)
sticking of VGT or EGR actuator or engine brake flap (if available)
turbocharger with slow response (bad efficiency)
wrong signal of HFM (or boost pressure sensor if HFM not available)
actual defect, the failure triggering the torque limitation should also be in the failure
If no failure stored in memory concerning EGR or Boost pressure control:

Failure repair
if failure occurred at high altitude > 1800m (ambient pressure < 780mbar): no action
needed.
check actuators of EGR, Boost pressure and exhaust flap control for sticking.
Check turbocharger for correct efficiency
Check HFM and Boost pressure sensor for correct measuring values
#T0020 L03 C10D-9
CAN Bus: Timeout Error of CAN-Receive-Frame CRI1 (Catalyst reagent informa-

Failure
tion)
Fault component SCR Control

Failure detection Time out for the CRI1 CAN frame is detected.
Failure cause CAN bus overload or disturbed, frame could not be received.
Failure repair Check after-treatment CAN bus wiring. Replace integrated DEF sensor.
40-78 WB93R-8
40 TROUBLESHOOTING
#T0021 L03 1A11-2
Failure EMF Signal Plausibility for NH3 Sensor
Fault component NOx Sensing
If the EMF1 or EMF2 signal values don't change within a given time the sensor shall
Failure detection
be detected as replaced and the DFC is set.
Failure cause Defective NH3 Sensor
Failure repair Replace NH3 Sensor

#T0022 L01 5BEA-E9
Failure Timeout error of CAN receive frame HCUData
Fault component SCR Reagent Heating

Failure detection Fault is detected if a TimeOut of HCU2EDC1 message occurs.
Failure cause CAN cable is disconnected or broken. Short circuit in wiring.
Failure repair Check HCU wiring harness. Replace HCU.
#T0023 L01 5CEA-E9
Failure Timeout error of CAN receive frame HCUData
Failure detection Fault is detected if a TimeOut of HCU2EDC2 message occurs.
Failure cause CAN cable is disconnected or broken. Short circuit in wiring. CAN bus overload.
Failure repair Check CAN netowrk wiring of HCU controller.
WB93R-8 40-79
40 TROUBLESHOOTING
#T0024 L03 1A11-9
Failure Timeout Error of CAN-Receive-Frame NH3Fact from NH3 sensor
Failure detection Fault is detected if a Timeout of NH3Fact message occurs.
Defective CAN controller of NH3 sensor, cable disconnected or broken. Short circuit
Failure cause
in wiring.
Check presence and correct connection of the NH3 sensor to the network, Check cor-
Failure repair
rect functioning of the CAN controller. Check wiring.

#T0025 L03 1A11-C
Failure NH3 sensor: Internal open load or short circuit error on measuring cell line
Fault component NH3 Sensor
Failure is detected in case of an open load or a short circuit on one of the measuring
Failure detection
cell lines of the sensor
#T0026 L03 1C11-4
Failure NH3 sensor: Internal open load or short circuit error on ground line
Failure is detected in case of an open load or a short circuit on on the signal ground
Failure detection
line of the sensor
40-80 WB93R-8
40 TROUBLESHOOTING
#T0027 L03 1E11-3
Failure NH3 sensor: Internal Short circuit on heater line (overheated Sensor)
Failure is detected in case of electrical (line) error which causes overheating of the
Failure detection
sensor (SCB of pos. heater line, SCG of neg. heater line).
#T0028 L03 1E11-4
Failure NH3 sensor: Internal Short circuit on heater line (underheated Sensor)
Failure is detected in case the sensor is reporting an electrical (line) error which
Failure detection causes underheating of the sensor (OL, SCB of neg. heater line, SCG of pos. heater
line).

#T0029 L03 1F11-4
Failure NH3 sensor: Internal Short circuit or open load error on temperature cell input line
Failure is detected in case the sensor is reporting an open load or a short circuit on
Failure detection
the temperature cell input line
WB93R-8 40-81
40 TROUBLESHOOTING
#T0030 L03 1C11-C
Failure NH3 sensor: Internal Short circuit or open load error on trim resistor line
Failure is detected in case the sensor is reporting an open load or a short circuit on
Failure detection
the trim resistor line input
#T0031 L03 1F11-1F
Failure NH3 sensor: Internal sensor heater control failure
Failure detection Failure is detected in case the sensor is reporting a heater control fault

#T0032 L03 1E11-7
Failure Heater Performance Error for NH3 Sensor
If the dew point has been reached the NH3 sensor must reach the heated up state
after a given time.
Failure detection
If the sensor cannot reach the heated up state a failure shall be detected.
Failure cause Sensor heating defective or insufficient.
Failure repair Check NH3 sensor wiring, replace NH3 sensor.
40-82 WB93R-8
40 TROUBLESHOOTING
#T0033 L03 1911-1F
Failure Signal Plausibility for NH3 Sensor
Failure detection Filtered difference between EMF2 and EMF1 > 1000,00mV or < -40,00mV
Failure cause Defective NH3 Sensor (NH3 sensor shows negative drift).
Failure repair Replace NH3 Sensor.
#T0034 L03 1F11-C
Failure NH3 sensor: Internal sensor heater supply failure
Failure is detected in case the sensor is reporting an error related to power supply of
Failure detection
heater or sensor

#T0035 L03 1911-C
Failure NH3 sensor: Electrical problem
Failure is detected in case the sensor is reporting an error related to ASIC, NVM or
Failure detection
flash memory.
WB93R-8 40-83
40 TROUBLESHOOTING
#T0036 L03 1911-9
Failure CAN Bus: Timeout Error of CAN-Receive-Frame NH3Sens from NH3 Sensor
Failure detection Timeout of NH3Sens message.
Defective CAN controller of NH3 Sensor , undervoltage of Sensor, missing Sensor,

Failure cause
CAN cable connecting the Sensor is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the NH3 Sensor to the network, Check
Failure repair
correct functioning of the Sensor CAN controller and its voltage supply. Check wiring.

#T0037 L03 A00C-5
Failure CAN NOx Sensor: Open Circuit Error for Nox Sensor
Fault component CAN NOx Sensor

If NOx sensor sends the Message "Open wire" (Error Byte value = 205, i.e. Bits 0-1 =
Failure detection
01)
Wiring defect.
Failure cause
NOx Sensor defect.
Check wiring (specially heating wires).

Failure repair
Check NOx Sensor.
#T0038 L03 A00C-6
Failure CAN NOx Sensor: Short Circuit Error for Nox Sensor
Failure detection If NOx sensor has detected Heater short circuit fault Com_stBytNOxSens[0]==1
Wiring harness has short circuit.

Failure cause
NOx Sensor defect.
Check wiring harness.
Failure repair
Check Sensor.
40-84 WB93R-8
40 TROUBLESHOOTING
#T0039 L03 A00C-C

Failure NOx Sensor (CAN): Sensor Heater performance insufficient
Fault component NOx Sensor (CAN)
Starting from the dew point detection during a cold start, the heater has not reached
Failure detection the working temperature
after 3,00 min
Failure cause NOx sensor heater efficiency decreased.
Failure repair Check wiring/supply, replace NOx sensor.

#T0040 L03 A20C-5
Failure NOx Sensor (CAN): Open circuit error detected by sensor

If NOx sensor has detected open wire fault Com_stErrBytNOxSens[1]==1 (open wire
Failure detection NOx), or Com_stErrBytNOxSens[2]==1 (open wire linear Lambda), or
Com_stErrBytNOxSens[3]==1 (open wire binary Lambda)
Wiring defect.
Failure cause
NOx Sensor defect.
Check wiring.
Failure repair
Check NOx Sensor.
#T0041 L03 A20C-6
Failure NOx Sensor (CAN): Short circuit error detected by sensor

If NOx sensor has detected short circuit fault Com_stErrBytNOxSens[5]==1 (short

Failure detection NOx), or Com_stErrBytNOxSens[6]==1 (short linear Lambda), or
Com_stErrBytNOxSens[7]==1 (short binary Lambda)
Wiring defect.
Failure cause
NOx Sensor defect.
Check wiring.
Failure repair
Check NOx Sensor.
WB93R-8 40-85
40 TROUBLESHOOTING
#T0042 L03 970C-5

Failure CAN NOx Sensor Upstream: Open Circuit Error for Nox Sensor upstream
Failure detection CAN message reports open circuit faults.

Wiring defect.
Failure cause
NOx Sensor upstream defect.

Failure repair
Check NOx Sensor Upstream.

#T0043 L03 970C-6
Failure CAN NOx Sensor Upstream: Short Circuit Error for Nox Sensor upstream

Failure detection If the Sensor sends the message "short circuit" detected.
Wiring defect.
Failure cause
NOx Sensor upstream defect.

Failure repair
Check NOx Sensor Upstream.
#T0044 L03 960C-C
Failure NOx Sensor Upstream (CAN): Sensor Heater performance insufficient
Starting from the dew point detection during a cold start, the heater has not reached
Failure detection the working temperature
after 3,00min.
Failure cause NOx upstream sensor heater efficiency decreased.

Failure repair Check wiring/supply, replace NOx upstream sensor.
40-86 WB93R-8
40 TROUBLESHOOTING
#T0045 L03 980C-5

Failure NOx Sensor Upstream (CAN): Open Wire error detected by sensor
If NOx upstream sensor has detected open wire fault Com_stErrBytNOxSens[1]==1

Failure detection (open wire NOx), or Com_stErrBytNOxSens[2]==1 (open wire linear Lambda), or
Com_stErrBytNOxSens[3]==1 (open wire binary Lambda)
Wiring defect
Failure cause
NOx Upstream Sensor defect.
Check wiring.
Failure repair
Check NOx Upstream Sensor.
#T0046 L03 980C-6
Failure NOx Sensor Upstream (CAN): Short circuit error detected by sensor

If NOx sensor has detected short circuit fault Com_stErrBytNOxSens[5]==1 (short
Failure detection NOx), or Com_stErrBytNOxSens[6]==1 (short linear Lambda), or
Com_stErrBytNOxSens[7]==1 (short binary Lambda)
Wiring defect.
Failure cause
NOx Upstream Sensor defect.
Check wiring.
Failure repair
#T0047 L03 F5E9-E9
Failure CAN Bus Received frames : CAN-Receive-Frame BC2EDC2
Failure detection Timeout for BC2EDC2 message is detected
Defective CAN controller of Body Computer , undervoltage of BC, missing BC, CAN
Failure cause
cable connecting the BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the BC to the network, Check correct
Failure repair
functioning of the BC CAN controller and its voltage supply. Check wiring.
WB93R-8 40-87
40 TROUBLESHOOTING
#T0048 L03 5316-9

CAN NOx Sensor: Timeout Error of CAN-Receive-Frame NOX sensor (NOxSens:
Failure
NOX concentration,Lambda function,Oxygen function, sensor status, sensor error)
Failure detection Timeout of NOxSens message.
Defective CAN controller of NOx Sensor , undervoltage of NOx Sensor, missing NOx
Failure cause Sensor, CAN cable connecting the NOx Sensor is disconnected or broken. Short cir-
cuit in wiring.
Check presence and correct connection of the NOx Sensor to the network, Check
Failure repair correct functioning of the NOx Sensor CAN controller and its voltage supply. Check
wiring.

#T0049 L03 980C-9
CAN NOx Sensor Upstream: Timeout Error of CAN-Receive-Frame NOX sensor

Failure upstream (NOxSens: NOX concentration,Lambda function,Oxygen function, sensor
status, sensor error)
Failure detection Timeout of NOxSensUs message.
Defective CAN controller of NOx Sensor Upstream , undervoltage of NOx Sensor,

Failure cause missing NOx Sensor Upstream, CAN cable connecting the NOx Sensor Upstream is
disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the NOx Sensor Upstream to the network,
Failure repair Check correct functioning of the NOx Sensor Upstream CAN controller and its volt-
age supply. Check wiring.
40-88 WB93R-8
40 TROUBLESHOOTING
#T0050 L03 9EE8-FF

CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from PE to
Failure
EDC through TSC1_PE Message active
Failure detection Timeout of TSC1_PE message.
Defective CAN controller of PTO Controller, CAN cable disconnected or broken.

Failure cause
Short circuit in wiring.
Check presence and correct connection of the PTO Controller to the network, Check
Failure repair
correct functioning of the CAN controller. Check wiring.
#T0051 L03 9EE8-E9
CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from PE to

Failure
EDC through TSC1_PE Message passive

Failure detection Timeout of TSC1_PE message
Defective CAN controller of PTO Controller, CAN cable disconnected or broken.

Failure cause
Check presence and correct connection of the PTO Controller to the network, Check
Failure repair
#T0052 L03 6F10-1F
CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from VE to

Failure
EDC through TSC1_VE Message active
Failure detection Timeout of TSC1_VE message.
Defective CAN controller of Vehicle Controller, CAN cable disconnected or broken.

Failure cause
Check presence and correct connection of the Vehicle Controller to the network,
Failure repair
Check correct functioning of the CAN controller. Check wiring.
WB93R-8 40-89
40 TROUBLESHOOTING
#T0053 L03 6F10-9

Failure CAN Bus: Passive Time out for Torque Speed Control TSC1VE message
Failure detection Timeout of TSC1_VE message.

Defective CAN controller of Vehicle Controller, CAN cable disconnected or broken.
Failure cause
Check presence and correct connection of the Body Computer to the network, Check
Failure repair

#T0054 L03 86EB-E9
Failure CAN Urea Level: Timeout Error of CAN-Receive-Frame Urea Tank Level (UreaLvl)
Fault component CAN Urea Level

Failure detection Timeout of UreaLvl message.
Defective CAN controller of Urea tank level sensor , CAN cable connecting the sen-
Failure cause
sor is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the Urea tank level sensor to the network,
Failure repair Check correct functioning of the sensor CAN controller and its voltage supply. Check
wiring.
#T0055 L03 69E8-E9
CAN Bus Received frames : CAN-Receive-Frame from the Vehicle Control Module to
Failure
EDC (VM2EDC)
Failure detection Fault is detected if a time out of the message occurs.
Defective CAN controller of Vehicle Control Module , undervoltage of VCM, missing

Failure cause VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wir-
ing.
Check presence and correct connection of the VCM to the network, Check correct
Failure repair
functioning of the VCM CAN controller and its voltage supply. Check wiring.
40-90 WB93R-8
40 TROUBLESHOOTING
#T0056 L00 B3EE-E0

Failure Info: Torque Limitation active: OBD performance limiter is active.
The OBD performance limitation is activated, if there is a failure active, which causes
high NOx emissions for a certain time (1,00s, 1,00s , 1,00s or 1,00s depending on
Failure detection
the failure). The performance limiter is activated immediately within 25,13min or
39,95min (depending on limitation).
Active power reduction due to the OBD performance limiter because of too high NOx
Failure cause
emissions
Check which failure activated the performance limitation

(FID_CoVehPrfmLim%%OBD with %%=11,12,21 or 22) and perform troubleshooting
on the basis of this defect.
Failure repair
Note: The OBD performance limiter can be disabled with service tester at maximum
5,00- times for 4,00h each time, to give the possibility to drive also a fully loaded
vehicle to the next repair station.
#T0057 L01 9E00-10
Failure Battery voltage: Power stage diagnosis could be disabled due to high Battery voltage
If battery voltage > 16,50V,

Bit 3 in DevLib_stPwrStgEnaCond is SET, indicating that there is a high battery volt-
Failure detection
age and power stage monitoring is disabled for all failure where this test condition is
enabled.
Power supply is to high --> possibly external power supply connected (battery
Failure cause
charger??) or internal failure of ECU (wrong measurement of supply voltage)
Check battery status and voltage level,Disconnect external device if connected or

Failure repair
replace ECU if no supply problem is found.
WB93R-8 40-91
40 TROUBLESHOOTING
#T0058 L01 9E00-12

Failure Battery voltage: Power stage diagnosis could be disabled due to low Battery voltage
If battery voltage is < 9,00V,

Bit 2 in DevLib_stPwrStgEnaCond is SET, indicating that there is a low battery volt-
Failure detection
age and power stage monitoring is disabled for all failure where this test condition is
enabled.
Too low battery voltage, possible also during engine cranking (possibly in cold condi-
Failure cause trion), too low measurement of battery voltage possibly due to corroded contacts or
wiring harness
Chech battery state (charge state). Check connectors and wiring harness to corro-
Failure repair
sion and/or too high electrical resistance
40-92 WB93R-8
40 TROUBLESHOOTING
#T0059 L03 8110-10

Failure Catalyst efficiency fault path
NOx mass upstream/downstream of catalyst is integrated during a catalyst tempera-

ture dependent time or until integrated NOx mass upstream exceeds a defined tem-
perature dependent quantity, then integrated calculated catalyst efficency (NOX
Failure detection
downstream/ NOX upstream of catalyst) is compared to the integrated expected ref-
erence efficiency, if measured efficiency does not match expected efficiency failure is
set.
a) Too low reagent injection or DEF deposits could influence reagent dosing /mixing .
Wrong reagent concetration
b)Wrong NOx measurement (NOx Sensor measures too high values) Engine NOx
raw emissions higher than epxected (humidity sensor measures too wet air, injection
timing anticipated, fuel pressure sensor measures too low fuel pressure...)
Failure cause
c) ATS efficiency reduction could be influenced by oil contamination due to :
obstructed turbo oil drain
orbstructed engine crankcase vent , engine blow-by filter clogging .
d) ATS efficiency reduction due to ATS contamination from fuel contents ( e.g sulphur
contamination)
Check Reagent concentration

Check Dosing quantity of SCR system and inspect dosing system
Check if engine raw emissions are OK (e.g. drive vehicle at constant speed without
Reagent injection and compare measured with estimated NOx with tester), if not
check:
Check NOx Sensor
Failure repair
Fuel pressure sensor
Injection timing
Check for any ATS /exhaust oil contamination .Remove obstruction or replace oil
drain line Check Pressure crackcase valve (PCV) valve and clear obstructionRe-
place blow-by filter if necessary.
Perform service deSOx and check for efficiency after procedure
WB93R-8 40-93
40 TROUBLESHOOTING
#T0060 L01 8110-1F

Failure SCR Control: Too high efficiency of the catalyst system
SCR efficiency ratio "expected/measured" Filtered by 10,01s < 1,01- (= measured

Failure detection
efficiency > 10009765625 % of expected
Reagent with too high UREA concentration (>>32%)
Too high Reagent injection

Failure cause
Wrong NOx measurement (NOx Sensor measures too low values)
Engine NOx raw emissions lower than epxected (humidity sensor measures too dry
air, injection timing retarded, fuel pressure sensor measures too high fuel pressure...)
Check Reagent, if correct concentration
Check Dosing quantity of SCR system
Check if engine raw emissions are OK (e.g. drive vehicle at constant speed without
Failure repair Reagent injection and compare measured with estimated NOx with tester), if not
check:
Check NOx Sensor
Humidity Sensor
Fuel pressure sensor
Injection timing
40-94 WB93R-8
40 TROUBLESHOOTING
#T0061 L03 A20C-2

Failure NOx Sensor: Lambda value measurement from NOx sensor incorrect
Lambda difference between value measured by NOx sensor downstream and calcu-
Failure detection lated lamda value (from AsMod) is outside window defined by maximum/minimum
curves, dependent on lambda value itself
NOx sensors downstream is not measuring correct lambda values or air/fuel quantity
estimation is incorrect.
Failure cause Check obstructions:

- Obstructed turbo oil drain
- Obstructed engine crankcase vent
- Clogged engine blow-by filter
Check NOx sensor, check system for presence other faults involving fuelling or air
quantity determination.
Remove obstruction or replace oil drain line

Failure repair
Check Pressure crackcase valve (PCV) valve and clear obstruction
Replace blow-by filter if necessary.

#T0062 L03 980C-2
Failure Upstream Lambda NOx sensor monitoring

Lambda difference between value measured by NOx sensor upstream and calcu-
Failure detection lated lambda value (from AsMod) is outside window defined by maximum/minimum
curves, dependent on lambda value itself.
NOx sensors upstream is not measuring correct lambda values or air/fuel quantity
Failure cause
estimation is incorrect.
Check NOx sensor, check system for presence other faults involving fuelling or air
Failure repair
quantity determination.
WB93R-8 40-95
40 TROUBLESHOOTING
#T0063 L03 9A0C-A

Failure NOx sensor: measured value stuck
Difference between maximal (DStgy_rMaxNOxCat2Ds_mp) and mini-

Failure detection mal(DStgy_rMinNOxCat2Ds_mp) measured NOx signal over defined sample period
is below 25,00ppm.
Failure cause NOx sensor defective or incorrectly mounted.
Failure repair Check sensor mounting, check NOx sensor or replace it.

#T0064 L03 C6EA-E2
Failure Upstream NOx sensor plausibility monitoring

The difference DStgy_rNOxSensUsPlDiff_mp between the NOx estimation and the
Failure detection
corrected NOx sensor signal is above the threshold DStgy_rNOxSensUsPlRef_mp
NOx sensors upstream is not measuring correct values, engine is emitting unex-
Failure cause
pected quantity of NOx or NOx estimation model is incorrect.
Check NOx sensor, check presence of other failures which could influence NOx
Failure repair
emission or NOx estimation.
#T0065 L03 7602-1F
Failure EEPROM : EEP Erase Error

If sector erase (Flash memory) cannot be performed or successfully completed, an

Failure detection
error will be registered.
Failure cause Wrong programming/flashing of the ECM, internal defect of the ECM.
Failure repair Try to flash the ECM correctly with a proper dataset, if defect persists: replace ECM.
40-96 WB93R-8
40 TROUBLESHOOTING
#T0066 L03 7602-13

Failure EEPROM : EEP Read Error based on the error for more blocks
Failure detection If at least three memory blocks cannot be read, an error will be registered.

#T0067 L03 7602-E
Failure EEPROM : EEP Write Error based on the error for one block
Failure detection If one memory block cannot be written more than 3 times, an error will be registered
#T0068 L03 630A-12
Failure EGR OBD Monitoring error
Fault component EGR Control
Error is set if a minimum expected variation of intake pressure is not observed in a

Failure detection
maximum allowed time interval (100,00ms) due to the performed EGR sweep.
Failure cause Possible causes: EGR valve/path tampering, severe EGR cooler/path clogging.
Inspect EGR path.
Case 1 - tampered: restore original connections/configuration.
Failure repair
Case 2 - clogged: try cleaning clogged part (e.g. with backflow compressed air), if not
effective, replace clogged part.
WB93R-8 40-97
40 TROUBLESHOOTING
#T0069 L03 E70A-1F

Failure EGR Valve: Current limited
Fault component EGR Valve
Failure detection If actuator current is set at its limit value, of 1.76 A for longer than debounce time.
EGR Valve actuation current is higher than allowed to reach the desired position:
Failure cause possibly electrical problem inside EGR Valve actuator or wiring harness ("short" cir-
cuit) or mechanical sticking of valve
Check EGR valve electric circuit

Failure repair
Check mechanical EGR valve functionality
#T0070 L03 1B00-F
Failure Permanent governor deviation for valve

The governor deviation for the monitoring is formed from the difference between
EGRVlv_rDesValFltMon and EGRVlv_rActSign.
Failure detection
A persistent governor deviation will be detected if the governor deviation is greater
than the threshold value 10,00% at 0,00% and the governor deviation is present for
longer than the time from EGRVlv_tiDebGovDvtDef_MAP.
Desired EGR valve position can not be reached.
Failure cause EGR valve sticks.
EGR valve position sensor mismatched.
Check for jammed valve.

Failure repair Clean EGR valve, try to open/closed manually the valve
Replace EGR Valve
40-98 WB93R-8
40 TROUBLESHOOTING
#T0071 L03 1B00-11

The governor deviation for the monitoring is formed from the difference between
EGRVlv_rDesValFltMon and EGRVlv_rActSign.
Failure detection
A persistent governor deviation will be detected if the governor deviation is less than
the threshold value -10,00% at 0,00%, and the governor deviation is present for
longer than the time from EGRVlv_tiDebGovDvtDef_MAP.
Desired EGR valve position can not be reached.
Failure cause EGR valve sticks.
EGR valve position sensor mismatched.

Failure repair Clean EGR valve, try to open/closed manually the valve
Replace EGR Valve.
#T0072 L03 1DEC-E5
Failure Open load error for power stage
Failure detection Hardware reports an "open load" (OL) error
Electrical problem of the EGR valve actuator: broken wiring harness, no contact of
Failure cause
connector, internal broken line in actuator.
Check if wiring harness is interrupted (open circuit).

Failure repair
Check if EGR valve actuator is interrupted (open circuit).
WB93R-8 40-99
40 TROUBLESHOOTING
#T0073 L03 1EEC-E6

Failure Over temperature error for H-bridge
Failure detection Over Temperature of TLE7209/CJ230 error

Failure cause High battery voltage, high temperature inside ECU, high load or wiring problem.
No reaction needed if failure isn't present after short time, check load and output,
Failure repair
check wiring, replace ECU.

#T0074 L03 1DEC-E3
Failure Short circuit to battery on Out1 error for H-bridge
Failure detection Short Circuit to Battery at Out1 of TLE7209/CJ230 error.
Failure cause Short circuit of wiring to external source.
Check if wiring harness is shorted to battery.

Failure repair
Check EGR valve
#T0075 L03 1EEC-E3

Check if wiring harness is shorted to battery.

Failure repair
Check EGR valve
40-100 WB93R-8
40 TROUBLESHOOTING
#T0076 L03 1DEC-E4

Failure Short circuit to ground on Out1 error for H-bridge
Failure detection Short Circuit to Ground at Out1 of TLE7209/CJ230 error.

Failure cause Short circuit of wiring to ground.
Check if wiring harness is shorted to ground.

Failure repair
Check EGR valve.

#T0077 L03 1EEC-E4
Check if wiring harness is shorted to ground.

Failure repair
Check EGR valve
WB93R-8 40-101
40 TROUBLESHOOTING
#T0078 L03 1FEC-E6

Failure Short circuit over load error for H-bridge
Short Circuit over Load error.
In case of short-circuit-to-ground error, the High side switches are closed. If there is
no more short-circuit-to-ground error then it is detected as short-circuit-over-load
error.
Failure detection
In case of short-circuit-to-battery error, low side switches are closed. If there is no
more short-circuit-to-battery error then it is detected as short-circuit-over-load error.
If short-circuit overload error is detected, then the pre-existing SCG/SCB error is

healed.
Failure cause Short circuit of wiring.
Failure repair Check if wiring harness leads are shorted.
#T0079 L03 1FEC-E5
Failure EGR Valve: Under voltage of H-bridge
Failure detection Hardware reports Under Voltage error
Too high Voltage fluctuations in system

Failure cause
internal failure of ECU
Failure repair Check of EGR Valve Actuator wiring (instable power supply).
40-102 WB93R-8
40 TROUBLESHOOTING
#T0080 L03 E70A-0

Failure DFC for valve position sensor voltage SRC high
Failure detection The sensor raw signal EGRVlv_uRaw (voltage) is above 4,86V
Failure cause Short circuit of wiring to external source or defective EGR valve position sensor
Failure repair Check of wiring or replace EGR valve position sensor

#T0081 L03 E70A-1
Failure DFC for valve position sensor voltage SRC low
Failure detection The sensor raw signal EGRVlv_uRaw (voltage) is below 225,00mV
Failure cause Short circuit of wiring to ground or defective EGR valve position sensor
Failure repair Check of wiring or replace EGR valve position sensor
#T0082 L00 6E00-10
Failure Engine Protection : Engine temperature reaches prewarning level
Engine temperature > 107,96°C
Failure detection Engine temperature is defined as:
Water coolant temperature
Failure cause Too high engine temperature

Cooling system problem or simply overheated engine due to heavy use or high envi-
Failure repair
ronmental temperature
WB93R-8 40-103
40 TROUBLESHOOTING
#T0083 L02 6E00-0

Failure Engine Protection : Engine temperature reaches warning level
Engine temperature > 111,96°C
Failure detection Engine temperature is defined as:
Water coolant temperature
Failure cause Too high engine temperature
Cooling system problem or simply overheated engine due to heavy use or high envi-
Failure repair
ronmental temperature

#T0084 L03 170E-E
Failure Injection cut off: Injection cut off demand (ICO) for shut off coordinator
Fault component ECU internal Check
If torque or injection quantity are not plausible (monitoring error) and engine speed
Failure detection
Epm_nEng > 1200,00rpm.
Another failure requested engine speed limitation.

Failure cause This failure path should always appear in failure memory with another lead failure
from ECM monitoring level (level 2)
If another lead failure from ECM monitoring level is not present try to flash the ECM
Failure repair
correctly with a proper dataset, if defect persists: replace ECM.
40-104 WB93R-8
40 TROUBLESHOOTING
#T0085 L02 BE00-0

Failure Engine Protection : Over speed detection in component engine protection
Fault component Engine Overspeed
Failure detection Engine speed exceeds threshold 3300,00rpm

Failure cause Engine overspeed has occurred
No reactions necessary only if this fault/information status reoccurs frequently. In this

case check driving conditions of vehicle, engine speed acquisition and injection sys-
Failure repair
tem for quantity set point and actual value during fault recognition, check also for
ECM errors.
#T0086 L03 6C00-0
Failure Ambient pressure sensor : Signal Range Check High failure
Fault component Ambient pressure sensor

Failure detection The sensed raw voltage value EnvP_uRaw is above 4,88V
Failure cause Ambient pressure sensor inside ECU is defect
Failure repair Replace ECU
#T0087 L03 6C00-1
Failure Ambient pressure sensor : Signal Range Check low failure
Fault component Ambient pressure sensor
Failure detection The sensed raw voltage value EnvP_uRaw is less than 190,00mV
Failure cause Ambient pressure sensor inside ECU is defect
WB93R-8 40-105
40 TROUBLESHOOTING
#T0088 L03 AB00-0

Failure Ambient temperature sensor : Signal Range Check High
Fault component Ambient temperature sensor
Failure detection The sensed raw voltage value EnvT_uRaw is above 4,93V
Failure cause Sensor defective or short circuit in wiring to external source

#T0089 L03 AB00-1
Failure Ambient temperature sensor : Signal range check low
Fault component Ambient temperature sensor
Failure detection The sensed raw voltage value EnvT_uRaw is less than 198,00mV
Failure cause Sensor defective or short circuit wiring to ground
#T0090 L01 7C02-2
Failure Camshaft Sensor : Camshaft signal diagnose - disturbed signal
Fault component Engine speed sensing
If camshaft signal does not match pattern (edge distance, level) or not all expected
Failure detection camshaft edges detected during a engine revolution. Different monitoring strategies
are active during synchronisation phase (engine start) and normal engine running.
Cam Shaft speed signal not stable:

- electrical intermittent open circuit
Failure cause - sensor not fixed correctly
- electrical disturbances due to damaged isolation of wiring harness
- electrical disturbances due to special electrical features
Check wiring, sensor installation and proper functioning of camshaft phase sensor
(evaluate raw signals)
Failure repair Check if sensor fixed correctly (should not be moveable),check wiring harness and
contacts, check if electrical lines with high electric performance are additionally
installed (components not validated by the vehicle manufacturer).
40-106 WB93R-8
40 TROUBLESHOOTING
#T0091 L03 7C02-9

Failure Camshaft Sensor : Camshaft signal diagnose - no signal
If crankshaft signal shows no errors and no camshaft edge is detected for at least
Failure detection
4,00- crankshaft revolutions.
Engine Camshaft timing incorrect.

Camshaft speed sensor defective
Failure cause
Wiring harness "open circuit"
Camshaft sensor not mounted
Check if sensor mounted correctly

Failure repair Check wiring harness
Check sensor functionality and replace it if necessary
#T0092 L01 7C02-1F
Failure Camshaft Sensor : Camshaft offset angle exceeded

Offset between crankshaft signal and expected camshaft first edge < -10,00°CrS OR
Failure detection
> 10,00°CrS for more than 4,00- consecutive cycles
Camshaft sensor position deviates form crankshaft position:

- camshaft mal positioned (e.g. tooth belt: 1 tooth skipped)
Failure cause - camshaft position wheel mal positioned (if adjustable)
- camshaft sensor position mal positioned (if adjustable)
- crankshaft signal mal positioned (same as camshaft)
Check correct positions of camshaft signal wheel and crankshaft signal wheel to pis-
Failure repair
ton position
WB93R-8 40-107
40 TROUBLESHOOTING
#T0093 L03 7D02-2

Failure Crankshaft Sensor : Crankshaft signal diagnose - disturbed signal
A disturbed crankshaft signal exists if the number of signal plausibility errors

Failure detection
EpmCrS_ctErrSig reaches the threshold 80,00-.
High vibration of crank shaft signal sensor.
Intermittent open circuit of sensor.

Failure cause
Electrical disturbances due to damaged isolation of wiring harness.
Electrical disturbances due external electromagnetic disturbances.
Check if sensor fixed correctly (should not be moveable).
Check wiring harness and contacts.

Failure repair
Check if electrical lines with high electric performance are additionally installed (com-
ponents not validated by the vehicle manufacturer)
#T0094 L03 7D02-9
Failure Crankshaft Sensor : Crankshaft signal diagnose - no signal
No crankshaft signal available for at least 4,00- camshaft revolutions.

Failure detection
Camshaft signal is tested and plausible.
Crank shaft speed sensor defect

Failure cause Crank shaft speed sensor not mounted correctly
Crank shaft speed sensor not connected electrically, open circuit or short circuit.
Check if crank shaft speed sensor mounted correctly

Failure repair Check wiring harness to open/short circuit
Check crank shaft speed sensor for correct function and replace it if necessary
40-108 WB93R-8
40 TROUBLESHOOTING
#T0095 L02 BE14-12

Failure Liquid HC in the exhaust system
Fault component Exhaust System
Fault is detected if the liquid mass of HC in the exhaust system exceeds the thresh-
Failure detection
old of 7500,00mg/l
Failure cause Big mass of liquid HC in the exhaust system
Increase the engine speed above 1100 rpm inside 30 minutes in order to decrease
Failure repair
the level of HC in the exhaust system.

#T0096 L01 BE14-1
Failure Accumulated HC in the exhaust system
Fault component Exhaust System

Fault is detected if the accumalated HC level in the exhaust system exceeds the sec-
Failure detection
ond warning level 6500,00mg/l
Failure cause Liquid HC in the exhaust system
Failure repair Decrease the level of HC in the exhaust system.
#T0099 L03 A90F-5
Failure Fuel filter heater: No load error in power stage of fuel filter heating
Fault component Fuel filter heater
Failure detection The power stage hardware reports a "no load" (OL) error.
Failure cause Broken or disconnected wiring or defective fuel filter heater.
Failure repair Check of wiring or replace fuel filter heater
WB93R-8 40-109
40 TROUBLESHOOTING
#T0100 L03 A90F-6

Failure Fuel filter heater: Over Temperature error at ECM power stage
Hardware reports an over temperature error (OT) on the power stage for the Fuel Fil-
Failure detection
ter heater.
Failure cause High battery voltage, high temperature inside ECU, high load or wiring problem
Failure repair Check load and output, check wiring, replace ECU

#T0101 L03 A90F-3
Failure ECU Power stages : Short circuit to battery error in power stage of fuel filter heating
Failure detection The power stage hardware reports a "short circuit to battery" (SCB) error.
Failure cause Short circuit of wiring to external source or inside fuel filter heater
Failure repair Check of wiring, replace fuel filter heater
#T0102 L03 A90F-4
Failure ECU Power stages : Short circuit to ground error in power stage of fuel filter heating
Failure detection The power stage hardware reports a "short circuit to ground" (SCG) error.
Failure cause Short circuit of wiring to ground or inside fuel filter heater
Failure repair Check of wiring, replace fuel filter heater
40-110 WB93R-8
40 TROUBLESHOOTING
#T0103 L01 6100-1F

Failure Water sensor in the fuel filter : Water in fuel level sensor defect detection
Fault component Water in Fuel determination
If the digital input is "active" longer than 200,00ms the sensor is in state "water in fuel
detected".
Failure detection
Water in fuel is true, if sensor is in state "water in fuel detected" longer than 60,00s
Water in fuel filter
Failure cause
Sensor defective
Clean fuel filter filter

Failure repair
Check Sensor

#T0104 L03 9A0C-1F
Failure NOx Sensor (CAN): NOx Sensor detects incorrect supply
Failure detection The NOx Sensor sends the message "Supply not OK" (Bits 6-7 = 00)
Failure cause Defective NOx sensor supply
Check wiring harness

Failure repair
Check NOx Sensor
WB93R-8 40-111
40 TROUBLESHOOTING
#T0105 L03 900C-1F

Failure NOx Sensor Upstream (CAN): NOx Sensor detects incorrect supply
The NOx Sensor upstream sends the message "Sensor supply not OK" (Bits 6-7 =
Failure detection
00)
Failure cause Defective NOx sensor upstream supply sensor supply.

Failure repair
#T0106 L03 AE00-0
Failure Fuel temperature Sensor : Signal Range check high for fuel temperature sensor
Fault component Fuel Temp Sensor

Failure detection The sensor raw signal >4,93V.
Failure cause Sensor defective or short circuit to external source
Failure repair Check wiring; Replace fuel temperature sensor.
#T0107 L03 AE00-1
Failure Fuel temperature Sensor : Signal Range check low for fuel temperature sensor
Fault component Fuel Temp Sensor
Failure detection The sensor raw signal < 198,00mV.
Failure cause Sensor defective or short circuit to ground
Failure repair Check wiring; Replace fuel temperature sensor.
40-112 WB93R-8
40 TROUBLESHOOTING
#T0108 L03 64E9-F3

Failure DFC for faulty diagnostic data transmission or protocol error
Fault component Glow Plug
Failure detection Faulty diagnostic data transmission or protocol error

Failure cause Defective Glow Plug system
Check of Glow Plug Control Unit wiring harness.

Failure repair
Replace Glow Plug Control Unit.

#T0109 L03 A402-5
Failure Glow Plug: Open Load error of low voltage glow system power stage
Failure detection The power stage reports an Open Load error.
Failure cause Broken or disconnected wiring or defective glow plug indicator lamp
Check of Glow Plug System wiring harness.

Failure repair
#T0110 L03 A402-6
Failure Over temperature error on ECU power stage for Glow plug Low Voltage System
Failure detection The power stage detects an over temperature error.
High battery voltage, high temperature inside ECU, high load or wiring problem or
Failure cause
proble with glow plug (resp relay if system has a relay between ECU and glow plug)
Failure repair Check glow plug continuity.
WB93R-8 40-113
40 TROUBLESHOOTING
#T0111 L03 A402-3

Failure Short circuit to battery error for Low Voltage System
Failure detection The power stage reports an SCB error.

Short circuit of wiring to external source or inside glow plug (resp relay if system has
Failure cause
a relay between ECU and glow plug)

#T0112 L03 A402-4
Failure Glow Plug: Short Circuit to Ground error of low voltage glow system power stage

Failure detection The power stage reports an SCG error.
Short circuit of wiring to ground or inside glow plug (resp relay if system has a relay
Failure cause
between ECU and glow plug)

#T0113 L03 CC14-4
Failure Array of DFCs for short circuit in 1th Glow Plug
Failure detection A short circuit or over current in the glow plug of cylinder 1 is detected
Failure cause Short circuit or over current in glow plug of cylinder 1 detected
Failure repair Check and replace glow plug of cylinder 1
40-114 WB93R-8
40 TROUBLESHOOTING
#T0114 L03 CD14-4


#T0115 L03 CE14-4
#T0116 L03 CF14-4
WB93R-8 40-115
40 TROUBLESHOOTING
#T0117 L01 7402-2

Failure EEPROM : Error in EEPROM block EEPData1. SD correction can not be calculated
If the correction values, used in pressure rail regulation, are corrupted or inaccessi-
Failure detection
ble.
Failure repair Reprogram ECM, replace ECM

#T0118 L01 E2EC-E5
Failure Hydraulic Load Deactivation: Open load error on the powerstage
Fault component Hydraulic Load Deactivation
Failure detection The power stage hardware reports an open load error.
Failure cause Wiring harness damaged (leads interrupted).
Failure repair Check if wiring harness is interrupted. Replace cable.
#T0119 L03 E2EC-E6
Failure Hydraulic Load Deactivation: Over temperature error on the powerstage
Failure detection The power stage hardware reports an over temperature error.
Failure cause Wiring harness damaged (leads shorted).

Failure repair Check if wiring harness is damaged. Replace cable.
40-116 WB93R-8
40 TROUBLESHOOTING
#T0120 L03 E2EC-E3

Failure Hydraulic Load Deactivation: Short circuit to battery error on the powerstage
Failure detection The power stage hardware reports a short circuit to battery error.
Failure cause Wiring harness damaged (shorted to battery).

#T0121 L03 E2EC-E4
Failure Hydraulic Load Deactivation: Short circuit to ground error on the powerstage
Failure detection The power stage hardware reports a short circuit to ground error.
Failure cause Wiring harness damaged (shorted to ground).
#T0122 L01 9D00-1
Failure Injection control: check of minimum rail pressure
Fault component Injector
If the rail pressure falls below 130,00bar or a limit value from curve InjVlv_pMin
Failure detection depending on engine temperature (160,00bar at -30,04°C at -30 degC down to
160,00bar at 109,96°C at 80 degC engine temperature)
Rail pressure controller problem (metering unit sticking), High Pressure pump effi-
Failure cause ciency too low, no fuel delivery from gear pump to high pressure pum or system leak-
ages
Check for rail or injector leakages.
Check for clogged main fuel filter.
Failure repair
Replace metering unit.
Replace high pressure pump.
WB93R-8 40-117
40 TROUBLESHOOTING
#T0123 L01 8B02-9
Failure Measured injection closing time exceeds a limit 1

The difference of the measured closing time IVActr_tiClsdActvVCC to the working-

point dependent reference value from a map exceeds a MIN/Max tolerance curve for
Failure detection at least 65535,00- OR
the energizing time correction IVActr_tiClsdCorETVCC is exceeds a MIN/MAX curve
for at least 65535,00-
Failure cause Wrong IMA programming or drifted injector on cylinder 1.

Check programming of IMA code correspond to the code on the injector, replace
Failure repair
injector on cylinder 1.
#T0124 L01 8C02-9

Failure repair
40-118 WB93R-8
40 TROUBLESHOOTING
#T0125 L01 8D02-9


Failure repair
#T0126 L01 8E02-9

Failure repair
WB93R-8 40-119
40 TROUBLESHOOTING
#T0127 L03 8B02-1F

Injector Adjustment programming: check of missing injector adjustment value pro-
Failure
gramming (IMA codes): injector %
the checksum of the injector adjustment code words is not correct

OR
the basic correction quantity of at least 1 correction class not within the acceptable
Failure detection
range for this class
OR
no injector adjustment values could be read due to faulty EEPROM access.
Invalid IMA code has been programmed
Failure cause wrong programming/flashing of the EDC (initialization of EEPROM)
internal defect of the ECU
Reprogram IMA code

Failure repair
if defect persists: replace EDC

#T0128 L03 8E02-1F

Failure

OR
Failure detection
OR
Reprogram IMA code

Failure repair
40-120 WB93R-8
40 TROUBLESHOOTING
#T0129 L03 8C02-1F

Failure

OR
Failure detection
OR
Reprogram IMA code

Failure repair

#T0130 L03 9002-1F

Failure

OR
Failure detection
OR
Reprogram IMA code

Failure repair
WB93R-8 40-121
40 TROUBLESHOOTING
#T0131 L01 8B02-2

Failure Injector Adjustment: IMA programming not compatible to software for injector cyl 1
Quantity adjustment resolution (IVAdj_stQntAdjRes = 0,00-) is compared to Type of

Failure detection IMA supported by software (IVAdj_stQntAdjCod = 0,00-), if there is not a match the
fault is raised.
Failure cause Wrong IMA codes/programming, or injectors not compatible to used software.
Failure repair Check injector type, check IMA programming.

#T0132 L01 8C02-2

fault is raised.
#T0133 L01 8D02-2

fault is raised.
40-122 WB93R-8
40 TROUBLESHOOTING
#T0134 L01 8E02-2


fault is raised.

#T0135 L03 ED0A-3
Injector, solenoid : Short circuit in an injection bank 1 (all injectors of the same bank
Failure
can be affected)

If the measured pattern for the evaluation of injector bank 1 is equal to applied
Failure detection
behaviour bit pattern for short circuit error detection.
Failure cause Short circuit in wiring harness or injector connected to bank 1
Failure repair Check the wiring and injectors connected to bank 1.
#T0136 L03 EE0A-3
Injector, solenoid : Short circuit in an injection bank 2 (all injectors of the same bank
Failure
can be affected)
If the measured pattern for the evaluation of injector bank 2 is equal to applied
Failure detection
behaviour bit pattern for short circuit error detection.
Failure cause Short circuit in wiring harness or injector connected to bank 2

Failure repair Check the wiring and injectors connected to bank 2.
WB93R-8 40-123
40 TROUBLESHOOTING
#T0137 L03 6102-C

Failure Injector: ECM internal failure of Injector actuation (chip error)
Fault component ECU Internal
Failure detection Chip error in the CY33 power stage component

Failure cause Defective ECM
Failure repair Replace ECM

#T0138 L03 8B02-5
Injector, solenoid: Open load error of an injector 1 (interruption of an electric connec-

Failure
tion)

If the measured pattern for the injector evaluation of cylinder 1 is equal to applied
Failure detection
behaviour bit pattern for open load detection.
Failure cause Open load for injector of cylinder 1 is detected.
Failure repair Check wiring, replace fuel injector of cylinder 1.
#T0139 L03 8E02-5

Failure
tion)
Failure detection
40-124 WB93R-8
40 TROUBLESHOOTING
#T0140 L03 8C02-5

Failure
tion)
Failure detection

#T0141 L03 9002-5

Failure
tion)

Failure detection
#T0142 L03 8B02-3
Failure Injector, solenoid Power stage : Short circuit in the injector 1

Failure detection
behaviour bit pattern for short circuit detection.
Failure cause Short circuit in wiring or injector
WB93R-8 40-125
40 TROUBLESHOOTING
#T0143 L03 8E02-3

Failure detection

#T0144 L03 8C02-3
Failure detection
#T0145 L03 9002-3

Failure detection
40-126 WB93R-8
40 TROUBLESHOOTING
#T0146 L04 A205-2

Failure Fuel Metering Unit : Intermittent contact between ECU and MeUn
Fault component Fuel metering unit
If the number of brief interruptions/short circuits > 1000,00-, and if the time between
Failure detection
the errors is less than 3,00s.
Bad Contacts on Connector
Failure cause "Broken" wiring harness or Insulation (--> short circuits)
Defective Metering Unit (MeUn)
Check Connector
Failure repair Check Wiring Harness
Check Metering unit (MeUn)

#T0147 L03 A205-5
Failure Fuel metering unit: open load of metering unit output
Failure detection Hardware reports "open load" (OL) error
Failure cause Broken or disconnected wiring, defective metering unit
Failure repair Check of wiring or metering unit
#T0148 L03 A205-6
Failure Fuel metering unit: over temperature of device driver of metering unit
Failure detection Hardware reports "overtemperature" (OT) error
Failure cause Battery overvoltage, high load or wiring problem. Fuel overheating.
Check of wiring or metering unit.

Failure repair Check resistance of wiring or metering unit.
Check fuel circuit/temperature
WB93R-8 40-127
40 TROUBLESHOOTING
#T0149 L03 A305-3

Failure Fuel Metering Unit : short circuit to battery
Hardware reports a Short Circuit to Battery error on power stage for Metering Unit at
Failure detection
Low Side
Failure cause Short circuit of wiring to battery or inside Metering Unit at Low Side
Failure repair Check of wiring, replace Metering Unit

#T0150 L03 A305-4
Failure Fuel Metering Unit : short circuit to ground
Hardware reports a Short Circuit to Ground error on power stage for Metering Unit
Failure detection
Low Side
Failure cause Short circuit of wiring to ground or inside Metering Unit at Low Side
Failure repair Check of wiring, replace Metering Unit
#T0151 L03 C415-E
Analog Digital Converter (ADC) : Diagnostic fault check to report the NTP error in
Failure
ADC monitoring
Failure detection Error in the check with the no-load test pulse operation (NTP)
Failure cause ECM internal failure

40-128 WB93R-8
40 TROUBLESHOOTING
#T0152 L03 C415-1F

Failure Analog Digital Converter (ADC) : Diagnostic fault check to report the ADC test error
A fixed test input voltage is cyclically converted by ADC, its value MoCADC_uTst_mp
Failure detection should be in range between 4,73V and 4,83V, if not a counter is incremented. If coun-
ter exceeds 15,00- failure is detected.

#T0153 L03 C415-2
Analog Digital Converter (ADC) : Diagnostic fault check to report the error in Voltage
Failure
ratio in ADC monitoring

If the ratio between 3.3V and 5V voltage supply converted is not in range between
Failure detection
0,951/1 and 1,051/1.
#T0154 L03 E8-FF
Analog Digital Converter (ADC) : Diagnostic fault check to report errors in

Failure
query-/response-communication
Failure detection If one of the error counters exceed limit.
Defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of
Failure cause
the EDC. Disturbed SPI-Bus.
If error exists only temporary (i.e. injection reoccurs) error can be ignored and error
Failure repair deleted in the fault memory. In case of a permanent error the injection remains
blocked and the ECU has to be replaced
WB93R-8 40-129
40 TROUBLESHOOTING
#T0155 L03 1E8-FF

Analog Digital Converter (ADC) : Diagnostic fault check to report errors in SPI-com-
Failure
munication
If the error counter MoCCom_ctErrSPI is greater than 0 and there is no active

Failure detection
shut-off path test
Failure cause Disturbed SPI-Bus
If ECM functions correctly after recovery only temporary SPI error occurred and fault
Failure repair memory can be deleted and error ignored. If permanent SPI error is present and the
ECM does not leave boot block --> Replace ECM
#T0156 L03 7402-E
Analog Digital Converter (ADC) : Diagnostic fault check to report multiple error while
Failure
checking the complete ROM-memory
Failure detection If checksum errors in ROM-memory blocks are detected.
Failure cause Corrupted datas in the ECM,ECM internal failure
Failure repair Reprogram ECM, replace ECM
#T0157 L03 1E8-E9
Failure Power stages, Injector : Loss of synchronization sending bytes to the MM from CPU
Wrong response from processor to CY320 (power stage supply), detected during
Failure detection
Shut Off Path test
Failure cause ECM internal failure.
Failure repair Try to flash the ECM correctly with a proper dataset, if defect persists replace ECM.
40-130 WB93R-8
40 TROUBLESHOOTING
#T0158 L03 7502-E

Power stages, Injector : DFC to set a torque limitation once an error is detected
Failure
before MoCSOP's error reaction is set
At least one error detected in redundant shut off paths test (MoCSOP_st >0) and also
Failure detection
injector diagnostic reported an error (bit 13 in MoCSOP_st is additionally set)
Failure cause ECM internal failure or injector problem

#T0159 L03 2E8-E9
Failure Power stages, Injector : Wrong set response time

Failure detection Timeout error of monitoring module
#T0160 L03 2E8-FF
Failure Power stages, Injector: Too many SPI errors during MoCSOP execution
Failure detection If faulty communication over SPI detected during Shut Off Path test
WB93R-8 40-131
40 TROUBLESHOOTING
#T0161 L03 8E13-1F

Power stages, Injector : Diagnostic fault check to report the error in under voltage
Failure
monitoring
Failure detection Under voltage detected during Shut Off Path test

#T0162 L03 3E8-FF
Power stages, Injector : Diagnostic fault check to report that WDA is not working cor-
Failure
rect

Failure detection Implausible response in the power stage feedback during Shut Off Path test
#T0163 L03 3E8-E9
Power stages, Injector : OS timeout in the shut off path test. Failure setting the alarm
Failure
task period
Alarm task cannot be set or reset detected after having detected a timeout problem
Failure detection
during Shut Off Path test
40-132 WB93R-8
40 TROUBLESHOOTING
#T0164 L03 4E8-FF

Failure Power stages, Injector : Diagnostic fault check to report that the positive test failed
Failure detection Irreversible error bit 10 set in MoCSOP_st


#T0165 L03 4E8-E9
Power stages, Injector : Diagnostic fault check to report the timeout in the shut off
Failure
path test

Failure detection Timeout in the power stage feedback detected during Shut Off Path test
#T0166 L03 8E13-E
Power stages, Injector : Diagnostic fault check to report the error in overvoltage mon-
Failure
itoring
Failure detection Over voltage detected during Shut Off Path test

WB93R-8 40-133
40 TROUBLESHOOTING
#T0167 L04 5B00-1F

Failure ECU Internal: Diagnostic fault check to report the accelerator pedal position error
Implausible accelerator pedal voltage.

Failure detection Fault is detected if there is a implausibilty between Low Idle Switch and APP1 volt-
age.
Failure cause ECM internal failure or calibration error.
Failure repair Check wiring or replace accelerator pedal.

#T0168 L04 E8-EE
Failure Engine speed : Diagnostic fault check to report the engine speed error

Fault is set if difference between Level2 speed (MoFESpd_nEngL2_mp) and Level1
Failure detection
speed (Epm_nEngLRes) > 400,00rpm.
#T0169 L04 4115-2
Failure Injection control : Error in the plausibility of the injection energizing time
Implausible injection energizing time for either Pilot Main or Post-injection, if the dif-
Failure detection
ference between measured and programmed injection duration > 13,11ms

40-134 WB93R-8
40 TROUBLESHOOTING
#T0170 L04 4115-1F

Failure Injection control : Error in the plausibility of the start of energizing angles
Implausible Start of Energising of either Main or a Pilot or a Post-injection, detection

Failure detection
not inhibited by another failure.

#T0171 L04 5E8-FF
Level 2 Monitoring: Error in the plausibility of the energizing times of the zero fuel
Failure
quantity calibration

The energising times of the zero fuel quantity calibration ZFC or ZFL are outside tol-
Failure detection erance range defined by a minimum curve MoFInjQnt_tiZFCETMin and maximum
curve MoFInjQnt_tiZFCETMax.
#T0172 L04 8E8-FF
Failure Level 2 Monitoring : Diagnostic fault check to report the error due to Over Run
The current energising time > engine speed dependant limit (from 6,00ms at 0,00rpm
Failure detection
to 200,00ms at 4000,00rpm ).

WB93R-8 40-135
40 TROUBLESHOOTING
#T0173 L04 5C04-1F

Level 2 Monitoring : Diagnostic fault check to report the error due to injection quantity
Failure
correction
One of the following conditions fulfilled:
Correction of Main injection > 655,34mg while all Pilot quantities (1,2,3) are 0.
Correction of Main injection exceeds the maximum possible correction of 655,34mg

or falls below -655,36mg by more than 655,34mg, while at least one of the 3 Pilot
quantities > 0.
Correction of Pilot injection 1 > 655,34mg while all Pilot quantities (1,2,3) are 0.
Correction of Pilot injection 1 exceeds the maximum possible correction of 655,34mg

or falls below -655,36mg by more than 655,34mg, while at least one Pilot quantity
(1,2,3) is not 0.
Failure detection
Correction of Pilot injection 2 > 655,34mg while both quantities of Pilot 2 and 3 are 0.

or falls below -655,36mg by more than 655,34mg, while at least one of the Pilot
quantities 2 and 3 is not 0.
Correction of Post injection 2 > 655,34mg while both quantities of Main and Post 2
are 0.

or falls below -655,36mg by more than 655,34mg, while at least one of the quantities
Main and Post 2 is not 0.
Failure cause ECU internal failure or calibration error.
40-136 WB93R-8
40 TROUBLESHOOTING
#T0174 L04 C114-2

Level 2 Monitoring : Diagnostic fault check to report the plausibility error in rail pres-
Failure
sure monitoring
Depending on calibration: Fuel pressure out of range (Case1) AND/OR fuel pressure
Failure detection
gradient out o range (Case 2).

#T0175 L04 BE8-FF
Level 2 Monitoring : Diagnostic fault check to report the error due to torque compari-
Failure
son

The actual plausible requested inner engine torque (MoFCoOfs_rTrqPtdOfs) > maxi-
Failure detection
mal allowed torque (MoFTrqIdc_rTrq)
#T0176 L04 9E8-FF
Level 2 Monitoring : Diagnosis of curr path limitation forced by ECU monitoring level
Failure
2
The calculated "lead torque" (Pa(thLead_trqInrCurrNoMo) > the limited maximal

Failure detection
torque (EngTrqPtd_trqLim)
ECU internal failure or failure in the dataset calibration of ECU or another vehicle
Failure cause
control unit.
WB93R-8 40-137
40 TROUBLESHOOTING
#T0177 L04 AE8-FF

Level 2 Monitoring : Diagnosis air path limitation due to a functional control unit mon-
Failure
itoring forced by ECU monitoring level 2
The calculated "lead torque" (PthLead_trqInrLeadNoMo) > the limited maximal

Failure detection
torque (EngTrqPtd_trqLim)
ECU internal failure or failure in the data set calibration of ECU or another vehicle
Failure cause
control unit

#T0178 L04 CE8-FF
Level 2 Monitoring : Diagnosis quantity path limitation due to a functional control unit
Failure
monitoring (level 2)

The calculated (inner) engine torque (PthSet_trqInrSetNoMo) > than max accepta-
Failure detection
ble (inner) engine torque (EngTrqPtd_trqInrSet) longer than 35,79min
ECU internal failure or failure in the data set calibration of ECU or another vehcile
Failure cause
cotnrol unit
#T0179 L03 D0E-3
Failure Level 2 Monitoring : Reported Overvoltage of Supply
Fault component ECU Voltage Supply
Failure detection If voltage supply exceeds internal maximal limit
Failure cause Overvoltage internal ECU

40-138 WB93R-8
40 TROUBLESHOOTING
#T0180 L03 D0E-4

Failure Level 2 Monitoring : Reported Under Voltage of Supply
Fault component ECU Voltage Supply
Failure detection If voltage supply below internal minimal limit

Failure cause Undervoltage internal ECU

#T0181 L03 CD05-D
Failure Main Relay : Early opening defect of main relay
Fault component ECU Main relay
Failure detection If the bit in the EEPROM is detected as "set" directly after system start.
The Main Relay is switched off directly by Key 15 instead of the request of ECU:
- in case vehicle equipped with "main electrical switch": engine stopped by "main
switch" instead of Key 15 OR Main switch disconnected before afterrun finished.
Failure cause
- due to wrong wiring to the Main Relay (direct contact to the battery missing or wiring
ECU to Main relay)
- due to internal defect of ECU
In case of vehicle equipped with "main electrical switch": inform driver of correct
engine shut off by Key 15.
In case of vehicle equipped with electronic "main electrical switch": check electronic
of main switch for correct working (if opens after afterrun finished)
Failure repair
Check wiring harness between main Relay and battery
Check wiring harness between ECU and Main Relay
Check ECU
WB93R-8 40-139
40 TROUBLESHOOTING
#T0182 L03 CD05-7

Failure Main Relay : DFC for stuck main relay error
Fault component ECU Main relay
Failure detection If the diagnosis detects a sticky main relay the error is set.
Failure cause Main relay has a short circuit or is mechanically stuck in closed position.
Failure repair Check wiring or replace main relay.

#T0183 L03 7006-C
ECU internal : Diagnostic fault check to report 'WDA active' due to errors in query-/
Failure
response communication

Failure detection Unexpected communication (wire active when it should not be)
#T0184 L03 7006-4
ECU internal : Diagnostic fault check to report 'ABE active' due to under voltage
Failure
detection
ABE wire between CJ945 (power stage chips) and CY320 (power stage voltage sup-
Failure detection
plier) is active due to undervoltage detection
40-140 WB93R-8
40 TROUBLESHOOTING
#T0185 L03 7006-3

ECU internal : Diagnostic fault check to report 'ABE active' due to overvoltage detec-
Failure
tion
Failure detection Active ABE wire due to overvoltage

#T0186 L03 7006-B
ECU internal : Diagnostic fault check to report 'WDA/ABE active' due to unknown
Failure
reason

Failure detection Active WDA/ABE communication wire due to unknown reason
#T0187 L03 6400-12
Failure Oil pressure sensing: Diagnostic fault check for oil pressure below minimum limit
Fault component Oil pressure sensing
Oil pressure is not present, oil pressure digital switch not active (Oil_stPSwmp ==
Failure detection
FALSE) when engine is running (engine speed Epm_nEng > 500,00rpm).
Failure cause Low oil pressure or digital oil pressure switch blocked
Failure repair Check oil level and pressure, check oil pressure switch
WB93R-8 40-141
40 TROUBLESHOOTING
#T0188 L03 6400-2

Failure Oil pressure sensing: Plausibility check for oil pressure sensor
Fault component Oil pressure sensing
Oil pressure is present, digital oil pressure switch active (Oil_stPSwmp == TRUE)
Failure detection
when engine is switched off (Epm_nEng == 0).
Failure cause Oil pressure digital switch defective
Failure repair Check oil pressure digital switch

#T0189 L03 6704-10
Failure Turbocharger : Over boost deviation at P2 too high in Pressure charger regulator
Fault component Turbocharger control
The negative boost pressure deviation (PCR_pDvtBP == boost pressure target value
Failure detection
- actual value ) > 250,00hPa for at least 10,00s
Bitron actuator or waste-gate sticking.

Failure cause
Intake Air Pressure control signal deviating.
Check pressure modulator and intake air pressure connection.

Failure repair Check waste gate for sticking.
Replace pressure modulator and Intake air pressure.
40-142 WB93R-8
40 TROUBLESHOOTING
#T0190 L03 6804-12

Failure Turbocharger : Under boost detected in Pressure charger regulator
If positive boost pressure deviation PCR_pDvtBP > PCR_pP2HiThrDev_mp for at

Failure detection
least 10,00s.
Bitron actuator or waste-gate sticking.

Intake Air Pressure control signal deviating.
Failure cause
Turbo-Charger damaged/seizure
Leakage in intake air path.
Check pressure modulator and intake air pressure connection.

Check waste gate for sticking.
Failure repair Check intake air path for proper operation.
Replace pressure modulator and Intake air pressure.
Replace Turbo-Charger.
#T0191 L01 C50D-0
Strategy to detect the inefficiency of the SCR catalyst DeSox regeneration (too much
Failure
time regeneration)

Failure detection Number of locked regenerations > 1,00-
Failure cause Inefficient DeSox regeneation
Failure repair Clear error memory and launch a forced regeneration
#T0192 L03 6600-F
Intake air pressure sensor : Plausibility Check for air pressure at the upstream of
Failure
intake valve sensor
Fault component Boost pressure
The difference between boost pressure minus environmental pressure

Failure detection
(Air_pSensPIntkVUs - EnvP_pSens) > 100,00hPa
Failure cause Inaccurate or defective boost pressure sensor, defect in the wiring
Failure repair Check wiring of the boost pressure sensor and replace it if necessary.
WB93R-8 40-143
40 TROUBLESHOOTING
#T0193 L03 6600-11

Intake air pressure sensor : Plausibility Check for air pressure at the upstream of
Failure
intake valve sensor
The difference between boost pressure minus environmental pressure

Failure detection
(Air_pSensPIntkVUs - EnvP_pSens) < -100,00hPa
Failure cause Inaccurate or defective boost pressure sensor, defect in the wiring
Failure repair Check wiring of the boost pressure sensor and replace it if necessary.

#T0194 L03 6600-0
Intake air pressure sensor : Diagnostic fault check for SRC high in air pressure
Failure
upstream of intake valve sensor

Failure detection The sensed raw voltage value boost pressure Air_uRawPIntkVUs is above 4,92V
Failure cause Short circuit of sensor to external source or defective sensor
#T0195 L03 6600-1
Intake air pressure sensor : Diagnostic fault check for SRC low in air pressure
Failure
upstream of intake valve sensor
The sensed raw voltage value of boost pressure sensor Air_uRawPIntkVUs is below
Failure detection
202,80mV
Short circuit at wiring harness or inside the boost pressure sensor to ground or open
Failure cause
circuit
Failure repair Check of wiring or replace boost pressure sensor
40-144 WB93R-8
40 TROUBLESHOOTING
#T0196 L03 C315-F

Pressure Relief valve : pressure relief valve reached maximum allowed opening
Failure
count
Fault component Pressure Relieve Valve
Failure detection Pressure relief valve opening counter PRV_ctOpn_mp exceeds 50,00-
PRV opens to often. Possible failure causes: Metering unit or wiring harness defec-
Failure cause
tive, rail pressure sensor failure, PRV problem (PRV opening pressure too low)
Check other rail control/component-related failure, check metering unit, check wiring
Failure repair harness.
Reset PLV open counter (refer to component replacement), Rail Substitution
#T0197 L03 C315-0
Pressure Relief valve : pressure relief valve is forced to open, perform pressure
Failure
increase
If rail pressure build up to prepare pressure shock (PRV_st ==

Failure detection
PRV_ST_FORCEOPN_PRESINC) is detected
Pressure increase and pressure shock are means to set system into limp home
mode. In case of rail pressure sensor failure or maximum rail pressure exceeded, the
Failure cause system is set into limp home mode by performing pressure increase (MeUn set to full
delivery) and pressure shock (MeUn set to full delivery and injection quantity set to
zero)
Failure repair No intervention necessary
WB93R-8 40-145
40 TROUBLESHOOTING
#T0198 L03 C315-A

Pressure Relief valve : pressure relief valve is forced to open, perform pressure
Failure
shock
Failure detection If rail pressure shock (PRV_st == PRV_ST_FORCEOPN_PRESSHCK) is detected
Pressure increase and pressure shock are means to set system into limp home
mode. In case of rail pressure sensor failure or maximum rail pressure exceede, the
Failure cause system is set into limp home mode by performing pressure increase (MeUn set to full
delivery) and pressure shock (MeUn set to full delivery and injection quantity set to
zero)
Failure repair No intervention necessary
#T0199 L04 C315-B
Failure Pressure Relief valve : pressure relief valve is open
Failure detection System detect opening of Pressure Relief Valve
Pressure Relief Valve is open due to: Failure of rail pressure sensor, wiring harness,
Failure cause
metering unit or rail pressure failure
Check wiring harness of rail pressure sensor, metering unit, PRV. Check rail pressure
Failure repair
sensor, metering unit, injectors. Replace above mentioned components if necessary.
#T0200 L03 C315-2
Pressure Relief valve : Averaged rail pressure is outside the expected tolerance
Failure
range
Failure detection Averaged rail pressure outside expected defined range
Pressure Relief Valve not or not completely opened or restriction at PRV connection.
Failure cause Wrong PRV limp home pressure due to defective PRV. Rail pressure sensor failure
(intermittend connection)
Check pressure sensor and PRV. Replace above mentioned components if neces-
Failure repair
sary.
40-146 WB93R-8
40 TROUBLESHOOTING
#T0201 L03 C315-10

Failure Pressure Relief valve : pressure relief valve reached maximum allowed open time
Failure detection Pressure relief valve time open PRV_tiOpn_mp >= 5,00h
PRV opens to often. Possible failure causes: Metering unit or wiring harness defec-
Failure cause
tive, rail pressure sensor failure, PRV problem (PRV opening pressure too low)
Replace PRV.
Failure repair
Reset EEPROM.

#T0202 L03 B904-0
Failure Turbine upstream pressure sensor : SRC High for Turbine upstream pressure sensor
Fault component P3 Pressure

Failure detection The sensed raw voltage value Exh_uRawPTrbnUs is above 4,74V
Failure cause Turbine Upstream Pressure sensor defective or short circuit to external source
#T0203 L03 B904-1
Failure Turbine upstream pressure sensor : SRC low for Turbine upstream pressure sensor
Fault component P3 Pressure
Failure detection The sensed raw voltage value Exh_uRawPTrbnUs is below 427,80mV
Failure cause Turbine Upstream Pressure sensor defective or short circuit to ground
WB93R-8 40-147
40 TROUBLESHOOTING
#T0204 L04 40EE-F2

Failure Fuel Metering Unit : maximum positive deviation of rail pressure exceeded
Fault component Fuel pressure control Metering unit
The measured rail pressure is lower than the desired pressure by > engine speed
Failure detection dependant threshold (from 100,00bar at 1250,00rpm over 100,00bar at 2200,00rpm
to 100,00bar at 5200,00rpm)
Leakage in the high pressure system: injection nozzle stuck in open position, low effi-
ciency of high pressure pump, internal leakage of injector, leaking pressure control
valve
Failure cause
Too low pressure at High pressure pump inlet due clogged filter, leaking low pressure
tubes, electric pre supply pump defective or gear pump defective.
Check low pressure system for clogging (specially fuel filter).
Check tubing between pre filter and gear pump.
Check high pressure part for leakages (internal / external).

Failure repair
Replace Metering Unit.
Replace High pressure pump.
Replace Injector.
40-148 WB93R-8
40 TROUBLESHOOTING
#T0205 L04 D804-1F

Failure Fuel Metering Unit : leakage is detected based on fuel quantity balance
Fault component Fuel pressure (Rail) control
If the high pressure pump delivery quantity exceeds the maximal expected fuel flow
Failure detection (see general remarks) by more than a fuel flow dependant limit (3800,00mm3/s at
3000,00mm3/s to 5000,00mm3/s at 58000,00mm3/s)
External leakage in the high pressure or low pressure system.
Fuel pressure sensor signal shows wrong (mainly too low) values.
Failure cause
Injectors leak internally (do not close)
High pressure pump has too low feeding efficiency
Check if system has no external leakage.
Check fuel supply line and check for clogged filter.
Failure repair Replace Metering Unit.
Replace Injector.
WB93R-8 40-149
40 TROUBLESHOOTING
#T0206 L04 40EE-EF

Fuel Metering Unit : maximum negative rail pressure deviation with metering unit on
Failure
lower limit is exceeded
The measured fuel rail pressure higher than the desired one by more than engine
Failure detection speed dependant value although the requested fuel feeding by MeUn < -
1800,00mm3/s
Metering unit stuck in open position, zero-delivery throttle clogged, metering unit
without power due to electrical error.
Failure cause
Low pressure side: Pressure after zero-delivery throttle too high (Pump backflow
pressure too high)
Check low pressure system for clogging (e.g. fuel filter).
Check fuel feeding on pre filter (possibly low due to clogged tubes at tank outlet).

Failure repair
Replace fuel filter.
Replace injectors.
40-150 WB93R-8
40 TROUBLESHOOTING
#T0207 L04 41EE-F1

Failure Fuel Metering Unit : minimum rail pressure exceeded
The rail pressure < engine speed dependant minimal value (from 420000,00hPa at
Failure detection
900,00rpm over 420000,00hPa at 1300,00rpm) to 550000,00hPa at 2000,00rpm))
Leakage in the high pressure system:
injection nozzle stuck in open position, low efficiency of high pressure pump, internal
leakage of injector, leaking pressure control valve
Failure cause
tubes, electric pre supply pump defective or gear pump defective

Failure repair
Replace injectors.
WB93R-8 40-151
40 TROUBLESHOOTING
#T0208 L04 A205-0

Failure Fuel Metering Unit : maximum rail pressure exceeded
Failure detection Measured rail pressure > 1950,00bar

Metering unit stuck in open position, zero-delivery throttle clogged, metering unit
without power due to electrical error.
Failure cause
Low pressure side: pressure after zero-delivery throttle too high (Pump backflow
pressure too high)

Failure repair
Replace injectors.
#T0209 L04 D804-B
Failure Error detection by metering unit set value in overrun

If the high pressure pump delivery quantity in overrun exceeds the threshold
Failure detection
Rail_dvolMeUnOvrRun curve based on the pressure, an error will be detected.
Leakage in the high pressure system.

Failure cause
There is no zero delivery in the metering unit (leakage in MeUn is too great).

Failure repair
Replace Metering Unit.
40-152 WB93R-8
40 TROUBLESHOOTING
#T0210 L04 D804-E

Fuel pressure control Metering unit: Leakage in high pressure system detected at
Failure
idle
Failure detection If the high pressure pump delivery quantity at low idle > 5500,00mm3/s.
Leakage in the high pressure system:
injection nozzle stuck in open position, low efficiency of high pressure pump, internal
leakage of injector, leaking pressure control valve
Failure cause
tubes, electric presupply pump defective or gear pump defective

Failure repair
Replace injectors.
#T0211 L01 9D00-2
Failure Rail pressure Sensor : rail pressure raw value is intermittent
Fault component Fuel pressure (Rail) sensor

More than 5,00- pressure jumps > 500,00bar /10ms task, and time between the sin-
Failure detection gle pressure jumps < 3,00s (counter reset to 0 if time between to pressure jumps >
3,00s)
Failure cause Periodical loose of contact in the weiring, the connectors or sensor itself
Check wiring and connectors of Rail pressure sensor for good contacts.
Failure repair
Check sensor, replace sensor if necessary and reset learning values in EEPROM
WB93R-8 40-153
40 TROUBLESHOOTING
#T0212 L04 C315-1F

Failure Rail pressure sensor: maximum rail pressure exceeded
Fault component Fuel pressure (Rail) control
If the rail pressure RailP_pFlt exceeds the limiting value 1990,00bar, an error will be
Failure detection
detected.
Failure cause PRV Valve stuck, fuel backflow clogged or fuel low pressure cycle too high.
Check for clogged fuel backflow in rail system.

Failure repair
Replace PRV valve.

#T0213 L04 9D00-B
Failure Rail pressure Sensor : Sensor voltage above upper limit

Failure detection The raw sensor voltage > 4,84V or the uncorrected raw sensor voltage > 4,90V
Failure cause Short circuit of wiring to external source or defective pressure sensor
Check wiring/rail pressure sensor.

Failure repair
Replace sensor if necessary and reset learning values in EEPROM
#T0214 L04 9D00-C
Failure Rail pressure Sensor : Sensor voltage below lower limit

Failure detection The raw sensor voltage < 342,20mV
Failure cause Short circuit of wiring to ground or defective pressure sensor
Check wiring/rail pressure sensor.

Failure repair
Replace sensor if necessary and reset learning values in EEPROM
40-154 WB93R-8
40 TROUBLESHOOTING
#T0215 L00 E106-11

Info: SCR reagent tank level below first warning level, DFC for triggering warning
Failure
action dependent on filling level of reducing agent
Fault component SCR Reagent Tank Level
Failure detection Reducing agent tank level (UDC_rRdcAgRmn ) below the calibratable limit 9,80%.
Failure cause Reducing agent tank level below first warning level
Failure repair Refill reducing agent tank

#T0216 L03 E106-B
Info: SCR reagent tank level below second warning level, DFC for triggering warning
Failure
action dependent on filling level of reducing agent

Failure detection Reducing agent tank level (UDC_rRdcAgRmn ) below the calibratable limit 4,80%.
Failure cause Reducing agent tank level below low second warning level
Failure repair Refill reducing agent tank
WB93R-8 40-155
40 TROUBLESHOOTING
#T0217 L03 1811-2

Failure SCR monitoring: general backflow line plausibility error
Fault component SCR Reagent Feeding
In the state DETECTIONMODE several checks of the hydraulic components are per-
formed.
The monitoring for a blockade of the back flow line takes place in the state
COSCR_DETECTIONMODE_BACKFLOW (in this state the back flow line is
checked).
Failure detection
If a bloackade is detected during this the state is left with an error
(SCRMon_stDetnModBackFlow == SCR_STM_EXIT_FCT_ERROR) and the coun-
ter SCRMon_ctDetModeWait is incremented.
If the counter exceeds the maximum acceptable number of repetitions ( 15,00- ,
respectively 42,00- in case of a defrosing) the fault is set.
Blocked, frozen or damage backflow line (tubing, hyd.connector)
Blocked or damaged backflow connector (throttle).
Failure cause
Backflow Pump is blocked closed
Heater ineffective.
Check the backflow line for blockage or damage.If needed disconnect the hydr.con-
nector and use compressed air to support the check. If blockage or damage is found,
Failure repair repair or replace Backflow Line.
Check the backflow connector (throttle).
Check the heater.
40-156 WB93R-8
40 TROUBLESHOOTING
#T0218 L03 86EB-EE

Failure SCR monitoring: general pressure check error
If a blocked pressure line is detected (pressure line > 4,30bar and the dosing valve is
not closed) and the pressure line heating UHC_stC3On is ON the fault is set with the
fault level of DSM_FAULT_PERCENT_25 because the AdBlue is still partly frozen.
Failure detection The system waits for 10,00min to give additional time for further defrosting (fault is
healed in this time). The loop waiting/checking can be repeated for 42,00- times.
When the maximum number of additional heating cyles is reached the error is set
with fault level of DSM_FAULT_PERCENT_100
Blocked, frozen or damage pressure line.

Failure cause Blocked or damaged dosing valve.
Heater ineffective
Check for pressure line or dosing valve leakage.

Replace pressure line.
Failure repair
Replace the dosing valve.
Replace the heater if ineffective.

#T0219 L03 EE10-A
Failure SCR monitoring: pressure stabilization error

In the state DETECTIONMODE several checks of the hydraulic components are per-
formed.
The monitoring for a stabilisation of the pressure takes place in the state
COSCR_DETECTIONMODE_PRESSURESTABILISATION (in this state the pres-
sure stabilisation is checked). If no stable pressure can't be achieved during this the
Failure detection
state is left with an error (SCRMon_stDetnModPStabn ==
SCR_STM_EXIT_FCT_ERROR) and the counter SCRMon_ctDetModeWait is incre-
mented.
If the counter exceeds the maximum acceptable number of repetitions ( 15,00- ,
respectively 42,00- in case of a defrosing) the fault is set.
Failure cause Blocked, frozen or damage pressure line.
Check for pressure line leakage.

Failure repair
Replace pressure line.
WB93R-8 40-157
40 TROUBLESHOOTING
#T0220 L03 EE10-F

Failure SCR Reagent Feeding: UREA pressure too high
UREA pressure exceeds 6,10bar and does no more drop below 5,90bar during
Failure detection
20,00s.
REA level too low (suction of air)
Back flow into tank clogged

Failure cause
Pump control not OK (e.g. pump is running on max due to electric failure).
UREA pressure sensor shows too high values.
Check if UREA level was OK when failure occurred (see ambient conditions).
Failure repair Check if back flow line into tank is open (with test: adjust system to normal pressure
(5bar) and check, if pressure is constant, if not, stop pump --> pressure must drop
down (=system emptying through back flow line)).
40-158 WB93R-8
40 TROUBLESHOOTING
#T0221 L03 EE10-11

Failure SCR Reagent Feeding: UREA pressure too low
UREA pressure drops below 3,90bar (but not below 450,00hPa ) and does no more
Failure detection
reach or exceed 4,10bar during 40,00s .
UREA level too low (suction of air)
Leakage in the UREA system outside or internal (i.e. back flow into tank, leakage into
pump housing, external leakage).
Failure cause Pump not delivering enough.
Reverting valve blocked "open" (occurrence during normal operation - low probabil-
ity)
UREA pressure sensor shows too low values.
Check, if enough UREA was in tank when failure occurred (ambient conditions)
Check if pump can reach enough pressure with tester: set system under normal
pressure (5 bar) :
- check if there is an external leakage (visible check)
Failure repair
- if 5bar reachable: open dosing valve fully for ~3 sec, if pressure drops < 4,10bar --
> pump not delivering enough or internal leakage --> replace pump module. If pres-
sure remains stable --> system seems to be OK
- if 5 bar not reachable: pump not delivering enough or internal leakage or reverting
valve blocked open--> replace pump module
WB93R-8 40-159
40 TROUBLESHOOTING
#T0222 L03 EE10-10

Failure SCR Reagent Feeding: UREA pressure too high (2nd level)
Failure detection UREA pressure > 7,50bar

Back flow into tank clogged

Failure cause
Pump control not OK (e.g. pump is running on max due to electric failure).
UREA pressure sensor shows too high values.
Check if UREA level was OK when failure occurred (see ambient conditions).
Failure repair Check if back flow line into tank is open (with test: adjust system to normal pressure
(5bar) and check, if pressure is constant, if not, stop pump --> pressure must drop
down (=system emptying through back flow line)).
40-160 WB93R-8
40 TROUBLESHOOTING
#T0223 L03 1015-9

Failure SCR Reagent Feeding: Pressurisation after start not possible
If the UREA pressure does not reach 1000,00hPa within 50,00s after 4,00- "pressure
Failure detection
build up" cycles.
Suction tube leaky
Leakage in the UREA system outside or internal (i.e. back flow into tank, leakage into
pump housing, external leakage).
Failure cause
Dosing valve blocked open.
Pump not delivering enough.
Reverting valve blocked open.
UREA pressure sensor shows too low values.
Check, if enough UREA was in tank when failure occurred (ambient conditions)
Check if pump can reach enough pressure with tester: set system under normal
pressure (5 bar) :
- check if there is an external leakage (visible check)
- if 5bar reachable: open dosing valve fully for ~3 sec, if pressure drops < 4,10bar --
> pump not delivering enough or internal leakage --> check tubing for correct con-
nection (suction tube!), replace pump module. If pressure remains stable --> system
seems to be OK
Failure repair - if 5 bar not reachable: pump not delivering enough or internal leakage or dosing
valve blocked open or reverting valve blocked open --> check tubing for correct con-
nection (suction tube!), check dosing valve, replace pump module
Check dosing valve and reverting valve: Set pump speed to ~20% and actuate
reverse valve --> pressure must drop down (< 0.8 bar absolute) - if OK: open dosing
valve --> pressure must rise to ~1 bar absolute (=ambient)
If no depressurisation detected: reverting valve blocked closed or dosing valve open.
If there was a depressurisation before actuating the reverting valve --> reverting
valve blocked closed.
WB93R-8 40-161
40 TROUBLESHOOTING
#T0224 L01 31F1-E7

Failure DeNOX relay stuck closed
If no open load error is detected in a component connected to the relay in spite of a

Failure detection
deactivated relay, the error will be set.
Failure cause DeNOX relay stuck closed.
Failure repair Check wiring harness or replace DeNOX Relay.

#T0225 L01 32F1-E7
Failure DeNOX relay stuck open
If an open load error is detected in the components connected to the relay in spite of
Failure detection
an activated relay, the error will be set.
Failure cause DeNOX relay stuck open.
Check wiring harness or replace DeNOX Relay.
Check SCR power supply after relay. In case of missing supply, check:
Failure repair
1) Fuse status --> change fuse
2) Relay command --> check wiring harness between ECU connector and SCR relay
3) Relay hardware --> change relay
#T0226 L03 31F1-FF
Failure Filter Clog reached warning level

The measured values are fed into the two software low-pass filters. The value of the
filter with longer time constant (slow filter) is compared with the reference value mul-
Failure detection tiplied by the factor 1,30-.
If the filter value is greater it means the filter clog reached warning level and the flag
SCRPOD_flgFilFull is set.
Failure cause Clogged filter.
Failure repair Change the filter.
40-162 WB93R-8
40 TROUBLESHOOTING
#T0227 L03 30F1-E2

Failure Voltage Plausibility: backflow and suction line heater power stage
The absolute difference of battery voltage BattU_u and power stage voltage of the
Failure detection
backflow and suction line heater UHtrBLDia_uDiag is above the threshold 3,00V
Failure cause Defective wiring between HCU and EDC or HCU defective.
Check the relevant harnesses and connectors between HCU and ECU for damage,
bent or dislocated pins, corroded terminals,"capillary creeping" of DEF, broken wires,
etc.
Verify that the connectors are installed and arrested correctly.
Failure repair Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring con-
cerned.
If there is a problem on the electrical system, correct the failure else if no problem on
the electrical system can be identified, replace the HCU.
#T0228 L01 31F1-E2
Failure Voltage Plausibility: pressure line power stage

The absolute difference of battery voltage BattU_u and voltage of the pressure line
Failure detection
power stage UHtrPLDia_uDiag is above the threshold 3,00V
etc.
cerned.
WB93R-8 40-163
40 TROUBLESHOOTING
#T0229 L01 32F1-E2

Failure Voltage Plausibility: supply module heater power stage
The absolute difference of battery voltage BattU_u and power stage voltage of the
Failure detection
supply module heater UHtrSMDia_uDiag is above the threshold 3,00V
etc.
cerned.
#T0230 L03 EB10-C
Failure Reporting the leakage in the system during no dosing

The fault is set, when the release conditions are met, the pressure is stable and the
Failure detection filtered duty cycle of the pump SCRPOD_ratUrPmpFild_MP is above the expected
duty cycle 34,00%.
Failure cause Leakage in SCR system.
Check for a leakage in urea dosing module, supply module or hydraulic circuit.
Failure repair
Replace supply module or dosing module according to leakage position.
40-164 WB93R-8
40 TROUBLESHOOTING
#T0231 L03 D70B-6

Failure Urea Tank temperature: overheating of the AdBlue tank
Fault component SCR Tank heater
Failure detection When tank temperature SCR_tUTnkT> 70,06°C

Tank overheated: tank temperature sensor measures implausible values or tank
Failure cause
heater valve permanently open
Failure repair Check tank temperature sensor, check tank heater valve

#T0232 L03 1215-7
Failure SCR Dosing valve: Dosing Valve is Blocked closed
Fault component SCR Dosing valve

The Dosing valve driver reports an opening error "stNoOpnErr" because no BIP was
detected.
Failure detection
The dosing valve will be blocked if no opening process is detected by the dosing
valve driver and
the operating conditions are within the evaluation range.
Failure cause Dosing valve blocked mechanically (or frozen)
Check if dosing valve opens.

Failure repair
Check if tube between pump and dosing valve is free.
#T0233 L03 1215-F

Failure Error in dosing valve plausibility at low voltage
The dosing valve will be blocked if no opening process is detected by the dosing
Failure detection
valve driver and the operating conditions are within the evaluation range.
Failure cause Dosing valve defect.
Failure repair Replace dosing valve.
WB93R-8 40-165
40 TROUBLESHOOTING
#T0234 L03 91EB-F3
Failure Defective pressure reduction

If the minimum pressure during COSCR_PRESSUREREDUCTION is greater than
Failure detection
0,00hPa
Failure cause Backflow pump damaged.
Failure repair Replace supply module.
#T0235 L03 7FEC-E2

Failure Error urea supply module heater temperature sensor dynamic plausibility
After the adjustable heating time 5,00min has elapsed it is checked whether the tem-
Failure detection perature of the supply module heater UPmpMot_tSMHeatrT has risen by the value of
5,00K.
Failure cause Defective SCR catalyst "upstream" temperature sensor.
Failure repair Check and replace the SCR catalyst "upstream" temperature sensor.
#T0236 L03 F110-2
Failure Error urea supply module temperature sensor dynamic plausibility
After defrosting of the supply module the temperature of the supply module
Failure detection SCR_tSMT has not risen by the value of 3,00K but the temperature of the supply
module heater has risen
Failure cause Defective SCR catalyst "upstream" temperature sensor.

Failure repair Check and replace the SCR catalyst "upstream" temperature sensor.
40-166 WB93R-8
40 TROUBLESHOOTING
#T0237 L03 230D-C
Failure SCR Tank heater: Urea tank heater is faulty
Fault component SCR Tank heater

No significant tank temperature increase as expected. SCRPOD_tUTnkTMax_mp
Failure detection greater than SCRPOD_tUTnkFlt - SCRPOD_tUTnkTemp_mp and
SCRPOD_tiCntrAcm greater than SCRPOD_tiUTnkTExpi_mp.
Heater in "air bubble" with frozen UREA then check ambient conditions, if failure hap-
pened at temp < -10°, this is a possible reason.
Failure cause
Tank heater defect,
Wiring harness defect.
Check tank heater.

Failure repair
#T0238 L03 33F1-E5
Failure SCR Relay: Open load error

Fault component SCR Relay
Failure detection The hardware detects no load at the power stage.
Failure cause Broken or disconnected wiring or defective sensor.

Failure repair Check of wiring or replace sensor.
#T0239 L01 33F1-E6

Failure SCR Relay: Overtemperature error
Failure detection The hardware detects an overtemperature error at the power stage.
Failure cause High battery voltage, high temperature inside, high load or wiring problem.
Failure repair
check wiring.
WB93R-8 40-167
40 TROUBLESHOOTING
#T0240 L03 33F1-E3

Failure SCR Relay: Short circuit to battery error
Failure detection The hardware detects a short circuit to battery at the power stage.
Failure cause Short circuit of wiring to battery.
Failure repair Check of wiring

#T0241 L03 33F1-E4
Failure SCR Relay: Short circuit to ground
Failure detection The hardware detects a short circuit to ground at the power stage.
Failure repair Check of wiring.
#T0242 L03 E106-13
Failure Diagnostic fault check for signal error from CAN
Fault component SCR Reagent Level Sensing
Failure detection The signals from CAN Com_rUTnkLvl or Com_lUTnkLvl is equal to 0x7FFF.
Failure cause Urea tank level sensor sending an error message
Failure repair Urea tank level sensor defective, replace it.
40-168 WB93R-8
40 TROUBLESHOOTING
#T0243 L03 220D-0

Failure SCR Reagent Pump: SRC high for Urea Pump Module Pressure Sensor
Fault component SCR Reagent Pump
Failure detection The Sensed raw voltage value is greater than 4,75V
Failure repair Check wiring or replace Urea Pump Module Pressure Sensor.

#T0244 L03 E106-10
Failure SCR Reagent Tank Level Sensor: Signal above maximum limit.
The sensed raw voltage value UTnkLvl_uRaw is greater than 3,20V or

Failure detection
Com_stUTnkLvlFMI is equal to 3,00-
Failure cause Reduction agent level in the tank sensor defective or short circuit to battery
#T0245 L03 220D-1
Failure SCR Reagent Pump: SRC low for Urea Pump Module Pressure Sensor
Failure detection The Sensed raw voltage value is less than 250,00mV
Failure cause Short circuit of sensor to ground or defective sensor

Failure repair Check wiring or replace Urea Pump Module Pressure Sensor.
WB93R-8 40-169
40 TROUBLESHOOTING
#T0246 L03 E106-12

Failure SCR Reagent Tank Level Sensor: Signal below minimum limit.
The sensed raw voltage value UTnkLvl_uRaw is less than 100,00mV or

Failure detection
Com_stUTnkLvlFMI is equal to 4,00-
Failure cause Reduction agent level in the tank sensor defective or short circuit to ground

#T0247 L03 B50D-C
Failure ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 1
Fault component ECU Power Stage 1
The sensor supply voltage is monitored by an HW comparator. If the sensor supply

Failure detection voltage lies outside of the switching thresholds, a fault is output. The detection
thresholds are defined by the hardware and cannot be calibrated.
Excessive battery voltage, defect in wiring harness, electrical failure in connected

Failure cause
sensors or in the ECM
Check battery voltage, check wiring for correct voltage supply of the connected sen-
Failure repair sor and the ECM.
Replace ECM
#T0248 L03 B60D-C
Failure ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 2


Failure cause
sensors or in the ECM
Replace ECM
40-170 WB93R-8
40 TROUBLESHOOTING
#T0249 L03 B70D-C

Failure ECU Sensor Supply Monitor: ECU internal: Error Sensor supplies 3

Failure cause
sensors or in the ECM.
Replace ECM.

#T0250 L01 8B06-E
Failure ECU Internal: Stop Counter Timer accuracy
At least one of these conditions are fulfilled:

- Communication time with CY320 exceeds the deadline.
Failure detection
- Acquired Stop Counter time t > 1.06 * 120s.
- Acquired Stop Counter time t < 0.94 * 120s.
Failure cause ECM internal problem.
#T0251 L03 A502-3
Failure ECU Power stages : Starter relay HS power stage output short circuit to battery
Fault component Starter control
Hardware reports a Short Circuit to Battery error on HS power stage for the starter
Failure detection
relay actuator.
Failure cause Short circuit of wiring to external source or defective HS starter relay
Failure repair Check of wiring or replacement of HS relay
WB93R-8 40-171
40 TROUBLESHOOTING
#T0252 L03 A502-4

Failure Starter Relay HS: power stage output short circuit to ground
Hardware reports a Short Circuit to Ground error on HS power stage for the starter
Failure detection
relay actuator.
Failure cause Short circuit of wiring to ground or defective HS starter relay
Failure repair Check of wiring or replacement of HS starter relay

#T0253 L03 2905-5
Failure Starter Relay LS: power stage output No Load error
Hardware reports an open load (OL) error on power stage for the LS starter relay
Failure detection
actuator.
Failure cause Broken or disconnected wiring or defective LS starter relay
Failure repair Check of wiring or replacement of LS starter relay
#T0254 L03 2905-6
Failure ECU Power stages : Starter relay HS power stage over temperature
Hardware reports an excess temperature (OT) error on the LS power stage for starter
Failure detection
relay actuator.
Failure repair Check battery voltage, wiring, power stage and LS starter relay
40-172 WB93R-8
40 TROUBLESHOOTING
#T0255 L03 2905-3

Failure Starter Relay LS: power stage output short circuit to battery.
Hardware reports a Short Circuit to Battery error on LS power stage for the starter
Failure detection
relay actuator.
Failure cause Short circuit of wiring to external source or defective LS starter relay

#T0256 L03 2905-4
ECU Power stages : Starter relay power stage: Short circuit to ground error for the
Failure
Low side

Hardware reports a Short Circuit to Ground error on LS power stage for the starter
Failure detection
relay actuator.
Failure cause Short circuit of wiring to ground or defective LS starter relay
#T0257 L01 9800-E
Failure ECU internal : Visibility of Software Resets in DSM

Fault component ECU SW Reset
The evaluation of the reset reason will be done after every reset. Depending on the
Failure detection configured visibility of the current reset, one of the fault checks in the array will be
set.
Electronic disturbances, various hardware defects (ECU internal) or configuration

Failure cause
problems
Failure repair If error occurs repeatedly, reprogram EDC. If error remains, replace EDC
WB93R-8 40-173
40 TROUBLESHOOTING
#T0258 L01 9800-1F

Failure ECU internal : Visibility of Software Resets in DSM
Fault component ECU SW Reset
The evaluation of the reset reason will be done after every reset. Depending on the
Failure detection configured visibility of the current reset, one of the fault checks in the array will be
set.
Electronic disturbances, various hardware defects (ECU internal) or configuration
Failure cause
problems
Failure repair If error occurs repeatedly, reprogram EDC. If error remains, replace EDC.

#T0260 L03 DDED-F0
Failure EGR Inducement - second step of engine derating
Fault component EGR Inducement

If at least one error belonging to "EGR valve blocked" group is set, the timer for
inducement level 1 (torque reduction) is incremented.
Failure detection
When timer exceeds 210,00min and at least one error belonging to the triggered
group is active, level 1 for "EGR valve blocked" group is set.
Failure cause INFO: Inducement Level1 due to EGR valve blocked activated
No intervention necessary on this fault.

Failure repair
EGR fault which is root cause for inducement should be repaired
#T0259 L01 DDED-E0
Failure EGR Inducement - first step of engine derating

Fault component EGR Inducement
If at least one error belonging to "EGR valve blocked" group is set, first step of
Failure detection
inducement is activated.
Failure cause INFO: Driver warning due to EGR valve blocked fault activated
Failure repair
EGR fault which is root cause for inducement should be repaired
40-174 WB93R-8
40 TROUBLESHOOTING
#T0261 L03 D016-10

Failure SCR Inducement - second step of engine derating
Fault component SCR Inducement
If at least one error belonging to "Interruption of dosing" group is set and the engine
is running, the timer for inducement level 1 is incremented.
Failure detection
When timer exceeds the calibratable threshold time
(120,00min), level 1 for "Interruption of dosing" group is set.
Activation of SCR Inducement Level 1 due to detection at least of one error belong-
Failure cause
ing to "Interruption of dosing group".

Failure repair
SCR fault which is root cause for inducement should be repaired.
#T0262 L04 D016-0
Failure SCR Inducement - Last step of engine derating most severe derating

If at least one error belonging to "Interruption of dosing" group is set and the engine
is running, the timer for inducement level 3 is incremented.
Failure detection
(210,00min), level 3 for "Interruption of dosing" group is set.
Failure cause
ing to "Interruption of dosing" group

Failure repair
SCR fault which is root cause for inducement should be repaired
WB93R-8 40-175
40 TROUBLESHOOTING
#T0263 L03 D016-F

Failure SCR Inducement - First step of engine derating
Failure detection If at least one error belonging to "Interruption dosing" group is set.
Activation of SCR Inducement sue to detection at least of one error belonging to
Failure cause
Interruption of dosing.

Failure repair
SCR fault which is root cause for inducement should be repaired

#T0264 L03 D116-10
Failure SCRInducement - second step of engine derating, triggered by Reagent quality fault

If at least one error belonging to "Reagent quality" group is set, the timer for induce-
ment level 1 (torque reduction) is incremented.
Failure detection
group is active, level 1 for "Reagent quality" group is set.
Failure cause INFO: Inducement Level1 due to "Reagent quality" fault activated

Failure repair
"Reagent quality" fault which is root cause for inducement should be repaired
#T0265 L04 D116-1F
Failure SCR Inducement - Last step of engine derating triggered by Reagent Quality fault
If at least one error belonging to "Reagent Quality" group is set, the timer for induce-
ment level 3 is incremented.
Failure detection
group is active, level 3 for "Reagent Quality" group is set.
Failure cause INFO: Inducement Level3 due to "Reagent Quality" fault activated
Failure repair
"Reagent Quality" fault which is root cause for inducement should be repaired
40-176 WB93R-8
40 TROUBLESHOOTING
#T0266 L01 D116-F
Failure SCR Inducement warning, triggered by Reagent Quality fault

If at least one error belonging to "Reagent Quality" group is set, inducement driver
Failure detection
warning is activated
Failure cause INFO: Driver warning due to "Reagent Quality" fault activated

Failure repair
"Reagent Quality" fault, which is root cause for inducement should be repaired
#T0267 L03 7E14-10

Failure SCR Inducement less severe derating level, triggered by Tampering fault
If at least one error belonging to SCR Inducement group is set and the engine is run-
ning, the timer (SysDiag_tiIndcTmr_mp[4]) for inducement level 1 (less severe torque
Failure detection reduction) is incremented.
(7200,00min), level 1 for SCR Inducement group is set.
Failure cause
ing to SCR Inducement group (SysDiag_nrIndcDFCTamprg).
See the "Fault Repair" section of detected error/s belonging to SCR Inducement
Failure repair
group (SysDiag_nrIndcDFCTamprg).
WB93R-8 40-177
40 TROUBLESHOOTING
#T0268 L04 7E14-0
Failure SCR Inducement most severe derating level, triggered by Tampering fault

If at least one error belonging to SCR Inducement group is set and the engine is run-
ning, the timer (SysDiag_tiIndcTmr_mp[4]) for inducement level 3 (more severe
Failure detection torque reduction) is incremented.
(12600,00min), level 3 for SCR Inducement group is set.
Failure cause
ing to SCR Inducement group (SysDiag_nrIndcDFCTamprg).
Failure repair
#T0269 L03 7E14-F
Failure SCR Inducement warning, triggered by Tampering fault
If at least one error belonging to SCR Inducement group

Failure detection (SysDiag_nrIndcDFCTamprg) is set, inducement driver warning is activated immedi-
ately (SysDiag_trgIndcCntrEntry is calibrated as "PendingDefect").
Detection at least of one error belonging to SCR Inducement group

Failure cause
(SysDiag_nrIndcDFCTamprg).
Failure repair
40-178 WB93R-8
40 TROUBLESHOOTING
#T0270 L00 A31A-1F

Failure Activation of Repeated Offenders logic
The status of Repeated Offenders SysDiag_stRepOffndr is valid

Failure detection (SysDiag_stRepOffndr.Bit7 = 0) and its bits are set referenced to bitmask
SysDiag_maskRepOffndrDFC.
Failure cause Repeated tampering.
Failure repair Info failure: no action needed.

#T0271 L00 DEED-FF
Failure Severe inducement for several times within a timeframe

If severe inducement activation > 3 and Timeframe elapsed since previous occur-
Failure detection
rence < 40h
Failure cause Inducement lock is active
Failure repair Service tool reset request
#T0272 L00 DCED-FF
Failure Validation mode activated: full power restart in case of inducement activation
Failure detection Error is set when the validation mode is active (SysDiag_stVldnMod = TRUE).
Failure cause Validation mode is active.
Failure repair Info failure: no action needed.
WB93R-8 40-179
40 TROUBLESHOOTING
#T0273 L03 8B06-1F

Failure Terminal 50 switch : Defective T50 switch
Fault component ECU Key 16
Failure detection The debounced signal is high (T50_st == 1) for a period longer than debounce time
Failure cause Too long cranking request, short circuit in ignition key module or in wiring
Failure repair Check ignition key module and crank control wiring harness

#T0274 L00 B721-E
Failure Cold start detected
Fault component Turbocharger Protection
Failure detection If there is a detection of Cold start (if bit0 of TCPrt_stCldStrt is equal to 1).
Failure cause Cold Start Detected.
Failure repair Info failure - No intervention necessary.
#T0275 L03 7004-C
Failure ECU temperature sensor : SPI Error ECU temperature sensor (LM71)
Fault component ECU Temperature sensing
When error message sent from sensor is detected (TECU_numSPI, bit 0 or 1 NOT
Failure detection
set).
Failure cause Temperature sensor defective (inside ECM)

40-180 WB93R-8
40 TROUBLESHOOTING
#T0276 L03 2F0-E0

Fault component Throttle Valve
Throttle valve position deviation > 10,00% at 0,00% (i.e. too low EGR flow) for a time
Failure detection longer than time from map ThrVlv_tiDebGovDvtDef depending from governor posi-
tion.
Desired Throttle valve position can not be reached
Failure cause Throttle valve sticks
Throttle valve position sensor mismatched

Failure repair Clean TVA, try to open/closed manually the valve
Replace TVA Valve.
#T0277 L03 2F0-E1

Throttle valve position deviation < -10,00% at 0,00% for a time longer than time from
Failure detection
map ThrVlv_tiDebGovDvtDef depending from governor position.
Desired Throttle valve position can not be reached

Failure cause Throttle valve sticks
Throttle valve position sensor mismatched
Check for free moviments of the throttle flap.

Failure repair
Clean TVA, try to open/closed manually the valve
Replace TVA Valve.
WB93R-8 40-181
40 TROUBLESHOOTING
#T0278 L03 3F0-E5

Failure Open load error for power stage
Failure detection Hardware reports an "open load" (OL) error

Electrical problem of the Throttle valve actuator: broken wiring harness, no contact of
Failure cause
connector, internal broken line in actuator
Check wiring harness on open circuit

Failure repair
Check Throttle valve actuator on open circuit

#T0279 L03 3F0-EF
Failure Over temperature error for H-bridge

Failure detection Over Temperature of TLE7209/CJ230 error
Failure repair
check wiring, replace ECU
#T0280 L03 3F0-E3
Failure repair Check of Throttle Valve Actuator wiring (possible short to battery).
40-182 WB93R-8
40 TROUBLESHOOTING
#T0281 L03 2F0-E3


Check of Throttle Valve Actuator wiring (possible short to battery).

Failure repair
Replace component.

#T0282 L03 3F0-E4
Check of Throttle Valve Actuator wiring (possible short to ground).

Failure repair
Replace component.
#T0283 L03 2F0-E4

Check of Throttle Valve Actuator wiring (possible short to ground).

Failure repair
Replace component.
WB93R-8 40-183
40 TROUBLESHOOTING
#T0284 L03 2F0-EF

Failure Short circuit over load error for H-bridge
Short Circuit over Load error.
In case of short-circuit-to-ground error, the High side switches are closed. If there is
no more short-circuit-to-ground error then it is detected as short-circuit-over-load
error.
Failure detection
In case of short-circuit-to-battery error, low side switches are closed. If there is no
more short-circuit-to-battery error then it is detected as short-circuit-over-load error.
If short-circuit overload error is detected, then the pre-existing SCG/SCB error is

healed.
Failure cause Short circuit of wiring.
Check if wiring harness leads are shorted.

Failure repair
Replace component if necessary.
#T0285 L03 2F0-E5
Failure Under voltage error for H-bridge
Failure detection Hardware reports Under Voltage error
Failure cause Too high Voltage fluctuations in system (instable power supply)
Failure repair Check of Throttle Valve Actuator wiring
#T0286 L03 2B15-0
Failure ECU Power stages : Throttle valve actuator power stage: SRC High
Failure detection The sensed raw voltage ThrVlv_uRaw is above the maximum threshold 4,75V.
Failure cause Short circuit of wiring to external source or defective Throttle Valve Actuator.
Failure repair Check of wiring or replace Throttle Valve Actuator.
40-184 WB93R-8
40 TROUBLESHOOTING
#T0287 L03 2B15-1

Failure ECU Power stages : Throttle valve actuator power stage: SRC low
The sensed raw voltage value ThrVlv_uRaw is below the minimum threshold
Failure detection
250,00mV
Failure cause Short circuit of wiring to ground or defective Throttle Valve Actuator.
Failure repair Check of wiring or replace Throttle Valve Actuator.

#T0288 L03 6900-0
Intake air temperature sensor : Diagnostic fault check for SRC high in engine inlet
Failure
valve air temperature upstream sensor
Fault component Boost temperature

Failure detection The sensed raw voltage value Air_uRawTIntkVUs is above 4,94V
#T0289 L03 6900-1
Intake air temperature sensor : Diagnostic fault check for SRC low in engine inlet
Failure
valve air temperature upstream sensor
Fault component Boost temperature
Failure detection The sensed raw voltage value Air_uRawTIntkVUs is less than 266,40mV

WB93R-8 40-185
40 TROUBLESHOOTING
#T0290 L03 9D12-0

OxiCat upstream temperature sensor : Diagnostic fault check for SRC high in Oxida-
Failure
tion Catalyst upstream temperature
Fault component Oxicat Temp Sensing
Failure detection The sensed raw voltage value Exh_uRawTOxiCatUs is above 3,59V
Failure repair Check wiring and sensor

#T0291 L03 9D12-1
OxiCat upstream temperature sensor : Diagnostic fault check for SRC low in Oxida-
Failure
tion Catalyst upstream temperature
Fault component Oxicat Temp Sensing

Failure detection The sensed raw voltage value Exh_uRawTOxiCatUs is below 459,40mV
#T0292 L04 8102-5
Failure Turbocharger control: Open load of VTG actuator

Failure detection Hardware reports "open load" (OL) error
Broken or disconnected wiring, PWM actuator doesn’t work properly (only for WG
Failure cause
and pnumatic VGT Turbo)
Failure repair Check of wiring, replace PWM actuator.
40-186 WB93R-8
40 TROUBLESHOOTING
#T0293 L01 B7EB-E6

Failure Turbocharger control: Over temperature of VTG actuator
Failure detection Hardware reports "over temperature" (OT) error

High battery voltage, high ECU temperature and high load or defective wiring, power
Failure cause stage or VGT actuator.
PWM actuator doesn’t work properly (only for WG and pnumatic VGT Turbo).
Failure repair Check wiring, power stage and VGT actuator.

#T0294 L04 8102-3
Failure Turbocharger control: Short circuit to battery of VTG actuator

Failure detection Hardware reports "short circuit to battery" (SCB) error
Short circuit of wiring to external source or inside PWM actuator.

Failure cause
PWM actuator doesn’t work properly (only for WG and pnumatic VGT Turbo)
#T0295 L04 8102-4
Failure Turbocharger control: Short circuit to ground of VTG actuator

Failure detection Hardware reports "short to ground" (SCG) error
Short circuit of wiring to ground or inside PWM.

Failure cause
PWM actuator doesn’t work properly (only for WG and pnumatic VGT Turbo).
WB93R-8 40-187
40 TROUBLESHOOTING
#T0296 L03 B2E8-F3

Failure J1939 Network #1, Primary Vehicle Network Special Instruction
Error for Rolling Counter and Checksum of TSEACo_Tsc1 CAN message was
Failure detection
detected
Failure cause Defect on ABS / ASR / ESP CAN controller, CAN cable problem.
Failure repair Check correct functioning of the CAN controller. Check wiring.

#T0297 L03 B11-0
Failure SCR Catalyst Temperature sensing: SRC high for Catalyst temperature downstream
Fault component SCR Temp Sensor Downstream
Failure detection The Sensed raw voltage value SCR_uRawUCatDsT is above 3,30V
#T0298 L03 B11-1
Failure SCR Catalyst Temperature sensing: SRC low for Catalyst temperature downstream
Fault component SCR Temp Sensor Downstream
Failure detection The Sensed raw voltage value SCR_uRawUCatDsT is below 200,00mV
Failure cause Sensor defective or short circuit in wiring to ground

40-188 WB93R-8
40 TROUBLESHOOTING
#T0299 L03 811-0

Failure SCR Catalyst Temperature sensing: SRC high for Catalyst temperature upstream
Fault component SCR Temp Sensor Upstream
Failure detection The Sensed raw voltage value SCR_uRawUCatUsT is above 3,59V

#T0300 L03 811-1
Failure SCR Catalyst Temperature sensing: SRC low for Catalyst temperature upstream
Fault component SCR Temp Sensor Upstream
Failure detection The Sensed raw voltage value SCR_uRawUCatUsT is below 459,40mV
Failure cause Sensor defective or short circuit in wiring to ground
#T0301 L04 E106-1F
Failure SCR Reagent Tank Level: Empty Urea Tank
If the calculation of the tank level reaches a value of 0 (= EMPTY), an error message
Failure detection
will be issued.
Failure cause Tank is empty

Failure repair Refill Urea tank
WB93R-8 40-189
40 TROUBLESHOOTING
#T0302 L03 210D-5

Failure SCR Dosing valve: Diagnostic error check for open load.
Hardware reports an open load (OL) error on power stage for the Urea dosing Valve
Failure detection
Actuator.
Failure cause Broken or disconnected wiring or defective Urea Dosing Valve Actuator
Failure repair Check of wiring, replace Urea Dosing Valve Actuator

#T0303 L01 1215-6
Failure SCR Dosing valve: Diagnostic error check for overtemperature.
Hardware reports an excess temperature (OT) error on the power stage for the Urea
Failure detection
dosing Valve Actuator.
High battery voltage, high ECU temperature and high load or defective wiring, power
Failure cause
stage or Urea Dosing Valve Actuator defective
Failure repair Check battery voltage, wiring, power stage and Urea Dosing Valve Actuator.
#T0304 L03 210D-3
Failure SCR Dosing valve: Diagnostic error check for short circuit to battery.
Hardware reports a short circuit to battery (SCB) error on the power stage for the
Failure detection
Urea dosing Valve Actuator.
Short circuit of wiring (Ground wire) to external source or inside Urea Dosing Valve
Failure cause
Actuator.
Failure repair Check of wiring or replace Urea Dosing Valve Actuator.
40-190 WB93R-8
40 TROUBLESHOOTING
#T0305 L03 8AEB-E3

SCR Dosing valve: Diagnostic error check for short circuit to battery on the high side
Failure
switch.
The hardware detects a short circuit to battery at high side AND Low side switch
Failure detection
does NOT report an Open Load error (i.e. failure "UDosVlvOL" not active),
Short circuit in the wiring (+ wire) to U-Batt
Failure cause
Short circuit inside dosing valve actuator.

Failure repair
Check Dosing valve actuator.
#T0306 L03 210D-4
Failure SCR Dosing valve: Diagnostic error check for short circuit to ground.

Hardware reports a short circuit to ground (SCG) error on the power stage for the
Failure detection
Urea dosing Valve Actuator.
Failure cause Short circuit of wiring (Ground Wire) to ground or inside Urea Dosing Valve Actuator
Failure repair Check of wiring or replace Urea Dosing Valve Actuator
WB93R-8 40-191
40 TROUBLESHOOTING
#T0307 L03 8AEB-E4

SCR Dosing valve: Diagnostic error check for short circuit to ground on the high side
Failure
switch.
Failure detection The hardware detects a short circuit to ground at high side.
Short circuit in the wiring (+ wire) to Ground.

Failure cause
Short circuit inside dosing valve actuator.

Failure repair
Check Dosing valve actuator.

#T0308 L03 211-E
Failure Pressure line heater error and temperature condition to perform an afterrun
Failure detection The tank temperature falls below the defreezing threshold of 399,96°C.
Failure cause Blocked, frozen or damage pressure line. Heater ineffective
Check for urea heater wiring.

Failure repair
Replace the heater if ineffective.
#T0309 L01 311-1F
Failure Urea Backflow Line Heater Actuator power stage: FET error
Failure detection The hardware detects an FET error in the power stage.
Failure cause HCU internal circuit error.

Failure repair Replace HCU.
40-192 WB93R-8
40 TROUBLESHOOTING
#T0310 L03 311-5

Failure Urea Backflow Line Heater Actuator power stage: Open Load error
Hardware reports an Open Load error on power stage for UREA Backflow Line
Failure detection
Heater.
Failure cause Broken or disconnected wiring or defective UREA Backflow Line Heater.
Failure repair Check of wiring, replace UREA Backflow Line Heater.

#T0311 L03 311-3
Failure Urea Backflow Line Heater Actuator power stage: Short Circuit to Battery
Hardware reports a Short Circuit to Battery error on power stage for UREA Backflow
Failure detection
Line Heater
Failure cause Short circuit of wiring to external source or inside UREA Backflow Line Heater.
#T0312 L03 311-4
Failure Urea Backflow Line Heater Actuator power stage: Short Circuit to Ground
Hardware reports a Short Circuit to Ground error on power stage for UREA Backflow
Failure detection
Line Heater
Failure cause Short circuit of wiring to ground or inside UREA Backflow Line Heater.
WB93R-8 40-193
40 TROUBLESHOOTING
#T0313 L03 211-C

Failure Urea Pressure Line Heater: FET error
Failure detection The hardware detects an FET error at the power stage.
Failure cause HCU internal ciruit error.
Failure repair Replace HCU.

#T0314 L03 211-5
Failure Urea Pressure Line Heater: No load error
Hardware reports an Open Load (OL) error on the power stage for the power stage
Failure detection
of Urea Pressure Line heater.
Failure cause Broken or disconnected wiring or defective relay.
Failure repair Check of wiring, replace Urea Pressure Line heater actuator.
#T0315 L03 211-3
Failure Urea Pressure Line Heater: Short circuit to battery error

Failure detection
power stage of Urea Pressure Line heater
Failure cause Short circuit of wiring to external source or insideSCR Reagent Heating.
Failure repair Check of wiring, replace SCR Reagent Heating.
40-194 WB93R-8
40 TROUBLESHOOTING
#T0316 L03 211-4

Failure Urea Pressure Line Heater: Short circuit to ground error
Failure detection
power stage of Urea Pressure Line heater.
Failure cause Short circuit of wiring to ground or inside SCR Reagent Heating
Failure repair Check of wiring, replace SCR Reagent Heating.

#T0317 L01 7EEC-FF
Failure FET error
Failure detection The hardware detects an FET error in the power stage.
Failure cause Urea Supply Module Heater internal circuit error.
Failure repair Replace Urea Supply Module Heater.
#T0318 L03 7EEC-E5
Failure Urea Supply Module Heater Actuator power stage: Open Load error
Hardware reports an Open Load error on power stage for UREA Supply Module
Failure detection
Heater
Failure cause Broken or disconnected wiring or defective UREA Supply Module Heater
Failure repair Check of wiring, replace UREA Supply Module Heater
WB93R-8 40-195
40 TROUBLESHOOTING
#T0319 L03 7EEC-E3

Failure Urea Supply Module Heater Actuator power stage: Short Circuit to Battery
Hardware reports a Short Circuit to Battery error on power stage for UREA Supply
Failure detection
Module Heater
Failure cause Short circuit of wiring to external source or inside UREA Supply Module Heater

#T0320 L03 7EEC-E4
Failure Urea Supply Module Heater Actuator power stage: Short Circuit to ground
Hardware reports a Short Circuit to Ground error on power stage for UREA Supply
Failure detection
Module Heater
Failure cause Short circuit of wiring to ground or inside UREA Supply Module Heater
#T0321 L03 230D-5
Failure Urea Tank Heater: No load error (Reagent Tank Heater)

Hardware reports an Open Load (OL) error on the power stage for the power stage
Failure detection
of Urea Tank heater
Failure cause Broken or disconnected wiring or defective Urea Tank Heater.
Failure repair Check of wiring, replace Urea Tank Heater.
40-196 WB93R-8
40 TROUBLESHOOTING
#T0322 L03 230D-6

Failure Urea Tank Heater: Over Temperature error
Failure detection The hardware detects an over temperature at the power stage.
High battery voltage, high temperature inside ECU, high load or wiring problem or
Failure cause
actuator defective.
Failure repair Check battery voltage, wiring, power stage and actuator.

#T0323 L03 230D-3
Failure Urea Tank Heater: Short circuit to battery error
Failure detection
power stage of Urea Tank heater
Failure cause Short circuit of wiring to external source or inside Urea Tank Heater.
#T0324 L03 230D-4
Failure Urea Tank Heater: Short circuit to ground error

Failure detection
power stage of Urea Tank heater
Failure cause Short circuit of wiring to ground or inside Urea Tank Heater.
WB93R-8 40-197
40 TROUBLESHOOTING
#T0325 L03 1611-9

Failure SCR Reagent Pump: Communication Receive Fail
Failure detection When the communication of the pump motor fails (UPmpMot_stTFin = TRUE)
Failure cause Communication between ECU and SCR Reagent Pump is interrupted.
Check if Pump is delivering:

Failure repair
- If OK: failure is only sporadic then probably no action needed. If failure appears
several times then replace pump module.
- If Not OK then replace Pump module.

#T0326 L01 1611-10
Failure SCR Reagent Pump: Pump motor speed deviation
If there is a Pump speed deviation, the pump driver reports an "OL" or "SCG" Error
Failure detection
for a dedicated time duration between 4,50s and 5,50s.
Pump motor defective (blocked, possibly due to crystallisation (after long stand still
Failure cause
period) or frozen UREA in case of cold ambient condition)

If OK: failure is only sporadic (possibly long still stand periode or by frozen Reagent -
check ambient conditions), then probably no action needed.
Failure repair
If failure appears several times then replace pump module.
If Not OK then replace Pump module.
40-198 WB93R-8
40 TROUBLESHOOTING
#T0327 L03 1611-0

Failure SCR Reagent Pump: Permanent Pump Motor Speed Deviation
An SCG was reported by the power stage for a specific time. Additionally, the pump
Failure detection
motor has been restarted more than 5,00- times in the same driving cycle.
Pump motor defective (blocked, possibly due to crystallisation (after long stand still
Failure cause
periode) or frozen UREA in case of cold ambient condition).

If OK: failure is only sporadic (possibly long still stand periode or by frozen Reagent -
Failure repair
check ambient conditions) then probably no action needed.
If failure appears several times then replace pump module.

#T0328 L03 3B15-5
Failure SCR Reagent Pump: No load error on power stage for urea pump motor
The hardware detects an open load error on the PWM output power stage for the
Failure detection
Urea Pump Module Motor Actuator.
Failure cause Broken or disconnected wiring or defective relay.
Failure repair Check of wiring, replace Urea pump motor.
#T0329 L03 3B15-6
Failure SCR Reagent Pump: Over temperature error on power stage for urea pump motor
The hardware detects an over temperature on the PWM output power stage for the
Failure detection
Urea Pump Module Motor Actuator.
Failure cause High battery voltage, high temperature inside ECU, high load or wiring problem.
Failure repair
check wiring, replace ECU.
WB93R-8 40-199
40 TROUBLESHOOTING
#T0330 L03 32E0-E0

Failure Urea Pump motor internal Duty cycle above the maximum range value
Fault component SCR Supply Module
Failure detection The raw duty cycle value of the sensor is greater than 86%.
Failure cause Pump Motor internal duty cycle in invalid range.
Failure repair Check of wiring harness, replace Urea Pump Motor Actuator.

#T0331 L03 32E0-E1
Failure Urea Pump motor internal Duty cycle below minimum range value
Failure detection The raw duty cycle value of the sensor is less than 4% .
Failure cause Pump Motor internal duty cycle in invalid range.
#T0332 L03 33E0-E0
Urea Pump Supply Heater Module temperature Duty cycle above the maximum
Failure
range value
Failure cause Supply Heater Module temperature greater than maximum range.
Failure repair Check of wiring harness, replace urea module heater.
40-200 WB93R-8
40 TROUBLESHOOTING
#T0333 L03 33E0-E1

Urea Pump Supply Heater Module temperature Duty cycle below minimum range
Failure
value
Failure detection The raw duty cycle value of the sensor is less than 4%.
Failure cause Supply Heater Module temperature below minimum range.
Failure repair Check of wiring harness, replace urea module heater.

#T0334 L03 34E0-E0
Failure Urea Pump motor speed Duty cycle above the maximum range value
Failure cause Pump Motor speed above maximum admitted value.
#T0335 L03 34E0-E1
Failure Urea Pump motor speed Duty cycle below minimum range value
Failure cause Pump Motor speed below minimum admitted value.

WB93R-8 40-201
40 TROUBLESHOOTING
#T0336 L03 35E0-E0

Failure Urea Pump Supply Module temperature Duty cycle above the maximum range value
Failure cause Supply Module temperature greater than maximum range.
Failure repair Check of wiring harness, replace urea supply module.

#T0337 L03 35E0-E1
Failure Urea Pump Supply Module temperature Duty cycle below minimum range value
Failure cause Supply Module temperature below minimum range.
Failure repair Check of wiring harness, replace urea supply module.
#T0338 L03 3B15-3
SCR Reagent Pump: Short circuit to battery error on power stage for urea pump
Failure
motor
The hardware detects a short circuit to battery error on the PWM output power stage
Failure detection
for the Urea Pump Module Motor Actuator.
Failure cause Short circuit of wiring to external source or inside Urea pump motor.
40-202 WB93R-8
40 TROUBLESHOOTING
#T0339 L03 3B15-4

SCR Reagent Pump: Short circuit to ground error on power stage for urea pump
Failure
motor
The hardware detects a short circuit to ground error on the PWM output power stage
Failure detection
for the Urea Pump Module Motor Actuator.
Failure cause Short circuit of wiring to ground or inside Urea pump motor.

#T0340 L03 96EB-E5
Failure No load error on low powerstage for Urea back flow pump
Fault component Urea Back Flow Pump

Failure detection The hardware detects an open load at the power stage.
Harness defect.
Failure cause
Urea Back Flow Pump damaged.
Check ECU, Back Flow Pump harness.

Failure repair
Replace Back Flow Pump.
#T0341 L03 96EB-E6
Failure Over temperature error on low powerstage for Urea back flow pump
Failure detection The hardware detects an over temperature at the power stage.
Harness defect.
Failure cause

Failure repair
WB93R-8 40-203
40 TROUBLESHOOTING
#T0342 L03 96EB-E3

Failure Short circuit to battery error on low powerstage for Urea back flow pump
Failure detection The hardware detects a short circuit to battery at the power stage.
Harness defect.
Failure cause

Failure repair

#T0343 L03 96EB-E4
Failure Short circuit to ground error on low powerstage for Urea back flow pump

Failure detection The hardware detects a short circuit to ground at the power stage.
Harness defect.
Failure cause

Failure repair
#T0344 L03 200D-E
Failure HCU: Missing Power Supply voltage
Fault component Urea Heater
Failure detection The hardware detects a missing voltage error.
Failure cause Power supply of HCU defect. Wiring defect.

Check HCU module power supply harness, replace if damaged.
Failure repair
Replace HCU module.
40-204 WB93R-8
40 TROUBLESHOOTING
#T0345 L01 200D-1F

Failure HCU: NVM (internal memory) error
Failure detection The hardware detects an NVM error (Non Volatile Memory)
Failure cause Power supply of HCU defect, wiring defect or HCU defect.

Failure repair
Replace HCU module.

#T0346 L01 200D-6
Failure HCU: Over temperature error
Failure detection The hardware detects an over temperature error.
Failure cause Heater damaged, wiring defect or HCU defect.
Check HCU module - pressure line and tank heaters harness; Replace pressure line
Failure repair and tank heaters;
Replace HCU module.
#T0347 L01 200D-3
Failure HCU: Power Supply Overvoltage error

Failure detection The hardware detects an overvoltage error.

Failure repair
Replace HCU module.
WB93R-8 40-205
40 TROUBLESHOOTING
#T0348 L03 200D-4

Failure HCU: Power Supply Undervoltage error
Failure detection The hardware detects an undervoltage error.


Failure repair
Replace HCU module.

#T0349 L01 240D-4
Urea Quality Sensor: Shortcut to Battery error, via Catalyst Reagent Properties Pre-
Failure
liminary FMI
Fault component Urea Quality Sensor

Failure detection The signal from CAN SCR_stPropRdcAgFMI is equal to 3,00-
#T0350 L01 240D-5
Urea Quality Sensor: Shortcut to Ground error, via Catalyst Reagent Properties Pre-
Failure
liminary FMI
Failure detection The signal from CAN SCR_stPropRdcAgFMI is equal to 4,00-

40-206 WB93R-8
40 TROUBLESHOOTING
#T0351 L01 64E0-FF

Urea Quality Sensor: sensor system error detected, via Catalyst Reagent Properties
Failure
Preliminary FMI
Failure detection The signal from CAN SCR_stPropRdcAgFMI is equal to 12,00- or 11,00-
Failure cause Sensor defective.
Failure repair Replace sensor.

#T0352 L01 20EC-E3
Urea Quality Sensor: Shortcut to Battery error, via Catalyst Reagent Temperature 2
Failure
Preliminary FMI

Failure detection The signal from CAN SCR_stTRdcAg2FMI is equal to 3,00-
#T0353 L01 20EC-E4
Urea Quality Sensor: Shortcut to Ground error, via Catalyst Reagent Temperature 2
Failure
Preliminary FMI
Failure detection The signal from CAN SCR_stTRdcAg2FMI is equal to 4,00-

WB93R-8 40-207
40 TROUBLESHOOTING
#T0354 L01 20EC-FF

Urea Quality Sensor: sensor system error detected, via Catalyst Reagent Tempera-
Failure
ture 2 Preliminary FMI
Failure detection The signal from CAN SCR_stTRdcAg2FMI is equal to 12,00- or 11,00-
Failure cause Sensor defective
Failure repair Replace sensor

#T0355 L01 BC0D-1F
Failure Urea Quality Sensor: Reducing agent concentration outside range
Reducing agent concentration SCR_concRdcAg is outside the limits of 25,00% and

Failure detection
65,00%
Failure cause Reducing agent concentration outside accepted range
Failure repair Check DEV tank content, replace fluid if necessary
#T0356 L03 C10D-1F
Failure Urea Quality Sensor: critical fluid identified

A concentration or conductivity out of range has been detected and the liquid was
Failure detection
classified as Diesel (SCR_stTypRdcAg == 2)
Critical substance instead of reagent was detected (diesel or other fluid potentially
Failure cause
destructive)
Failure repair Replace reagent
40-208 WB93R-8
40 TROUBLESHOOTING
#T0357 L01 E106-E
Failure SCR Reagent Tank Level: Diagnostic Fault Check for signal error from CAN

Failure detection Com_stUTnkLvlFMI is equal to 11,00- or 12,00-
Failure cause Wrong sensor message.
Failure repair Check the sensor, and replace it if needed
WB93R-8 40-209
40 TROUBLESHOOTING
40-210 WB93R-8
WB93R-8
HYDRAULIC EXCAVATOR
WB93R-8

50 DISASSEMBLY AND ASSEMBLY 01-
WB93R-8 50-1
CONTENTS
CONTENTS .............................................................................................................................................. 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY........................................................ 50-11

HOW TO READ THIS MANUAL ......................................................................................................... 50-11
COATING MATERIALS LIST.................................................................................................................. 50-13

Sketches of special tools...................................................................................................................... 50-17

REMOVE AND INSTALL RADIATOR ASSEMBLY ............................................................................. 50-19
REMOVAL AND INSTALL OF FAN CLUTCH ASSEMBLY ................................................................. 50-25
REMOVE AND INSTALL ENGINE....................................................................................................... 50-30
REMOVE AND INSTALL FUEL COOLER ASSEMBLY....................................................................... 50-40
REMOVE AND INSTALL EXHAUST PIPE .......................................................................................... 50-41
REMOVAL AND INSTALL BELLOWS PIPE ASSEMBLY ................................................................... 50-42
REMOVAL AND INSTALL KDOC ASSEMBLY.................................................................................... 50-46
REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY............................................... 50-52
REMOVE AND INSTALL DEF TANK SENSOR .................................................................................. 50-59
REMOVE AND INSTALL DEF TANK STRAINER ............................................................................... 50-61
REMOVE AND INSTALL DEF INJECTOR .......................................................................................... 50-62
REMOVE AND INSTALL AIR CLEANER ASSEMBLY ........................................................................ 50-69
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY........................................ 50-70
REMOVE AND INSTALL AIR CONDITIONER BELT .......................................................................... 50-72
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ......................................................... 50-74

REMOVE AND INSTALL ENGINE HOOD........................................................................................... 50-77
REMOVE AND INSTALL COUNTERWEIGHT .................................................................................... 50-79
REMOVAL AND INSTALL FRONT AXLE............................................................................................ 50-81
DISASSEMBLY AND ASSEMBLY FRONT AXLE ............................................................................... 50-84
REMOVAL AND INSTALL REAR AXLE ............................................................................................ 50-125
DISASSEMBLY AND ASSEMBLY REAR AXLE................................................................................ 50-128
REMOVAL AND INSTALL TRANSMISSION ..................................................................................... 50-181
DISASSEMBLY AND ASSEMBLY TRANSMISSION ........................................................................ 50-189
HYDRAULIC SYSTEM.......................................................................................................................... 50-285

REMOVAL AND INSTALL HYDRAULIC PUMP ASSEMBLY............................................................ 50-285
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY................... 50-289
WORK EQUIPMENT............................................................................................................................. 50-291

REMOVAL AND INSTALL LOADER WORK EQUIPMENT ASSEMBLY........................................... 50-291
REMOVAL AND INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY........................................ 50-295
REMOVAL AND INSTALL BACKHOE BOOM CYLINDER................................................................ 50-299
50-2 WB93R-8
REMOVAL AND INSTALL BACKHOE ARM CYLINDER .................................................................. 50-302

REMOVAL AND INSTALL BACKHOE TELESCOPIC ARM CYLINDER........................................... 50-305
REMOVAL AND INSTALL OUTRIGGER CYLINDER ....................................................................... 50-307
REMOVAL AND INSTALL BACKHOE BOOM SWING CYLINDERS................................................ 50-309
REMOVAL AND INSTALL BACKHOE BUCKET CYLINDER............................................................ 50-312
REMOVAL AND INSTALL BACKHOE BOOM LOCK CYLINDER..................................................... 50-314
REMOVAL AND INSTALL BACKHOE BOOM................................................................................... 50-316
REMOVAL AND INSTALL BACKHOE ARM ASSEMBLY ................................................................. 50-318
REMOVAL AND INSTALL BACKHOE TELESCOPIC ARM ASSEMBLY ......................................... 50-320
REMOVAL AND INSTALL BACKHOE BOOM SWING BRACKET ................................................... 50-322
REMOVAL AND INSTALL BACKHOE SLIDING BRACKET ............................................................. 50-324
REMOVAL AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON.............................. 50-327
CAB AND ITS ATTACHMENTS ........................................................................................................... 50-329

REMOVAL AND INSTALL OPERATOR'S CAB ASSEMBLY ............................................................ 50-329
ELECTRICAL SYSTEM ........................................................................................................................ 50-338

REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................... 50-338
REMOVE AND INSTALL FRONT PANEL ......................................................................................... 50-340
REMOVAL AND INSTALL STEERING COLUMN SWITCHES ......................................................... 50-342
REMOVAL AND INSTALL KOMTRAX TERMINAL ASSEMBLY....................................................... 50-344
WB93R-8 50-3
ABBREVIATION LIST
of the meaning.

Abbrevia-
tion
the tires rotate.
AISS Engine
reverse direction.
ARAC
ASR
BCV
not being used.
work tronic control
machine.
Crankcase Depres-
sion Regulator
50-4 WB93R-8

Abbrevia-
tion
than OLSS).
Electronic Control
Module
ECMV
Electronically Con-
System
EGR Engine
failure history).
portional Control
tive Structure
3449.
Forward-Neu-
tral-Reverse
WB93R-8 50-5

Abbrevia-
tion
Communication
Plus)
Communication
Plus)
System (D Series)
HST
(Same as IMV)
Unit
KCCV Engine
Komatsu Catalyzed
KCSF Engine gas.
Soot Filter
KDOC Engine
muffler.
ulate Filter
muffler.
50-6 WB93R-8

Abbrevia-
tion
KTCS
soft ground.
direction.
work tronic control
machine.
machine.
MMS Communication
NC Normally Closed
actuated.
NO Normally Open
actuated.
Open-center Load
Sensing System
less of the load.
PC Hydraulic system
tion sure.
PCCS
WB93R-8 50-7

Abbrevia-
tion
Pre-stroke Control
Valve

Motor (D, PC, etc)
ROPS Cab and canopy
structure)
3471 or ISO 12117-2.
SCR Urea SCR system
Le Systeme Interna-
principle applied.
energized.
TOPS Cab and canopy
12117.
direction of flow.
bocharger
is variable.
50-8 WB93R-8

Abbrevia-
tion
VHPC Engine control

HD: Dump truck
WA: Wheel loader

A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
WB93R-8 50-9

PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
50-10 WB93R-8
HOW TO READ THIS MANUAL
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY

This section describes the special tools, work procedures, and safety precautions necessary for removal,
installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity,
and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
Reading the special tools list

• The special tools required for removal and installation work are described in the list as symbols such as
A1, ..., X1. Part number, part name, necessity, and quantity are described.
• Details of the special tools are on “SPECIAL TOOLS LIST”. Details of sketches are on “SKETCHES OF
SPECIAL TOOLS”. Special tools required for a specified work is also described in each work proce-
dures.
• The symbols used in the table of special tools indicate the following meanings.
t: Not substitutable, and work cannot be performed without the tool.
q: Very useful tools to use which can be substituted with commercially available tools.
Reading the work procedures

All the necessary information for the work procedure, the precautions and prior knowledge relating to the work
procedures is described step by step.
Reading the symbols

Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
k
This signal indicates an extremely hazardous situation which will
Danger
k
Warning
k
Caution result in injury or property damage around the machine if it is not
avoided.
4
This signal indicates the weight of parts and components, and items
Weight which requires great attention to a selection of wires and working
posture for slinging work.
3
This signal indicates the tightening torque for portions which
Tightening torque
requires special care in assembling work.
2
This signal indicates a place to be coated with adhesive, grease, etc.
Coat
in assembling work.
5
This signal indicates a place to supply oil, coolant, etc. and the
Oil and coolant
quantity. (*1)
6
This signal indicates a place to drain oil, coolant, etc. and the quan-
Draining
tity.
*1:For places to supply oil, coolant, etc. and their quantities, see SPECIFICATIONS “TABLE OF FUEL,
COOLANT, AND LUBRICANTS”.
WB93R-8 50-11
Reading the signal word

Signal word for notice and remark describes the following.
Symbol Item Remark

If the precaution of this signal word is not observed, the machine
NOTICE NOTICE
damage or shortening of service life may occur.
REMARK
Remarks This signals contains useful information to know.
a
Reading the unit

International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.
50-12 WB93R-8
COATING MATERIALS LIST

Coating materials which are not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from falling off.
• Use for plastic (except polyethylene, poly-
20 g (con- Polyethyl- propylene, tetrafluoroethylene and vinyl
LT-1B 790-129-9050 tained 2 ene con- chloride), rubber, metal, and non-metal parts
pieces) tainer which require immediate and strong adhe-
sion.
Polyethyl- • Features: Resistance to heat and chemicals
LT-2 790-129-9180 50 g ene con- • Use to keep bolts and plugs from coming
tainer loose and as sealant.
790-129-9060
Adhesive
Set of adhe- • Use to bond and seal metal, glass and plas-
LT-3 1 kg Hard- Pail
sive and hard- tics.
ener 500 g
ener
Polyethyl-
LT-4 790-129-9040 250 g ene con- • Use to seal plugs for blank holes.
tainer
Holts MH705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines
• Instantaneous adhesive • Curing time: From
Polyethyl-
5 sec. to 3 min.
LT-1D 790-129-9140 50 g ene con-
tainer • Use to bond mainly metals, rubbers, plas-
tics, and woods.
• Instantaneous adhesive
Polyethyl-
Aron Alpha • Quick-curing type (max. strength is obtained
790-129-9130 2 g ene con-
201 after 30 minutes)
tainer
• Use to bond rubbers, plastics, and metals.
• General-purpose instantaneous adhesive
with excellent resistance to heat and impact
Loctite 499 428-99-80070 20 cc Tube
• Use for the bushing mounting faces of axle
supports.
Polyethyl-
• Features: Resistance to heat and chemicals
Loctite 648-50 79A-129-9110 50 cc ene con-
tainer • Use to bond high-temperature fit parts.
WB93R-8 50-13
Liquid gasket
Polyethyl- • Use to seal various threaded parts, pipe
LG-5 790-129-9080 1 kg ene con- joints, and flanges. • Use to seal taper plugs,
tainer elbows, and nipples for hydraulic piping.
• Features: Silicon-based heat and cold-resist-
ant
LG-6 790-129-9160 200 g Tube • Use to seal flange surface and threaded
parts
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based heat, vibration, and
LG-8 THREE-
419-15-18131 100 g Tube shock-resistant
BOND 1207B
• Use to seal transfer case, etc.
• Use for rough surfaces such as the circle
LG-9 THREE- gear top seal which is not clamped by bolts,
790-129-9310 200 g Tube
BOND 1206D gaps in the weld which must be caulked, etc.
• Can be coated with paint.
• Use as lubricant or sealant when inserting
LG-10 THREE-
790-129-9320 200 g Tube radiator hoses
BOND 1206E
• Can be coated with paint.
• Feature: Can be used together with solid
LG-11 THREE- gaskets.
790-129-9330 200 g Tube
BOND 1121 • Use for covers of the transmission case and
steering case etc.
THREEBOND
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211
Molybdenum disulfide lubricant
• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted parts, and
LM-P — 200 g Tube
threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are made
on metal surfaces to prevent the metals from
LM-S — 190 g Pail
galling.
• Use for the drive shaft splines, needle bear-
ings, various link pins, bolts, etc.
50-14 WB93R-8
Seizure prevention compound
• Feature: Seizure and galling prevention com-
pound with metallic super-fine-grain, etc.
LC-G
— — Pail • Use for the mounting bolt in the high temper-
NEVER-SEEZ
ature area of the exhaust manifold and the
turbocharger, etc.
Grease
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
G2-LI G0-LI (*)
SY-GA-160CN • Lithium grease with extreme pressure lubri-
*: For cold dis- Various Various
LI cation performance, general purpose type.
tricts
SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.
• Caution: Do not use this grease for rolling
Molybdenum
SYG2-400M 400 gx 10 Bellows- bearings like swing circle bearings, etc. and
disulfide
SYG2-400M-A 400 gx 20 type con- spline.
grease LM-G
SYGA-16CNM 16 kg tainer Pail • Caution: Use this grease for work equipment
(G2-M)
pins only when installing them, but do not
use it afterwards.
SYG2-400T-A
• Higher seizure resistance, heat resistance,
Hyper white SYG2-16CNT
Bellows- and waterproof than molybdenum disulfide
grease G2-T SYG0-400T-A
400 g 16 kg type con- grease
G0-T(*) *: For (*)
tainer Pail • Not so conspicuous on machine since color
cold districts SYG0-16CNT
(*) is white.
Biogrease SYG2-400B
G2-B G2-BT (*) SYGA-16CNB • Since this grease is bacterially biodegrada-
Bellows-
*: For use at SYG2-400BT ble in short period, the impact on microor-
400 g 16 kg type con-
high tempera- (*) ganisms, animals, and plants is kept to the
tainer Pail
ture and under SY-GA-16CNB minimum.
high load T (*)
• Feature: Silicon-based grease with wider
operating temperature range and superior
G2-S THREE-
— 200 g Tube thermal oxidative stability to prevent deterio-
BOND 1855
ration of rubber and plastic.
• Use for oil seals of the transmission, etc.
• Feature: Urea (organic) grease with heat
resistance and long service life, inclusion
G2-U-SENS type.
427-12-11871 2 kg Pail
Grease • Use for rubber, bearing and oil seal in
damper.
• Caution: Do not mix with lithium grease.
WB93R-8 50-15
Primer
Glass con- • Use to accelerate hardening of instantane-
Loctite 712 428-99-80080 100 mℓ
tainer ous adhesive.
SUNSTAR
For adhered window glass

Glass con- • Use as primer for cab side (Expiration
Paint Surface 22M-54–27260 150 mℓ
tainer date: 4 months after its production date)
Primer 435-98
• Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbon-
PRIMER
22M-54-27240 150 mℓ Steel can ate-coated surface (Expiration date: 6
435-41 for
days after its production date)
glass
• Use as primer for sash (alumite surface
SUNSTAR treatment) (Expiration date:6 months
sash primer 22M-54-27250 900 mℓ Steel can after its production date)
GP-402
Adhesive
Polyethyl-
Sika Japan
20Y-54-39850 310 mℓ ene con-
Sikaflex 256HV • Use as adhesive for glass (Expiration
tainer
date: 6 months after its production date)
SUNSTAR Ecocart
Penguin Super 22M-54-27210 320 mℓ (special • Use as adhesive for glass (Expiration
560 container) date: 6 months after its production date)
• Use as adhesive for glass (Expiration
SUNSTAR Ecocart date: 6 months after its production date)
Penguin Seal 416–926–6950 320 mℓ (special
#560 container)
Caulking material
SUNSTAR Polyethyl-
Penguin Seal 417-926-3920 320 mℓ ene con- • Use to seal for joint between glasses
No.2505 tainer (Expiration date: 4 months after its pro-
duction date)
Polyethyl-
SEKISUI Sili- • Use to seal front window (Expiration
20Y-54-55130 333 mℓ ene con-
cone Sealant date: 6 months after its production)
tainer
• Translucent white seal used for joint
GE TOSHIBA between glasses (Expiration date: 12
SILICONES 22M-54-27220 333 mℓ Cartridge months after its production date)
TOSSEAL381
50-16 WB93R-8
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
Transmission support
WB93R-8 50-17
Special key
50-18 WB93R-8
REMOVE AND INSTALL RADIATOR ASSEMBLY

k Place the machine on a level ground, fully raise the front work equipment and lock them in posi-
tion with safety bar.
k Set the work equipment lock lever to LOCK position.
k Turn the starting switch to OFF position to stop the engine.
k Turn the battery disconnect switch to OFF position, and remove the key. (For details, see “30
TESTING AND ADJUSTING - HANDLING BATTERY DISCONNECT SWITCH”).
REMARK
• Check the connector numbers and installed positions before disconnecting wirings and hoses, and
record them.
• Fit a plug or flange in the place where a hydraulic hose is disconnected to prevent oil from flowing out.
METHOD FOR REMOVING RADIATOR ASSEMBLY

1. Drain oil from the hydraulic tank (For details, see
“40 TROUBLESHOOTING - METHOD FOR
CHANGING OIL IN HYDRAULIC TANK, CLEAN-
ING HYDRAULIC TANK STRAINER”).
[*1]
2. Remove engine hood (For details, see
“REMOVE AND INSTALL ENGINE HOOD”).
3. Remove counterweight (For details, see
“REMOVE AND INSTALL COUNTERWEIGHT”).
4. Loosen the drain valve (1) of the radiator, and
drain coolant.
6 Radiator: 12 ℓ
1
RKAD4450
5. Disconnect the connector HORN (2) of front horn

(3). [*2] 3 2
6. Remove bolts (4) and (5) and place the con- 4 4
denser assembly (6) aside so that it does not hin-
der the work.
6
RKAD4270
WB93R-8 50-19
7. Remove bolts (7) and place the fuel cooler (8)

aside so that it does not hinder the work.
8
RKAD4280
8. Disconnect the connector FFH (9) and WIF (10)

of fuel prefilter. [*3]
9. Remove lower and upper bolts (11),and place 11
the wiring harness (12) aside.
10
12
11
RKAD4290
10. Remove bolt (13) disconnect clamp (14).
13
14
RKAD4300
11. Remove bolts (15) and place the fuel prefilter

(16) aside so that it does not hinder the work.
15
16
RKAD4310
50-20 WB93R-8
12. Loosen clamp (17) and (18) and disconnect

hoses (19) and (20).
18 20
13. Disconnect hose (21) and union (22).
17
14. Remove bolts (23).
19
RKAD4320
23
22
21
RKAD4321
15. Remove bolts (24) (3 pieces) and remove fan

guard (25).
24
25
24
RKAD4330
16. Disconnect hose (26).
26
RKAD4340
WB93R-8 50-21
43
RKAD6540
18. Remove bolts (27) and expansion tank (28).

27
29
28
29
RKAD4350
20. Remove bolts (30) and move the conveyor (31)

backwards so that it does not hinder the work.
[*4]
31
30
RKAD4360
21. Loosen clamps (32) and disconnect hoses (33)

from the transmission oil cooler.
REMARK 38
• Mark hoses to avoid mistake when installing. 32
33
RKAD4380
50-22 WB93R-8
22. Loosen clamp (34) and disconnect hose (35)

from the engine cooling water radiator.
23. Loosen clamp (36) and disconnect hose (37)
from the intercooler.
24. Disconnect hose (38) from hydraulic oil cooler.
34
35
36
37
RKAD4370
25. Remove nuts (39), washer (40) and puffer (41).

[*5]
41
40
39
RKAD4440
26. Sling the radiator assembly (42) and remove it.

NOTICE
• Be careful not to damage the fin on the sur-
face of the radiator assembly (42) when
42
installing.
RKAD4390
WB93R-8 50-23
METHOD FOR INSTALLING RADIATOR ASSEMBLY

• Perform installation in the reverse order to
removal.
[*1]
• Refill the machine with coolant and hydraulic oil.
(For details, see “40 TROUBLESHOOTING” -
“METHOD FOR CHANGING OIL IN HYDRAU-
LIC TANK, CLEANING HYDRAULIC TANK
STRAINER” and “METHOD FOR CHECKING
COOLANT LEVEL, ADDING COOLANT”)
[*2]
• Connect the connector HORN (2).
[*3]
• Connect connectors FFH (9) and WIF (10).
[*4]
• Position the radiator assembly so that the cooling
fan is inserted of about 2/3 (around 50 mm) of its
thickness (75 mm) inside the conveyor when the 50 25
radiator assembly is in vertical position, then
tighten bolt (38).
RKA84010
[*5]
• Do not finally tighten nut (39) in this procedure,
because radiator has to be aligned with the cool-
ing fan once the conveyor is installed.
50-24 WB93R-8
REMOVAL AND INSTALL OF FAN CLUTCH ASSEMBLY

REMARK
record them.
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY

1. Drain oil from the hydraulic tank (For details, see
“40 TROUBLESHOOTING - METHOD FOR
CHANGING OIL IN HYDRAULIC TANK, CLEAN-
ING HYDRAULIC TANK STRAINER”).
[*1]
3. Loosen the drain valve (1) of the radiator, and
drain coolant.
6 Radiator: 12 ℓ
1
RKAD4450
4. Disconnect the connector FFH (2) and WIF (3) of

fuel prefilter. [*2]
5. Remove lower and upper bolts (4),and place the 4
wiring harness (5) a side.
3
5
2
4
RKAD4291
WB93R-8 50-25
RKAD4301
7. Remove bolts (8) and place the fuel prefilter (9)

RKAD4311
8. Loosen clamp (10) and (11) and disconnect

hoses (12) and (13).
11 13
9. Disconnect hose (14) and union (15).
10
12
RKAD4322
16
15
14
RKAD4323
50-26 WB93R-8
11. Remove bolts (17) (3 pieces) and remove fan

guard (18).
17
18
17
RKAD4331
12. Disconnect hose (19).
19
RKAD4341
43
RKAD6540
14. Remove bolts (20) and expansion tank (21).

20
22
21
22
RKAD4351
WB93R-8 50-27
16. Remove bolts (23) (3 pieces)
23
RKAD4400
17. Disconnect connector FC01 (24) of fan clutch.

[*3]
24
RKAD4410
18. Remove bolts (25). Disconnect cooling fan (26)

from engine and move it inside the conveyor
(27). [*4] 26
NOTICE
faces of the radiator assembly when han-
dling the cooling fan. 25
RKAD4420
19. Remove bolts (28) (3 pieces).
28
RKAD4361
50-28 WB93R-8
20. Remove conveyor (27) together with the cooling

fan (26).
NOTICE 27
face of the radiator assembly when remov-
ing.
RKAD4430
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY

removal.
[*1]
[*2]
• Connect connectors FFH (9) and WIF (10).
[*3]
• Connect connectors FC01 (24).
3 Bolts (25): 56 - 77 Nm { 5.70 - 7.85 kgm}

[*4]
2 Bolts (25): Loctite 262
WB93R-8 50-29
REMOVE AND INSTALL ENGINE

Tools to be used when removing and installing engine assembly
New/Redesign
Necessity
Sketch
Q'ty
Symbol Part No. Part name Remarks
A - Special key q 1 q See schetch

Commercially
B Jack q 1
available
Commercially
C Fabric belt q 1
available
Commercially
D Lifting tool (with hook) q 1
available
k Place the machine on a level ground, and lower the work equipment to the ground in a stable
posture.
REMARK
record them.
METHOD FOR REMOVING ENGINE

1. Drain oil from the hydraulic tank (For details, see “40 TROUBLESHOOTING - METHOD FOR CHANG-
ING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER”). [*1]
2. Remove engine hood (For details, see “REMOVE AND INSTALL ENGINE HOOD”).
3. Remove loader work equipment (For details, see “REMOVAL AND INSTALL LOADER WORK EQUIP-
MENT ASSEMBLY”).
4. Remove radiator assembly (For details, see “REMOVE AND INSTALL RADIATOR ASSEMBLY”).
5. Remove fan clutch assembly (For details, see “REMOVAL AND INSTALL OF FAN CLUTCH ASSEM-
BLY”).
6. Remove air cleaner assembly (For details, see “REMOVE AND INSTALL AIR CLEANER ASSEMBLY”).
7. Remove KDOC assembly (For details, see “REMOVAL AND INSTALL KDOC ASSEMBLY”).
8. Remove bellows pipe assembly (For details, see “REMOVAL AND INSTALL BELLOWS PIPE ASSEM-
BLY”).
50-30 WB93R-8
9. Loosen bolts (1) (2 pieces) and (2) (2 pieces).

2 2
1 1
RKAD4720
10. Loosen bolt (3) and nut (4) and unscrew bolt (5).
11. Remove air conditioner compressor belt (6). [*2] 3
5
6
4
RKAD4730
12. Remove the bolts (1) and (2) and place the air
conditioner compressor assembly (8) aside so
that it does not hinder the work.
13. Loosen bolts (9), and remove protection (10).
10
RKAD4740
WB93R-8 50-31
14. Disconnect connector K12 (11) and remove

clamps (12).
11
12
RKAD4750
15. Disconnect connectors ENG01 (13) and GCU

(14) of engine.
14
13
RKAD4760
16. Disconnect connectors AC01 (15) of air condi-

tione compressor.
17. Remove all the clamps (16).
15
16
RKAD4770
18. Disconnect fuel hoses (17).

NOTICE
• Plug hoses to prevent fuel leakage and
entry of foreign materials.
17
RKAD4780
50-32 WB93R-8
19. Remove bolt (18) and disconnect transmission oil

level pipe (19). [*3]
20. Remove bolts (20) and clamps (21).
18 21
21
20
19
RKAD4790
21. Disconnect connectors E20 (22) of alternator.

22. Remove clamp (23) and disconnect hose (24).
22
24 23
RKAD4800
23. Remove cover (25) and disconnect connectors

E18 (26) and cables (27) and (28) of starting
27
motor. [*4] 28
25 26
RKAD4810
24. Remove bolts (29) and clamps (30).
29
30
30
29
RKAD4820
WB93R-8 50-33
25. Remove clamp (31) and disconnect hose (32).
31
32
RKAD4830
26. Disconnect connector B22 (33) and ground cable

(34) from frame.
33
35
34
RKAD4840
28. Disconnect hose (36) from DEF coolant solenoid

valve (37).
36
37
RKAD4850
29. Disconnect hose (38) and remove union (39).
38
39
RKAD4860
50-34 WB93R-8
30. Use special tool A inserted into the cranckshaft

pulley to rotate the engine and loosen screws
(40) locking engine flywheel to torque converter.
[*5]
40
RKAD4870
31. Remove front floor mat (41).
41
RKAD3702
42
RKAD3711
33. Remove floor cover (43)
43
RKAD3721
WB93R-8 50-35
34. Loosen and remove upper bolts (44) (6 pieces).

[*6]. 44
35. Loosen and remove lower bolts (45) (6 pieces). 44
NOTICE
• Leave in position the 2 lower bolts (45) for
safety.
45
RKAD4880
36. Position a stand B under the transmission (46) to

support it.
37. Using a fabric belt C and a chain D connected to

the air filter support (47), sling the engine (48).
50-36 WB93R-8
NOTICE
• Take care not to damage the rail pressure
sensor (49).
49
RKAD4890
NOTICE
• Make the fabric belt route between flywheel
housing and cylinder block.
• Do not route the belt under the oil sump
directly, because it can be damaged.
RKAD4900
NOTICE
• Make the fabric belt route between cylinder
block and starting motor.
RKAD4910
38. Loosen bolt (50) and remove nuts (51). [*7]
50
51
RKAD4920
WB93R-8 50-37
39. Remove lower bolts (45) (2 pieces) fixing trans-

mission (46) to engine (48).
45
RKAD4930
40. Remove engine assembly (48).
4 Engine assembly: 380 kg

48
RKAD4940
METHOD FOR INSTALLING ENGINE ASSEMBLY

removal.
[*1]
[*2]
• Install air compressor belt (6) (For details, see
“REMOVE AND INSTALL AIR CONDITIONER
BELT”)
[*3]
3 Bolt (18): 72-99 Nm {7,4-10,1 kgm}
2 Bolt (18): Loctite 262
[*4]
3 Nut fixing ground cable (M10):
3 Nut fixing connector E18 (M6):

15-21 Nm {1.3-2.1 kgm}
3 Nut fixing supply cable (M10):

4.8-6.8 Nm {0.5-0.7 kgm}
12-18 Nm {1.22-1.84 kgm}
50-38 WB93R-8
[*5]
3 Bolt (38): 52-71,5 Nm {5,3-7,29 kgm}
2 Bolt (38): Loctite 242)
[*6]
3 Bolt (44) and (45): 39,2-53,9 Nm {4-5,5 kgm}
2 Bolt (44) and (45): Loctite 262
[*7]
3 Bolt (50): 156-214,5 Nm {15,9-21,9 kgm}
WB93R-8 50-39
REMOVE AND INSTALL FUEL COOLER ASSEMBLY
REMOVE AND INSTALL FUEL COOLER ASSEMBLY

REMARK
If the fuel level is higher, fuel flowing from the fuel tank return hose does not stop. Therefore, drain fuel before
starting any work.
METHOD FOR REMOVING FUEL COOLER ASSEMBLY

1. Remove the bolts (1), and remove front mask (2).
1 2
RKAD4021
2. Disconnect the fuel tank return hose (3) and fuel
inlet hose (4) of the fuel cooler assembly (5). 3
NOTICE
• Fix the elbow head with a wrench, rotate the 5
hose fitting in the loosening direction with 4
another wrench, and then disconnect the 6
hose.
• Do not apply a force to the fuel cooler when
loosening. Otherwise, the fuel cooler tube
is damaged.
3. Remove the bolts (6), and remove the fuel cooler
assembly (5). RKAD4281
NOTICE
faces of the fuel cooler assembly (5) when
removing.
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY

removal.
50-40 WB93R-8
REMOVE AND INSTALL EXHAUST PIPE
REMOVE AND INSTALL EXHAUST PIPE

REMARK
If the fuel level is higher, fuel flowing from the fuel tank return hose does not stop. Therefore, drain fuel before
starting any work.
METHOD FOR REMOVING EXHAUST PIPE

1. Loosen nuts(1).
1
RKAD4460
2. Loosen screw (2) and remove exhaust pipe (3).

NOTICE
• Loosen nut (4) before loosening screw (2).
2
RKAD4120
METHOD FOR INSTALLING EXHAUST PIPE

removal.
WB93R-8 50-41
REMOVAL AND INSTALL BELLOWS PIPE ASSEMBLY

METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY

1. Remove bolts (1) and protection (2).
2
1
RKAD4470
2. Remove bolt (3) and clamp (4).

3. Remove bolt (5) and protection (6)
3
5
RKAD4480
4. Disconnect turbocharger outlet NOx sensor (7).

and the KDOC inlet temperature sensor (8).
RKAD4490
50-42 WB93R-8
NOTICE
• Loosen the nut (a), hold the metal part (b),
and then pull out the sensor (7) vertically in
the direction of the arrow.
NOTICE
• Loosen the nut (a), hold the metal part (b),
and then pull out the sensors (8)vertically b
RKAD4560
5. Remove the clamp (9) of the bellows pipe

assembly (10). [*1] 9
6. Remove the clamp (11), and remove the bellows
pipe assembly(10)
10
11
RKAD4500
NOTICE
• Discard gasket (12).
12
RKAD4510
WB93R-8 50-43
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY

removal.
[*1]
1. Align the installing position of the bellows pipe
assembly (10), and tighten the clamps (9) and
(11) lightly according to the following procedure.
NOTICE
• Use a new gasket (12).
• Replace the clamps (9) and (11) with new
ones.
• Align the KDOC inlet with the bellows pipe.
1) Tighten the nuts of the clamps (9) and (11)
until you feel reaction force of they being
tightened.
2) Loosen the nuts of the clamp (9) by 3 turns.
2. Tighten the clamps (9) to the specified torque

according to the following procedure.
1) Check that the clearance (a) is secured
between the whole circumferences of the a
clamps (9) and flare.
9
2) Hit the clamps (9) from 180 ° opposite side of
the bolt in the order of (d) to (e) and of (f) to
(g) shown in the following drawing by using
the plastic hammer.
3) Tighten the clamps (9) to the specified
torque.
3 Clamps (9): 6 to 8 Nm {0.61 to 0.82 kgm}
RKA76623
e g
d f RKA84040
50-44 WB93R-8
[*2]
NOTICE
• Hold the metal parts (b) by hands, and
insert the sensors (8) vertically in the direc-
b
2 Threaded portion of sensor: Seizure preven-
tion of the arrow, and tighten the nuts (a).
a
tion compound (LC-G)
3 KDOC inlet temperature sensor (3): 40 to 50
Nm {4.1 to 5.1 kgm}
RKAD4570
NOTICE
• Hold the metal parts (b) by hands, and
insert the sensor (7) vertically in the direc-
2 Threaded portion of sensor: Seizure preven-

tion of the arrow, and tighten the nuts (a).
tion compound (LC-G)

3 Turbocharger outlet NOx sensor (14):
40 to 60 Nm {4.1 to 6.1 kgm}
WB93R-8 50-45
REMOVAL AND INSTALL KDOC ASSEMBLY

Tools to be used when removing and installing KDOC and SCR.
New/Redesign
Necessity
Sketch
Q'ty
A EA5801954033 DEF injector cap kit q 1

Plug (for 5/16 inch hose
B 600-919-5050 q 2
diameter)
DEF injector electric connec- Disconnecting DEF hose
C 6540-71-1310 q 2
tor cover
Commercially
D Vinyl gloves q 1
available
Be sure that the DEF purging procedure has been completed before removing any DEF hose.
k Before opening the water filler cap or draining coolant, check that the coolant temperature cools
down to the temperature safe enough for anyone not to get burn.
k KDOC and SCR assembly, and the periphery are heated to 500 °C or above. Take care not to get
burn injury.
k Check that KDOC and SCR assembly, and the periphery have cooled down to the temperature
safe enough for anyone not to get burn before performing the work.
k Check that no combustible material (dry leaves, twigs, etc.) is accumulated around KDOC, DEF
mixing tube, and SCR. If any dusts or combustible materials are found, remove them.
k Handle KDOC, DEF mixing tube, and SCR with care since they are fragile against shock such as
falling. Do not reuse damaged part.
k Use anti-dust mask during the work to prevent inhaling mat material or metallic powder always
when disposing KDOC, DEF mixing tube, and SCR.
k Be sure that the DEF purging procedure has

METHOD FOR REMOVING KDOC ASSEMBLY
been completed before removing any DEF

hose.
1. Disconnect the coolant hoses (1). 1
2. Install cap (A) on cooling port of DEF injector.
REMARK 3
The cap (A) are installed to prevent entry of
foreign materials.
NOTICE
• After disconnecting the coolant hoses (1),
2
be careful not to drain the coolant from the RKAD4520
hose.
50-46 WB93R-8
3. Wear the vinyl gloves and disconnect the DEF

hose (2). [*1]
NOTICE
D
• Be sure to wear the vinyl gloves (D) when
handling DEF.
• Disconnect the DEF hose (2), and then
disconnect the DEF injector connector
MB03 (3). (To prevent DEF from sticking
to the connector)
REMARK
Pinch the protruding portions (e) of the clip with RKAD4580
your fingers, then the lock is unlocked. Pull out
DEF hose (2) directly while they are kept pinched.
RKAD4590
4. Slide the lock (red) of the connector MB03 (3) in

the direction of the arrow (a) as shown in the fig-
ure, and disconnect the connector MB03 while
pressing the part (b) and pulling it.
a
b
RKAD4600
NOTICE
After disconnecting the connector MB03 (3),
install the cover (C) to the connector in DEF
injector side. C
RKAD4610
WB93R-8 50-47
5. Install the plug (B) on DEF hose (2) side, and

install the cap (A) on the pin side of DEF injector.
REMARK B
The plug (B) and cap (A) are installed to prevent A
DEF leakage and entry of foreign materials.
RKAD4620
5
4
RKAD4471
7. Remove clamps (6) and (7) of the bellows pipe

assembly (8). [*2]
6 7
8
RKAD4530
NOTICE
• Discard gasket (9).
9
RKAD4511
50-48 WB93R-8
10
10
RKAD4540
9. Remove KDOC assembly (11).
11
RKAD4550
WB93R-8 50-49
METHOD FOR INSTALLING KDOC ASSEMBLY

removal.
[*1]
1. Wear the vinyl gloves (D) to remove the plug (B)
from DEF hose, and cap (A) from the DEF injec-
tor pin.
NOTICE D
handling DEF.
RKAD4580
B
A
RKAD4620
50-50 WB93R-8
2. Wear the vinyl gloves (D) to connect the DEF

hose (2).
NOTICE
D
handling DEF.
• Connect the DEF hose (2), and then con-
nect the DEF injector connector MB03
(22).
• (To prevent DEF from sticking to the con-
nector)
• Clean the connection of DEF hose (2) and RKAD4580
DEF injector pin thoroughly, and check

that there is no dust or damage.
• Click the connector (m) of DEF hose (2)
into the pin (k) on the injector side. 1
•
When the connector is inserted until the
convex part (n) of the pin (k) passes the 3
convex part inside the clip, it can be
locked by the clip.
3. Connect the coolant hoses (1).
2
RKAD4520
m
n
k
RKAD4630
4. Connect the connector MB03 (3).

1) Remove the cover (C) that was fitted to the
connector on DEF injector side of the con-
nector MB03 (3). C
NOTICE
• After connecting the connector MB03 (3),
return the lock (red) in the direction of the
arrow (a) as shown in the figure.
RKAD4610
[*2]
• Install the clamps (6) and (7) of the bellows pipe
assembly (For details see “REMOVAL AND
INSTALL BELLOWS PIPE ASSEMBLY”
WB93R-8 50-51
REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY

Tools to be used when removing and installing DEF tank sensor flange assembly
New/Redesign
Necessity
Sketch
Q'ty
Commercially Disconnecting and connect-

A Vinyl gloves q 1
available ing DEF hose
Commercially
Vinyl hose q 1
available
B Drain of DEF
Commercially
Fitting with valve q 1
available
Commercially
C Oil pan q 2 Draining DEF and coolant
available
Plug (for 3/8 inch hose diam-
D 600-919-5030 q 2
eter) Disconnecting DEF hose
E 6540-71-2720 DEF pump cap kit q 1
Commercially Removing and installing DEF
F Lifting tool (with hook) q 1
available tank assembly
k Place the machine on a level ground, lower the work equipment to the ground, and stop the
engine.
METOD FOR REMOVING DEF TANK SENSOR FLANGE

1. Loosen screws (1) and remove L.H. cover (2).
1
RKAD5171
50-52 WB93R-8
2. Loosen bolts (3) and remove protection (4).
RKAD6350
3. Loosen bolts (5) (6 pieces) and remove cover (6).
5
6
5 RKAD6360
4. Disconnect the breather hose (7), and connect
the vinyl hose (B) with valve.
NOTICE
7
• Close the cap (8) securely so that no air
enters DEF tank assembly.
• Be sure to close the valve (B1) when con-
necting the vinyl hose (B) with valve.
8
RKAD6430
B1
RKAD6390
WB93R-8 50-53
5. Place the oil pan under the DEF tank.

NOTICE
• Never use an iron or aluminium container
when disposing DEF fluid, because toxic 9
gas may be generated and a chemical reac-
tion may corrode the container.
• Use a container made of resin (PP, PE) or
stainless steel to catch the draining DEF.
6. Wear the vinyl gloves (A) to loosen the drain plug
(9), and drain DEF. [*1]
6 DEF tank assembly: 21.1 l RKAD6380
NOTICE
• Be sure to wear the vinyl gloves (A) when
handling DEF. A
• Drain the DEF while adjusting DEF flow by
using the valve (B1) of the vinyl hose (B)
with valve.
7. Close the drain plug (9) when the draining is fin-
ished.
3 Drain plug (9):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
RKAD4581
B1
RKAD6390
50-54 WB93R-8
8. Using an appropriate plier, clamp the coolant

hoses (10) and (11) to avoid cooling liquid leak-
ages, disconnect and plug them.
9. Remove the clamp (12) of the coolant hoses (10) 12 14
10. Remove the clamps (13) and (14) 13
11. Wear the vinyl gloves (A) to disconnect the DEF
hoses (15) [*1]. 15
NOTICE 10
handling /DEF.
11
• Before disconnecting DEF hose (15), wash RKAD6450
the connecting portions with clean tap

water to remove the fouling.
A
RKAD4581
REMARK
Pinch the protruding portions (e) of the clip with your
fingers, then the lock is unlocked. Pull out DEF hose
(15) directly while they are kept pinched.
12. Install the plug (D) on DEF hose (15) side, and
install the cap (E) on the disconnected nipple
side. D
REMARK E
The plug (D) and cap (E) are installed to prevent
WB93R-8 50-55
13. Disconnect connector P63 (16).
16
RKAD6440
14. Remove the bolts (17) (12 pieces), and remove
the DEF tank sensor flange assembly (18). [*2] 17
NOTICE 17
Pull out the curved tip (a) of DEF tank sensor
flange assembly (18) carefully not to interfere
with DEF tank (19). 17
18
RKAD6400
18
19
RKAD6410
50-56 WB93R-8
METOD FOR INSTALLING DEF TANK SENSOR FLANGE ASSEMBLY

removal.
[*1]
• Refill DEF tank with DEF to the specified level through the filler port. (For details, see "01 SPECIFICA-
TION“ - “TABLE OF FUEL, COOLANT, AND LUBRICANTS".)
5 DEF tank: 21.1 l

• If necessary, refill the radiator with coolant to the specified level through the coolant filler port. Run the
engine to circulate the coolant. Then check the coolant level again. (For details, see "01 SPECIFICA-
TION“ - “TABLE OF FUEL, COOLANT, AND LUBRICANTS".)
[*2]
1. Wear the vinyl gloves (A) to install O-ring (20) to
DEF tank (19).
NOTICE A
handling DEF.
• Use a new O-ring (20).
2. Install the O-ring (20) to the tip of DEF tank sen-
sor flange assembly (18).
NOTICE
RKAD4581
handling DEF.
3. Apply distilled water to O-rings (20) and (21) as 21
lubricant.
20
NOTICE
Do not use grease, lubricating oil, or any lubri-
cating substance. Otherwise, it may cause
19
2 O-rings (20), (21): Distilled water
failures if it is mixed into the DEF tank.
RKAD6420
WB93R-8 50-57
4. Press the top of DEF tank sensor flange assem-

bly (18) by hands with careful attention not to get
O-rings (20) and (21) caught, so that the mount-
ing face is seated on the flange.
NOTICE
• Install the DEF tank sensor flange assembly
(18) straight without rotating when the flange is
seated on the installing face. (To prevent
O-rings (20) and (21) from falling off, and twist-
ing.)
• Check that the tip (b) of DEF tank sensor 18
flange assembly (18) is securely inserted into RKAD6401
the installing groove (c) of the bottom flange.

5. Install the DEF tank sensor flange assembly (18)
with the bolts (17) (12 pieces).
3 Mounting bolt (17):
b
c
9.5 to 10.5 Nm {0.97 to 1.07 kgm}
RKA84340
50-58 WB93R-8
REMOVE AND INSTALL DEF TANK SENSOR

posture.
METHOD FOR REMOVING DEF TANK SENSOR
1. Remove the DEF tank sensor flange assembly by referring to “REMOVE AND INSTALL DEF TANK
SENSOR FLANGE ASSEMBLY”.
2. Remove the clamp (1).
3. Remove the mounting bolts (2), and remove the
DEF tank sensor (3).
NOTICE
• Pull out the DEF tank sensor (3) while tak- 2
ing care to prevent the tip (4) of DEF tank
sensor from being stuck halfway.
1 3
RKAD6460
RKAD6470
METHOD FOR INSTALLING DEF TANK SENSOR
1. Install O-ring (5) to DEF sensor (3).

NOTICE
2. Apply distilled water to O-ring (5) as lubricant. 5
NOTICE
• Do not use grease, lubricating oil, or any
lubricating substance. Otherwise, it may
cause failures if it is mixed into the DEF
2 O-ring (5): Distilled water

tank.
3
RKAD6480
WB93R-8 50-59
3. Install the DEF sensor (3) with the bolts (2).

REMARK
• When installing the DEF tank sensor (3), do
not turn it to prevent the O-ring (5) from falling
off and twisting. 2
• Press the top of DEF tank sensor (3) by hands
with careful attention not to get O-ring (5)
caught, so that the mounting face is seated on
the flange. 1 3
3 Bolts (2):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
RKAD6460
4. Install the clamp (1).
5. Install the DEF tank sensor flange assembly by
referring to “REMOVE AND INSTALL DEF TANK
50-60 WB93R-8
REMOVE AND INSTALL DEF TANK STRAINER
REMOVE AND INSTALL DEF TANK STRAINER

posture.
METHOD FOR REMOVING DEF TANK STRAINER
DEF tank sensor flange assembly
1. Remove the DEF tank sensor flange assembly by referring to “REMOVE AND INSTALL DEF TANK
2. Remove the bolt (1), and remove the strainer (2).
RKAD6490
METHOD FOR INSTALLING DEF TANK STRAINER

1. Install O-ring (3).
REMARK
• Use a new O-ring.
• If any foreign material is mixed into DEF tank, it 3
may cause failures. Do not use grease, lubri-
cating oil or any lubricating substance.
• Apply distilled water for lubricating O-ring (3).
2 O-ring (3): Distilled water
RKAD6500
2. Install the strainer (2) with the bolt (1).

3 Bolt (1): 4.9 to 5.9 Nm {0.5 to 0.6 kgm}
3. Install the DEF tank sensor flange assembly by
2
referring to “REMOVE AND INSTALL DEF TANK
1
RKAD6490
WB93R-8 50-61
REMOVE AND INSTALL DEF INJECTOR

Tools to be used when removing and installing DEF injector
New/Redesign
Necessity
Sketch
Q'ty
A EA5801954033 Injector cap kit q 1

Plug (for 5/16 inch hose
B 600-919-5050 q 1 Disconnecting DEF hose,
diameter)
connector, and coolant hose
DEF injector electric con-
C 6540-71-1310 q 1
nector cover
Commercially
D Vinyl gloves q 1 Disconnecting DEF hose
available
k KDOC and SCR assembly, and the periphery are heated to 500 °C or above. Take care not to get
burn injury.
k Check that KDOC and SCR assembly, and the periphery have cooled down to the temperature
safe enough for anyone not to get burn before performing the work.
k Check that no combustible material (dry leaves, twigs, etc.) is accumulated around KDOC, DEF
mixing tube, and SCR. If any dusts or combustible materials are found, remove them.
k Handle KDOC, DEF mixing tube, and SCR with care since they are fragile against shock such as
falling. Do not reuse damaged part.
k Use anti-dust mask during the work to prevent inhaling mat material or metallic powder always
when disposing KDOC, DEF mixing tube, and SCR.
METHOD FOR REMOVING DEF INJECTOR
k Be sure that the automatic DEF purging pro-

cedure has been completed before removing
any DEF hose.
1. Disconnect the coolant hoses (1). 1
2. Install cap (A) on cooling port of DEF injector.
REMARK 3
The cap (A) are installed to prevent entry of
foreign materials.
NOTICE
• After disconnecting the coolant hoses (1), 2
be careful not to drain the coolant from the RKAD4520
hose.
50-62 WB93R-8
3. Wear the vinyl gloves and disconnect the DEF

hose (2). [*1]
NOTICE
D
handling DEF.
• Disconnect the DEF hose (2), and then
disconnect the DEF injector connector
MB03 (3). (To prevent DEF from sticking
to the connector)
REMARK
Pinch the protruding portions (e) of the clip with RKAD4580
your fingers, then the lock is unlocked. Pull out
DEF hose (2) directly while they are kept pinched.
RKAD4590
4. Slide the lock (red) of the connector MB03 (3) in

the direction of the arrow (a) as shown in the fig-
ure, and disconnect the connector MB03 while
pressing the part (b) and pulling it.
a
b
RKAD4600
NOTICE
• After disconnecting the connector MB03
(3), install the cover (C) to the connector in
DEF injector side. C
RKAD4610
WB93R-8 50-63
5. Install the plug (B) on DEF hose (2) side, and

install the cap (A) on the pin side of DEF injector.
REMARK B
The plug (B) and cap (A) are installed to prevent A
RKAD4620
6. Loosen clamp (3) and remove it.

NOTICE
• Always discard clamp (3).
7. Remove the DEF injector (4) and install the cap

(A) to the nozzle. [*2]
8. Install cap (A) on nozzle of DEF injector.
REMARK
The cap (A) is installed to prevent entry of foreign
materials.
NOTICE
• Always discard gasket (5).
50-64 WB93R-8
METHOD FOR INSTALLING DEF INJECTOR

removal.
[*1]
tor pin.
NOTICE D
Be sure to wear the vinyl gloves (D) when
handling DEF.
RKAD4580
B
A
RKAD4620
WB93R-8 50-65
2. Wear the vinyl gloves (D) to connect the DEF

hose (2).
NOTICE
D
handling DEF.
• Connect the DEF hose (2), and then con-
nect the DEF injector connector MB03
(22).
• (To prevent DEF from sticking to the con-
nector)
• Clean the connection of DEF hose (2) and RKAD4580
DEF injector pin thoroughly, and check

that there is no dust or damage.
• Click the connector (m) of DEF hose (2)
into the pin (k) on the injector side. 1
• When the connector is inserted until the
convex part (n) of the pin (k) passes the 3
convex part inside the clip, it can be
locked by the clip.
3. Connect the coolant hoses (1).
2
RKAD4520
m
n
k
RKAD4630
4. Connect the connector MB03 (3).

1) Remove the cover (C) that was fitted to the
connector on DEF injector side of the con-
nector MB03 (3). C
NOTICE
• After connecting the connector MB03 (3),
return the lock (red) in the direction of the
arrow (a) as shown in the figure.
RKAD4610
50-66 WB93R-8
[*2]
tor pin.
NOTICE D
Be sure to wear the vinyl gloves (D) when
handling DEF.
RKAD4580
B
A
RKAD4620
1. Remove the cap (A) at the nozzle tip. and install

a new gasket (5).
NOTICE
• Use a new gasket (5).
NOTICE
• Gasket (5) is coloured.
The black side has to be fitted towards the
KDOC assembly and the green side
towards the DEF injector.
WB93R-8 50-67
2. Install the DEF injector (4) in the KDOC assem-

bly.
3. Install clamp (3) and using a proper tool, close it

until the clamp hook locks
4. Tighten bolt (6).
3 Bolt (6): 9.0 - 12.2 Nm {0.92 - 1.24 kgm}
50-68 WB93R-8
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CLEANER ASSEMBLY

METHOD FOR REMOVING AIR CLEANER ASSEMBLY

1. Disconnect connector AF01 (1) of air filter clog-
ging sensor. [*1]
2. Loosen clamps (2) and remove hose (3).
2
1
3
RKAD4230
3. Remove fastening bolts (3) and remove air filter

assembly (4).
NOTICE
4
• Cover the intake hose to prevent entering
of dirty or foreign material.
3
RKAD4240
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY

removal.
[*1]
• Connect the connector AF01 (1).
WB93R-8 50-69
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY

k If refrigerant gas (HFC 134a) gets in your eyes, you may lose your sight. If it touches your skins,
you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working
clothes with long sleeves while you are collecting or filling the refrigerant.
NOTICE
• Never release the refrigerant to the atmosphere.
• Ask a qualified person for collecting, adding and filling operations of the refrigerant. (Only quali-
fied persons can work.)
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY

1. Collect the refrigerant (air conditioner gas: HFC
134a) from the air conditioner circuit. [*1]
6 Quantity of refrigerant to be collected:

1500±50 g 2
1
2. Remove the bolts (1), and remove front mask (2).
RKAD4021
3. Disconnect the upper air conditioner hose (3)

from the air conditioner drier (4).
4. Disconnect the lower air conditioner hose (5) 4
3
from the air conditioner condenser assembly
(6).[*1]
RKAD4090
50-70 WB93R-8
5. Remove the bolts (7), and remove the air condi-

tioner condenser assembly (6). [*2]
NOTICE
7
faces of the air conditioner condenser 6
assembly (6) when removing.
RKAD4250
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY

removal.
[*1]
• Refill the air conditioner circuit with refrigerant
(air conditioner gas: HFC 134a).
Filling quantity: 1500±50 g
• Refill with the air conditioner compressor oil.
[*2]
• Connect the air conditioner hoses (3) and (5).
NOTICE
• When installing the air conditioner piping,
be careful so that dirt, dusts and water do
not enter the hose.
• Check that O-ring is fitted to the joints
• Check that O-ring is not damaged or deteri-
2 O-ring:
orated.
Refrigerant (HFC 134a) compressor oil

(DENSO: ND-OIL8)
3 Hoses (3) and (5):
15.4 to 17 Nm {1.57 to 1.73 kgm}
[*3]
• Install the air conditioner condenser assembly (6)
with the bolts (7).
NOTICE
face of the air conditioner condenser
assembly (6) when installing.
WB93R-8 50-71
REMOVE AND INSTALL AIR CONDITIONER BELT

METHOD FOR REMOVING AIR CONDITIONER BELT

1. Disconnect fan clutch assembly from engine (For
details, see “REMOVAL AND INSTALL OF FAN
CLUTCH ASSEMBLY”).
2. Measure the tension of the belt to judge if it has
to be replaced or reused, and notate the value. 2
2
NOTICE
• If the compressor belt do not have to be
replaced, when installing it, do not tension
it to the value of a new belt. 1
1
3. Loosen bolts (1) (2 pieces) and (2) (2 pieces).
RKAD4720
4. Loosen bolt (3) and nuts (4) and unscrew bolt (5)
[*1]. 3
5. Remove air conditioner compressor belt (6). 5
6
4
RKAD4730
50-72 WB93R-8
METHOD FOR INSTALLING AIR CONDITIONER BELT

removal.
[*1]
• Install belt (6) and tighten bolt (5) until belt ten-
sion reaches the correct value.
a Belt tension: 5
• In the case the belt is replaced, the tension has
to be max. 142 to 147 Hz.
• In the case the belt (6) is reused, the tension
has to be the same notated before removing. 6
NOTICE
• Never use the tension value of a new belt
when installing a used one.
RKAD4731
WB93R-8 50-73
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR

k If refrigerant gas (HFC 134a) gets in your eyes, you may lose your sight. If it touches your skins,
you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working
clothes with long sleeves while you are collecting or filling the refrigerant.
NOTICE
• Never release the refrigerant to the atmosphere.
• Ask a qualified person for collecting, adding and filling operations of the refrigerant. (Only quali-
fied persons can work.)
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR


3
1500±50 g
2. Disconnect the connector FFH (1) and WIF (2) of 2
fuel prefilter. [*1] 4
3. Remove lower and upper bolts (3),and place the
wiring harness (4) a side.
1
3
RKAD4292
RKAD4302
5. Remove bolts (7) and place the fuel prefilter (8)

RKAD4312
50-74 WB93R-8
6. Disconnect connectors AC01 (9) of air conditione

compressor.
RKAD4771
7. Disconnect hose (10) and (11) from compressor

(12). [*2]
NOTICE
11
• Fit a plug or flange in the place where the 10

hose is disconnected to prevent dust and 12
water from entering.
• Remove O-ring (13). Do not reuse it. (O-ring
is deformed and deteriorated if it is used
even once.)
RKAD4950
13
RKAD4960
8. Loosen bolt (14) and nut (15) and unscrew bolt

(16). 14
16
15
RKAD4732
WB93R-8 50-75
9. Loosen bolts (17) (2 pieces) and (17) (2 pieces)

and remove the compressor (12). 17
17
12
17 17
RKAD4721
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR

removal.
[*1]
• Refill with the air conditioner compressor oil..
[*2]
• Connect the air conditioner hoses (11) and (12).
NOTICE
not enter the hose.
2 O-ring:
orated.

(DENSO: ND-OIL8)
3 Hoses (10) and (11):
20 - 27,5 Nm {2,04 - 2,8 kgm}
50-76 WB93R-8
REMOVE AND INSTALL ENGINE HOOD

METHOD FOR REMOVING ENGINE HOOD
1. Remove the bolts (1), and remove front mask (2)
1 2
RKAD4020
3. Remove safety pins (4).

4. Remove pins (5) and disconnect gas accumula-
tor (6).
6
5
RKAD4030
5. Remove snap ring (7) and washer (8) from both

side.
RKAD4040
WB93R-8 50-77
6. Remove pins (9) on both side and sling engine

hood (3).
RKAD4050
RKAD4060
METOD FOR INSTALLING ENGINE HOOD

removal.
50-78 WB93R-8
REMOVE AND INSTALL COUNTERWEIGHT

METHOD FOR REMOVING COUNTERWEIGHT

RKAD4060
2. Remove bolts (1) on both side.
RKAD4260
WB93R-8 50-79
3. Connect the lifting tool (A) to counterweight (2).

4. Sling the counterweight (2), and hold it. A
4 Counterweight assembly (2): 95 kg
5. Remove the bolts (3), sling the counterweight 2
assembly (2), and remove it. [*1]
• Bolts (3) (Width across flats): 30 mm
REMARK
Slide the counterweight assembly (2) horizontally
and backward at first to prevent it from interfering
with the machine, and then sling it.
RKAD4081
2
3
RKAD4071
METHOD FOR INSTALLING COUNTERWEIGHT

• Perform installation in the reverse order to removal.
[*1]
3 Bolts (2): 240-330 Nm {24,47-33,65 kgm}
50-80 WB93R-8
REMOVAL AND INSTALL FRONT AXLE

k Place the machine on a level ground.
METHOD FOR REMOVING FRONT AXLE
1. Start the engine and raise the machine using

front work equipment until the wheels are about
50 mm from the ground.
2. Set the work equipment lock lever to LOCK posi-

tion.
3. Turn the starting switch to OFF position to stop A
the engine.
4. Position a stand “A” under the machine.
RKAD5260

“REMOVE AND INSTALL COUNTERWEIGHT”).
6. Remove counterweight (For details, see
“REMOVE AND INSTALL COUNTERWEIGHT”). 1
7. Remove nuts (1). [*1]
8. Slowly remove the front wheel (2).
4 Wheel assembly: 85 kg 2
RKAD5320
9. Disconnect the drive shaft (3) from axle (4). [*2]
RKAD5270
WB93R-8 50-81
10. Disconnect the hoses (5) from the steering cylin-

der (6).
7
11. Disconnect lubricating hose (7). 5
5
6
RKAD5280
12. Place a lifting tool (B) and some blocks (C)

beneath the axle. Raise this until the blocks are
being forced up against the arms of the axle (4).
4
C
B
RKAD5290
13. Loosen bolt (8) and extract pin (9).

14. Lower the lifting tool (B) until the axle is free.
9
15. Extract the axle (4).
4 Front axle: 320 kg
RKAD5300
50-82 WB93R-8
METHOD FOR INSTALLING FRONT AXLE

[*1]
3 Nuts (1): 280-385 Nm {28,55-39,26 kgm}
[*2]
3 Cardan shaft fixing:
30.4-41.8 Nm {3.1-4.3 kgm}
2 Cardan shaft fixing screws: Loctite 242
WB93R-8 50-83
DISASSEMBLY AND ASSEMBLY FRONT AXLE

STEERING CYLINDER GROUP
METHOD FOR DISASSEMBLING

1. Loosen the nut (1) with enough turns till it is pro-
truding over the threaded pin end of the tie rod
(3).
Beat on the nut (1) with an appropriate hammer
in order to disjoin the tie rod (3) from the swivel
housing (2).
Repeat the whole sequence at the other side.
k Don't beat on the threaded pin end of the
tie rod (3).
NOTICE
This is a destructive operation for the nut (1).
2. Remove the tie rods (3) and (12) by loosing the
nuts (4) and (11) with a suitable wrench, then
check them conditions.
Unscrew the fastening screws (6) and take the
steering cylinder (7) out of its housing, if neces-
sary use a rubber hammer.
Remove only parts that need to be overhauled
and/or replaced.
50-84 WB93R-8
3. Detach the cylinder head (15) from the cylinder

case (19) and remove it from the rod (17).
Remove the rod (17) from the cylinder case (19).
Remove all the seals and O-Rings (13, 14, 16,
18, 20 and 21) from the cylinder case (19), the
cylinder head (15), and the rod (17).
NOTICE
Discard seals and O-rings.
METHOD FOR ASSEMBLING

1. Assemble new seals and O-Rings (13, 14, 16,
18, 20 and 21) on the cylinder head (15), on the
rod piston (17) and on the cylinder body (19).
NOTICE
Replace seals and O-rings with a new ones.
2. Fit the cylinder head (15) on the rod (17).

Slide the pre-assembled rod (17) into the cylinder
body (19).
3. Fit the tie rods (3) and (12), the ball joints (5) and
(10), the nuts (4) and (11) to the ends of the rod
(17), then tighten with a dynamometric wrench to
the requested torque.
3 Ball joints (5) and (10): 250 Nm
4. Install the steering cylinder (7) already assem-

bled on the central body. Assemble and tighten
the screws (6) with dynamometric wrench to the
requested torque.
3 Screws (6): 120 Nm
WB93R-8 50-85
5. Align the swivel housing (8) with the axle.

Screw the tie rod (12) so that its ball joint can be
inserted into the swivel housing (8) arm.
NOTICE
It is important to unscrew the lock nut (11) to
carry out this operation.
6. Repeat the whole sequence of the mentioned
operations to the other side.
7. Insert the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (2).
Assemble and tighten the lock nut (1) with a
dynamometric wrench to the requested torque.
3 Lock nut (1): 220 Nm
8. Repeat the whole sequence of the mentioned
operations to the other side.
NOTICE
Screw the lock nuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been
carried out.
For detail see Toe-in/steering angle.
50-86 WB93R-8
EPICYCLIC REDUCTION GEAR GROUP

1. Drain the oil completely from the epicyclic reduc-
tion gear.
2. Unscrew and remove the two fastening screws

(1) of the planetary carrier (4) with a wrench.
WB93R-8 50-87
3. Remove the planetary carrier (4) from the wheel

hub and remove the relative O-Ring (10).
NOTICE
Discard O-ring (10).
4. Position the planetary carrier (4) on a workbench
and check its wear conditions.
5. If required replace the planetary gears as follows:

1) remove the snap rings (9) on every pin (3);
2) remove the planetary gears (6) from the pins;
3) collect the needle bearings (7) and (5),
checking their conditions;
4) collect the washer (8).

1. Collect all epicyclic reduction gear parts: the
planetary gears carrier (4), the planetary gears
(6), the needle bearings (5) and (7), washer (8)
and the snap rings (9) of every pin (3).
NOTICE
With new planetary gears it is advisable to
assembly new needle bearings.
2. Insert the needles (5) and (7) into the gears (6).
NOTICE
Grease well the needles (5) and (7).
3. Insert the gears (6) with assembled needles in
the planetary carrier pins.
4. Assemble the washer (8) and snap ring (9) on

every pin (3).
50-88 WB93R-8
5. Assemble a new O-Ring (10).

Fit the epicyclic reduction gear assembly (4) to
the wheel hub. Assemble the screws (1) and
tighten them to the prescribed torque.
3 Screws: 25 Nm
6. Load the specified oil in the epicyclic reduction

gear.
Fit the plug (2) on the epicyclic reduction gear (4)
and tighten to the prescribed torque.
3 Plug: 80 Nm
WB93R-8 50-89
WHEEL HUB GROUP
Tools to be used when disassembling and assembling wheel hub group
New/Redesign
Necessity
Sketch
Q'ty
A CA715655 Driver q 1 For wheel carrier bearings

B CA119097 Driver q 1 For swivel housing bushing
C CA715360 Driver q 1 For swivel housing seal
D CA715026 Driver q 1 For bearing cup
E CA716867 Driver q For wheel hub seal
50-90 WB93R-8

1. Insert a lever between the swivel housing (14)
and the axle beam and fit it into the double
U-Joint (24).
With the lever push the double U-Joint (24) in the
direction of the wheel hub to allow the lock ring
(1) removal.
k Do not damage the double U-Joint.
2. Remove the lock ring (1) from the double U-Joint

shaft.
Collect the double U-Joint shaft washers (2) and
(3).
3. Unscrew and remove the fastening bolts (5) from

the wheel carrier (7).
4. To extract the wheel carrier screw two of the just

removed bolts (5) in the threaded holes.
Remove the wheel carrier (7) with the epicyclic
ring gear (4).
5. Remove the steel lock ring (8) and disjoin the

wheel carrier (7) from the epicyclic ring gear (4).
Only if necessary, remove the centering bushes
(6) from the wheel carrier with a hammer and the
special tool (A).
WB93R-8 50-91
6. Remove the wheel hub (11) using levers and a

hammer to facilitate the operation.
REMARK
Collect the bearing cone (9).
RKA85910
7. Position the wheel hub (11) on a flat surface and

remove the seal ring (13) with a puller.
NOTICE
Discard seal ring.
8. Remove the bearing cups (9) and (12) using a
hammer and a suitable drift.
Remove the bearing cone (12) from the swivel
housing end (14), using a suitable puller.
9. Unscrew and remove the fastening bolts (19) and

(17) from the upper (18) and lower (16) king pin.
k Before removing the king pins (16) and
(18), secure the swivel housing (14) with a
belt or a rope to a hoist or any other sup-
porting device; observe all current safety
regu latio ns to g uaran tee operato r's
safety.
10. Remove the king pins (16) and (18).
11. Remove the swivel housing (14) from the axle

beam and from the short shaft of the double
U-Joint.
Collect the belleville washers (25) and (27).
12. Position the swivel housing (14) on a flat surface

and take the seal ring (23) out with a puller.
NOTICE
Discard seal ring.
13. Overturn the swivel housing and take the bush
(22) out, using a suitable drift and a hammer.
50-92 WB93R-8
14. Remove the two double U-Joints (24) from the

axle beam (26).

1. Insert the double U-Joint (24) inside the axle
beam (26).
k Be careful not to damage the seal ring in
the axle beam.
2. If it has been previously removed, reassemble

the steering stop composed by the screw (21)
and nut (20).
REMARK
Do not tighten the nut (20) until the steering
angle adjustment has been done. For details
see Toe-in/steering angle.
3. Force the bush (22) into the swivel housing (14)

with the special tool (B) and a hammer or a
press.
Assemble a new seal ring (23) on the swivel
housing (14) with the special tool (C) and a ham-
mer.
Grease carefully the seal ring (23).
2 Grease: G2-LI
4. If the cone (15) of the spherical joint has been

previously removed, reassemble it to the lower
king pin (16) using a suitable tool under a press.
Grease carefully the seats of king pin (16) and
(18).
2 Grease: G2-LI
5. Position the belleville washers (25) and (27) on
the king pin (16) and (18) housings.
WB93R-8 50-93
k Secure the swivel housing (14) with a belt or a

rope to a hoist or any other supporting
device.
Protect the splined end of the axle shaft by
winding it with an adhesive tape to avoid
damage to the seal ring (23).
Assemble the swivel housing (14) on the axle
beam and after assembly, remove completely
the adhesive tape.
6. Assemble the king pins, the lower (16) and the

upper (18), and tighten the retaining screws (17)
and (19) to the requested torque.
3 Screws: 190 Nm
REMARK
Make sure that the belleville washers (25) and
(27) remain in their position.
7. The special operation "Set Right" of the bearings

does not require preload or backlash adjustment.
Anyway, before assembling new spare parts
check the indicated dimensions.
A = 5.900 to 5.905 mm
B = 52.229 to 52.279 mm
C = 23.072 to 23.173 mm
8. Force both bearing cups (9) and (12) to their

wheel hub (11) housings using the special tool
(D) under a press or with a hammer.
Insert a new seal ring (13) into the wheel hub
(11) with the special tool (E) and a hammer.
NOTICE
Do not lubricate the seal ring (13).
9. Assemble the bearing cone (12) on the swivel

housing (14) end. Assemble the wheel hub (11)
on the swivel housing (14) and fit the bearing
cone (9).
50-94 WB93R-8
10. Position the wheel carrier (7) on a workbench

and, if previously removed, force the bushes (6)
to the carrier surface level with the special tool
(A).
NOTICE
At least two bushes (diametrically-opposed)
should be set slightly higher than the carrier
surface level to be used as dowel pins.
11. Preassemble the wheel carrier (7) and the epicy-

clic ring gear (4) with the lock ring (8) shown in
figure.
12. Assemble the wheel carrier group on the wheel

hub using the two projecting bushes as dowel
pins and screw the relative screws (5) in order to
put in contact the ring bevel gear with the wheel
hub.
13. Force all the hub dowel bushes (6) completely

with the special tool (A) and a hammer.
Assemble the wheel carrier (7) fastening bolts (5)
and tighten to the requested torque.
3 Bolts: 120 Nm
14. Insert a lever between the swivel housing (14)

and the axle beam and fit it into the double
U-Joint (24).
With the lever push the double U-Joint (24) in the
direction of the wheel hub to make easier the
lock ring (1) insertion.
WB93R-8 50-95
15. Slide the thrust washers (2) and (3) onto the dou-
ble U-Joint shaft end (24).
Insert the lock ring (1) at the end of the splined
hub and push it into its seat.
REMARK
Check that the lock ring (1) is correctly fitted
in its seat. Push the double U-Joint thor-
oughly.
50-96 WB93R-8
DIFFERENTIAL SUPPORT GROUP
Tools to be used when disassembling and assembling differential support group
New/Redesign
Necessity
Sketch
Q'ty
A CA716546 Wrench q 1 For differential support nuts

For preloading measurement
B CA716522 Tool q 1 (gauge diameter Dm = 104.7
mm)
C CA716519 Wrench q 1 Pinion locking wrench
D CA716868 Driver q 1 For pinion seal
WB93R-8 50-97

1. Drain the oil completely from the differential.
2. Disassemble the wheel/double U-joint group
from the axle beam. For details see Special
repair operations.
NOTICE
Remove the double U-joint from the differen-
tial before disassembling the differential
support group.
3. Remove the seal ring (1).

REMARK
Destructive operation for the seal ring (1); the
seal ring must be replaced.
4. Loosen and remove the screws (2) from the dif-

ferential support (3). Remove the differential sup-
port (3) from the axle housing (4).
k Support the differential support with a
rope or other appropriate means.
5. Measure the starting total preloading FT0 of the

bearings (pinion- crown gear system), using a
dynamometer whose cord is wound on the pinion
splined end.
REMARK
The value FT0 that is necessary in the bearings
reassembly.
For detail see METHOD FOR ASSEMBLING
DIFFERENTIAL SUPPORT GROUP step 10.
6. Loosen and remove the screws (5) and (9) to

take out the two ring nut retainers (6) and (10).
50-98 WB93R-8
7. Before removing the bolts, mark both half-collars

(13) and the differential support with permanent
reference marks to avoid inverting them during
re-assembly.
REMARK
Mark the area between the ring nuts (7) and
(11) and the differential support (3) as well.
8. Unscrew and remove the adjuster ring nuts (7)

and (11) by using the special tool (A) and a
wrench.
9. Remove the 4 screws (14) and remove both

half-collars (13).
REMARK
Check that the bushes (15) remains in their
housings.
10. Remove the differential housing (16).

11. The bearing cups (8) and (12) are removed
together with the differential housing.
NOTICE
Do not invert the bearing cups if the bearings
are not replaced.

1. Assemble the bearings cups (8) and (12) on the
differential group (16).
WB93R-8 50-99
k Do not invert the bearing cups if the bear-

ings are not replaced.
2. Position the complete differential box with bear-
ings on the differential carrier (3).
NOTICE
Check the right side of the bevel crown
assembly.
3. Move the differential group so to place the bevel

crown gear on the pinion.
Check that all bushes (15) are in their housings
and position both half collars (13) on their seats
using the previously traced reference marks.
Lock both collars with their fastening bolts (14).
4. Assemble the adjusting ring nuts (7) and (11) to

the differential support.
Tighten both ring nuts (7) and (11) by using the
special tool (A), till the backlash is eliminated and
the differential bearings are slightly preloaded.
Check that the differential bearings are well set-
tled; if necessary, knock slightly with a soft ham-
mer, in order to properly set the bearings in
position.
5. Position a magnetic-base dial gauge on the dif-

ferential support, so that the feeler stylus touches
the surface of one tooth of the crown gear with a
90° angle.
50-100 WB93R-8
6. Lock the pinion and move the crown gear alter-

natively and note the pinion-ring gear backlash,
measured with the comparator.
Repeat this operation on two or more teeth and
calculate the average of measured backlash val-
ues.
Check if the average backlash value is within the
requested range:
Gmin< Gm< Gmax [mm]
• Gmin= 0.15 mm
• Gmax= 0.30 mm
If this condition is verified go to the step [10], if not
carry out the backlash adjustment as follows.
7. Adjust the ring nuts (7) and (11) by using the spe-
cial tool (A).
NOTICE
Unscrew/screw the adjuster ring nuts, as indi-
cated in the next step, both of about 30
degrees at once then check the backlash.
8. Adjust the ring nuts (7) and (11), remembering

that:
(A) if the measured backlash is greater than the
given tolerance range, unscrew the adjuster ring
nut (7) and screw in the adjuster ring nut (11) by
the same measure;
(B) if the measured backlash is less than the
nut (11) and screw in the adjuster ring nut (7) by
the same measure.
9. Once the adjustment of the pinion-ring gear

backlash has been carried out, check also that
there is a minimum preloading on the differential
box bearings.
Repeat the whole sequence of the above men-
tioned operations till the indicated conditions are
reached.
WB93R-8 50-101
10. Once the pinion-ring gear backlash has been

established, if the bearings have been not
replaced, measure the total preloading FTm of the
bearings (pinion-crown bevel gear system), using
a dynamometer whose cord is wound on the pin-
ion splined end.
NOTICE
Do not use this method with new bearings, if
the bearings have been replaced see step 11.
The measured value FTm should be within the
following range (see METHOD FOR DISASSEM-
BLING DIFFERENTIAL SUPPORT GROUP step
5):
FTm = FT0 ÷ (FT0+ 10) N
follow the operating procedures in step 15.
11. If the bearings have been replaced, measure the
total preloading FTm of the bearings (pinion-crown
bevel gear system), using a dynamometer whose
cord is wound on the special tool (B) inserted on
the pinion splined end.
12. Measure the diameter Dm (Diameter of measure-

ment) of the special tool (B) and diameter of the
pinion end DP (diameter of pinion), then calculate
the ratio R between the diameters:
R= Dm/DP
• DP : 34.874 mm
The measured value of total preloading FTm must
be within the following range:
FTmin/R < FTm < FTmax/R [N]
• FTmin : FP + 37.3 N
• FTmax : FP + 55.9 N
50-102 WB93R-8
13. If you do not use the prescribed special tool to

measure the total preloading FTm, the reference
diameter is the diameter of pinion shaft splined
end.
The measured value should be within the follow-
ing range:
FTmin < FTm < FTmax [N]
• FTmin : FP + 37.3 N
• FTmax : FP + 55.9 N
REMARK
With new bearings this way give inaccurate
result and it's not recommended.
established, instead proceeding with step 11 and
13 measure the total rolling torque (MTm) of the
bearings (pinion-crown bevel gear system) with a
torque meter and the special wrench (C).
• MTmin : MP + 0.65 Nm
• MTmax : MP + 0.98 Nm
k All the preloads must be measured with-
out the seal installed.
15. The total rolling torque MTm must be within the

following range:
MTmin < MTm < MTmax [N]
• MTmin : MP + 0.65 Nm
• MTmax : MP + 0.98 Nm
16. If the measurement is not within the requested

range, check well the assembly of each compo-
nent and operate on the adjuster ring nuts (7)
and (11) of the differential support:
(A) if the total preloading is less than the given
range, screw in both adjuster ring nuts (7) and
(11) by the same measure, keeping the
pinion-ring gear backlash value unchanged;
(B) if the total preloading is greater than the given
range, unscrew both adjuster ring nuts (7) and
(11) by the same measure, keeping the
pinion-ring gear backlash value unchanged.
WB93R-8 50-103
17. Once all the adjustment operations have been

completed, fit the ring nut retainers (6) and (10)
and their screws (5) and (9), tightening them to
3 Bolts: 13 Nm
2 Bolts: Loctite 270
18. Tighten the bolts (14) of both half collars (13) to

3 Bolts: 220 Nm
19. Before matching surfaces, make sure that they

are perfectly clean, degrease and clean them
with appropriate detergents.
Spread a film of adhesive on the contact surface
between the axle beam (4) and the differential
carrier (4).
2 Loctite 510
REMARK
Check that two dowel pins (17) are in their
seats.
20. Position the differential support (3) on the axle

housing (4), and tighten the retaining screws (2)
to the requested torque.
3 Screws: 169 Nm
21. Assemble a new seal ring (1) by using the spe-

cial tool (D) and a hammer.
50-104 WB93R-8
22. Assemble the wheel/double U-joint group to the

axle beam.
For detail see SPECIAL REPAIR OPERATIONS
23. Perform the axle oil filling as prescribed.
BEVEL GEAR MARKING TEST

To test the marks of the bevel gear teeth, paint the ring
gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides.
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the teeth
surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in order
to adjust the backlash.
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in
order to adjust the backlash.
Movements to correct:
1. move the pinion for type X contact adjustment.
2. move the pinion for type Z contact adjustment.
WB93R-8 50-105
DIFFERENTIAL GROUP
Tools to be used when disassembling and assembling differential group
New/Redesign
Necessity
Sketch
Q'ty
A CA119230 Driver q 1 For differential bearings

1. Lock the differential with a clamp.
2. Unscrew the fastening bolts (1) and remove the
bevel gear crown (2).
k This will make both differential half boxes
(4) and (11) free, so take care not to drop
the internal components.
50-106 WB93R-8
3. Disassemble the differential box in two half

boxes (4) and (11) complete with the relative
components.
REMARK
Make alignment marks on the half boxes
before separating them.
4. Disassemble all the components.
5. Check the operating and wear conditions of the
components.
6. Remove the bearing cones (3) from the half

boxes (4) and (11) using a standard extractor.

1. Assemble the bearing cones (3) and (20) on the
half boxes (4) and (19), using the special tool (A)
and a hammer.
2. Position a half housing (4) on a workbench and

assemble all inner components: trust washers
(5), sun gears (6), spider (7), spider gears (8),
thrust washers (9), pin (10), as shown in figure.
Join the two half housing, aligning the reference
marks made upon them.
3. Position the bevel crown gear (2) on the half box

(4).
REMARK
Clean with care the matching surfaces
4. Apply the specified sealant on the thread and
tighten the bolts (1) to the requested torque.
3 Bolts: 96 Nm
2 Bolts: Loctite 270
WB93R-8 50-107
PINION GROUP
Tools to be used when disassembling and assembling pinion group
New/Redesign
Necessity
Sketch
Q'ty
A CA716518 Wrench q 1 For pinion nut

B CA716519 Wrench q 1 Pinion locking
C CA119225 Driver q 1 For pinion bearings
D CA716381 False pinion q 1
False differential box - disk
E CA716547 q 1
(n. 2)
F CA119206 False differential box - Pin q 1
G CA715179 Driver q 1 For bearings
For preloading measurement
H CA716522 Tool q 1 (gauge diameter Dm = 104.7
mm)
50-108 WB93R-8
1. Measure the starting preloading FP0 of the pinion

bearings using a dynamometer whose cord is
wound on the pinion splined end.
Note the value FP0 that is necessary in the bear-
ings reassembly.
step 15.
2. Lock the differential carrier with a vise.

Unscrew the lock nut (10) using special tools (A)
and (B).
NOTICE
This operation will irretrievably damage the
lock nut (10).
3. Remove the ring nut (10) and collect its retaining

washer (9).
4. Tap the shaft with a plastic mallet to remove the

bevel pinion (1).
k Take care not to drop the bevel pinion (1).
5. Collect the washers (4) and (6), the collapsible
spacer (5) and the bearing cone (8).
WB93R-8 50-109
6. Remove the bearing cups (3) and (8) from the

differential carrier (7) using a drift and a hammer.
7. To remove the cone of the tapered roller bearing

(3) of the bevel pinion (1), use a standard puller.
Collect the bearing cone (3) and the underlying
shim (2).
8. Check all pinion components for wear.

k The ring nut (10) and the collapsible
spacer (5) must be replaced when reas-
sembling the unit.

1. Place the differential support (7) on a workbench.
Fit the bearing cups (3) and (8) using the special
drift (C) and a hammer.
2. Prepare the kit consisting of the special tools

called "false pinion" (D) and "false differential
box" (E) and (F) and a depth gauge.
50-110 WB93R-8
3. Insert bearing cones (3) and (8) in their housings.

Assemble the false pinion (D).
Assemble the ring nut (10) and tighten it, without
exceeding, till the backlash is eliminated.
4. Assemble the false differential box (F) and the

plates (E) on the differential group supports (7).
5. Assembly diagram of the "false differential box"

tools (on the left). Use a depth gauge to measure
distance "X" (distance between the axis of the
differential bearings and the point at which the
pinion head is supported, or base of the bearing).
6. In order to determine the necessary thickness

value (S) between the pinion and the bearing,
subtract the value (V), stamped on the pinion
head (V= requested distance), from the meas-
ured value (X).
S= X –V mm
7. Select the shim (2) of thickness value (S) among

the range of available shims.
SHIMS RANGE
Thickness
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
(mm)
Quantity - - - - - - - - - -
WB93R-8 50-111
8. Remove the false differential box from the differ-

ential group supports (7).
Remove the ring nut (10), the false pinion (D)
and the bearing cones (3) and (8).
9. Once you have chosen the suitable shim (2),

insert it on the pinion shaft with the chamfer
against the pinion head, as shown in figure.
10. Force the bearing (3) into the pinion shaft (1) by
using the special tool (G) under a press, making
sure that it is well set.
Insert the shims (4) and (6) and a new collapsible
spacer (5).
REMARK
Use always a new collapsible spacer (5).
11. Check the right assembly sequence.
12. Insert the bevel pinion (1) unit into the differential
support housing (7) and the bearing cone (8) on
the pinion shaft, as shown in figure.
Use the special tool (G) and a hammer to drive
the bearing (8).
50-112 WB93R-8
13. Insert the ring nut washer (9) and screw a new
lock ring nut (10) on the pinion end.
14. Screw the ring nut (10) in, using the wrench for
ring nut (A) and for pinion retainer (B).
k The torque setting is given by the pre-
loading measurement on bearings (3) and
(8); tighten the ring nut (10) gradually.
REMARK
If the tightening is excessive, the elastic
spacer (5) must be replaced and the proce-
dure repeated. When you check the
preloading, it is advisable to beat slightly both
pinion ends (1) with a soft hammer, so as to
help setting the bearings (3) and (8).
15. If the bearings have been not replaced, to meas-
ure the preloading P m of the pinion taper roller
bearings (3) and (8), use a dynamometer whose
cord is wound on the end of pinion shaft (1).
k Do not use this method with new bear-
ings, if the bearings have been replaced
see next step.
The measured value should must be the starting
value. (For details see METHOD FOR DISAS-
SEMBLING step 1).
FPm= FP0–( FP0+ 10 ) N
16. If the pinion taper roller bearings (3) and (8) are
new, to measure the preloading FPm of the bear-
ings, use a dynamometer whose cord is wound
on the special tool (H) inserted on the end of pin-
ion shaft.
WB93R-8 50-113

ment) of the special tool (H) and diameter of the
R= Dm/DP
The measured value of preloading must be within
the following range:
FPmin/R < FPm < FPmax/R [N]
• FPmin= 91.8 N
• FPmax= 137.6 N
Example Data measured:
• Dm= 100.0 mm
• DP= 29.75 mm
Example Product Data:
• FPmin= 107.6 N
• FPmax= 161.3 N
Calculate R= 100.0/29.75= 3.36
then (107.6/3.36) < FPm < (161.3/3.36),
in this case the measured preload value must be
within the range 32 < FPm < 48 N
measure the pinion bearing preloading, the refer-
ence diameter is the diameter of pinion shaft
splined end.
FPmin < FPm < FPmax [N]
• FPmin= 91.8 N
• FPmax= 137.6 N
19. Instead proceeding with step 15 and 16 measure

the pinion shaft bearings rolling torque MPm with a
torque meter and the special wrench (B).
k All the preloads must be measured with-
out the seal ring.
20. The measured value MP must be within the fol-

lowing range:
MPmin < MP < MPmax [Nm]
• MPmin= 1.60 Nm
• MPmax= 2.40 Nm
50-114 WB93R-8
21. The adjustment is carried out by increasing the

ring nut (10) torque gradually, being careful not to
exceed.
k All preloadings must be measured with-
out the seal rings. Once the requested
preloading value is achieved, caulk the
ring nut (10), using a hammer and a
chisel.
WB93R-8 50-115
AXLE BEAM GROUP
Tools to be used when disassembling and assembling axle beam group
New/Redesign
Necessity
Sketch
Q'ty
For beam upper bushing

A CA715034 Driver q 1
For spherical joint cone
B CA715649 Driver q 1 For beam trumpet bushing
C CA715779 Driver q 1 For wheel shaft seal
D CA715164 Driver q 1 For axle beam pivot seal
E CA715163 Driver q 1 For axle beam pivot bushing
50-116 WB93R-8

1. Remove the seal rings (5) from the axle beam
(1).
REMARK
Destructive operation for the seal rings (5);
the seal rings must be replaced.
2. Remove the bush (4) from the axle beam (1) only
if the wear conditions require this.
k Be careful not to damage the bush seat.
3. Remove the upper king pin bush (2) and the ball
bearing cup (3) from the king pin seats using a
suitable puller only if the wear conditions require
this.

(1).
REMARK
Destructive operation for the seal rings (6);
the seal rings must be replaced.
5. Remove the bushes (7) from the axle beam (1)
only if the wear
k Be careful not to damage the bush seats.

1. Cool the upper king pin bush (2) and the ball
bearing cup (3) at a temperature lower than -100
°C with liquid nitrogen.
k Wear safety gloves.
2. Assemble the upper bush (2) on the upper king
pin seat with the special tool (A) and a hammer.
3. Assemble the ball bearing cup (3) on the lower
king pin seat with the special tool (A) and a ham-
mer.
WB93R-8 50-117
4. Assemble the bush (4) on the axle beam (1) with

the special tool (B) and a hammer.
5. Assemble the seal ring (5) on the axle beam with
the special tool (C) and a hammer.
REMARK
2 Seal rings: Tecnolube® POLYMER 400

Grease carefully the seal rings
k Assemble the seal ring (5) as in figure.
6. Assemble the bushes (7) on the axle beam (1)

with the special tool (E) and a hammer.
7. Assemble new seal rings (6) on the axle beam
with the special tool (D) and a hammer.
NOTICE
Usage of tools (D) and (E).
k Assemble the seal rings (6) as in figure.
50-118 WB93R-8
WHEEL AND DOUBLE U-JOINT GROUP
Tools to be used
New/Redesign
Necessity
Sketch
Q'ty
A CA715779 Driver q 1 For wheel shaft seal

B CA715649 Driver q 1 For beam trumpet bushing

1. Remove the nut (2) and detach the tie rod (3)
from the swivel housing (1) as described in
"STEERING CYLINDER GROUP" - “METHOD
FOR DISASSMBLING”.
k Don't beat on the threaded pin end of the
tie rod (3).
REMARK
This is a destructive operation for the nut (2);
use a new nut in the reassembly.
WB93R-8 50-119
k Do not unscrew the tie rod (3) nor the nut (4)
to preserve the correct toe-in adjustment.
k Secure the swivel housing (2) with a belt or a

rope to a hoist or any other suitable support-
ing device.
Unscrew and remove the fastening screws (5)
and (9) from the upper (6) and lower (10) king
pin.
2. Remove the king pins (6) and (10).

REMARK
Collect the belleville washers (7) and (8).
3. Remove the wheel hub/reduction gear group

from the axle.

axle beam.
REMARK
The differential support group must be
assembled to the axle.
k Be careful not to damage the seal ring
(11); couple with care the double U-joint
splined end to the differential.
50-120 WB93R-8
2. Grease carefully the seats of king pin (6) and

(10) with specific grease.
2 Seat pin: G2-LI
3. Position the belleville washers (7) and (8) on the
king pin seats. Assemble the king pins, the lower
(10) and the upper (6), and tighten the retaining
screws (9) and (5) to the requested torque.
3 Screws: 190 Nm
4. Insert the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (1).
k Do not unscrew the tie rod (3) nor the nut
(4) to preserve the correct toe-in adjust-
ment.
5. Assemble and tighten the lock nut (2) with a

dynamometric wrench to the requested torque.
3 Lock nut: 220 Nm
6. Check the differential oil level from the oil fill plug
(14) and top up if necessary.
7. Reassemble the plug (14) to the prescribed
torque.
3 Plug: 80 Nm
WB93R-8 50-121
DOUBLE U-JOINT SEAL RING

METHOD FOR REPLACING ON AXLE BEAM SIDE
from the axle beam as described in "WHEEL
AND DOUBLE U-JOINT GROUP" - METHOD
FOR DISASSEMBLING.
2. Remove the seal ring (11) from the axle beam
(12).
k Be careful not to damage the seal ring
seat.
3. Assemble the seal ring (11) on the axle beam

(12) with the special tool (A) and a hammer.
REMARK
2 Seal ring: Tecnolube POLYMER 400

Grease carefully the seal ring.
k Assemble the seal ring (11) as in figure.

4. Check the correct position of the seal ring after
the assembly in depending of the axle type.
axle beam as described in "WHEEL AND DOU-
BLE U-JOINT GROUP" - METHOD FOR
ASSEMBLING.
50-122 WB93R-8
DOUBLE U-JOINT BUSHING

METHOD FOR REPLACING ON AXLE BEAM SIDE
from the axle beam as described in "WHEEL
AND DOUBLE U-JOINT GROUP" - METHOD
FOR DISASSEMBLING.
(12).
REMARK
Destructive operation for the seal ring (11);
the seal ring must be replaced in the
assembly.
3. Use a puller to remove the bush (13) from the
axle beam (12).
k Be careful not to damage the bush seat.
4. Assemble the new bush (13) on the axle beam
(12) with the special tool (B) and a hammer.
5. Assemble the seal ring (11) to the axle beam (12)

as described in "DOUBLE U-JOINT SEAL
RING".
REMARK
2 Seal ring: Tecnolube POLYMER 400

Grease carefully the seal ring.
6. Check the correct position of the seal ring after

the assembly. Assemble the wheel/double
U-joint group to the axle beam as described in
"WHEEL AND DOUBLE U-JOINT GROUP" -
METHOD FOR ASSEMBLING.
WB93R-8 50-123
TESTING AFTER ASSEMBLY

1. With engine off, lift the axle so that the tyres get
away from the ground.
2. Engage the gear so that the pinion gets locked.
3. With the help of another person standing on the
opposite side, begin the assembly testing by
rotating as much as possible both the wheels for-
ward. (Both the wheels should get locked after a
while.)
4. Keeping the pinion locked, free the right wheel
and rotate the left one in the line of march. Rotate
the right wheels in the opposite direction.
5. The wheel will move freely without difficulty and
the right wheel will move in the opposite direction
if the assembly has been carried out correctly.
6. Repeat the same operation in the opposite direc-
tion (reverse gear).
k If one wheel does not rotate freely in both
directions, then check step by step all assem-
bly operations.
7. Check and see that the brakes are regulated cor-
rectly and functioning properly.
50-124 WB93R-8
REMOVAL AND INSTALL REAR AXLE

METHOD FOR REMOVING REAR AXLE
1. Start the engine and fully raise the machine with

rear outrigger (1).
2. Position two stands “A” under the machine.
1
A 1
k Lower front and rear work equipment to the

RKAD5401
ground in a stable posture.

k Set the work equipment lock lever to LOCK
position.
k Turn the starting switch to OFF position to
stop the engine.
k Turn the battery disconnect switch to OFF
position, and remove the key. (For details, see
“30 TESTING AND ADJUSTING - HANDLING
BATTERY DISCONNECT SWITCH”).
RKAD5410

4. Slowly remove the rear wheel (3).
4 Wheel assembly: 160 - 190 kg
3
2
RKAD5420
5. Disconnect differential lock hose (4) from axle

(5).
5
4
RKAD5430
WB93R-8 50-125
6. Disconnect brake line hoses (6) and (7).

NOTICE
6
re-assembling.
• Plug all hoses to prevent entry of any impu-
7
rities.
RKAD3591
7. Disconnect the drive shaft (8) from axle (5). [*2]
RKAD5440
8. Disconnect parking brake cable (9) from support

proceeding as follow.
1. Remove safety spring (a) end pin (b) and dis- 9
connect parking brake cable (9) from parking d
brake. b
2. Compress spring (c) and remove snap ring
(d). c
3. Disconnect parking brake cable (9) from sup-
port.
a
RKAD5311
9. Place a lifting tool (C) and some blocks beneath

the axle. Raise this until the blocks are being
5
forced up against the arms of the axle (5).
C
RKAD5450
50-126 WB93R-8
10. Loosen bolt (10). [*3]

11. Lower the lifting tool (C) until the axle is free.
12. Extract the axle (5).
4 Rear axle: 460 kg

5
10
RKAD5460
METHOD FOR INSTALLING REAR AXLE

[*1]
3 Nuts (1): 400-550 Nm {40,79-56,08 kgm}
[*2]
3 Cardan shaft fixing screws:
30.4-41.8 Nm {3.1-4.3 kgm}
[*3]
a Install bolts (10) tightening them in 3 steps using
the cross-clamping method.
3 Bolts (10):
• 1st step: 160-220 Nm {16.5-22.5 kgm}
• 2nd step: 720-990 Nm {73.5-101 kgm}
• 3rd step: 1160-1595 Nm {118-163 kgm}
WB93R-8 50-127
DISASSEMBLY AND ASSEMBLY REAR AXLE

BRAKES GROUP
Tools to be used when disassembling and assembling brakes group
New/Redesign
Necessity
Sketch
Q'ty
A CA715902 Self-adjust kit driver q 1 -

50-128 WB93R-8
2. Remove all but two of the cap screws (1).
3. Connect the hub (2) to a lifting device and ten-

sion the rope.
REMARK
It's advisable assembly almost two threaded
rod in the seat of removed bolts to align the
parts in the disassembly.
k Check that the wheel hub (2) is properly sup-

ported.
4. Remove last two cap screws (1) and separate
the hub (2) from the axle (3).
5. Slowly pull hub (2) away from axle (3) and the
half shaft (4), make sure that counter plates (5)
and brake disks (6) stay with the hub.
6. Stand the hub up, mark the counter plates (5)

that was against the axle housing (3).
Remove the brake disks (6), counter plates (5)
and dowel pins (7).
WB93R-8 50-129
7. Remove half shaft (4) from the hub (2).
REMARK
In some cases the half shaft can be supplied as
two pieces type.
8. Loosen and remove the shouldered bolts (8), and

spring washers (9) from the brake self adjusters
(10).
9. Check springs (9) and shouldered bolt (8) for

damage.
REMARK
If brake disks are being replaced, replace
springs and bolts with kit.
10. Remove the lock ring (11) and remove the self
adjuster (12).
50-130 WB93R-8
11. Place self-adjust kit (12) on special tool (A) and

drive out the spring clips (13) from the adjuster.
12. Inspect adjuster bushing (14) for wear.

REMARK
Repeat procedure for the remaining 2 kit self
adjust.
13. Use an acceptable flat bars and pry the brake

piston (10) up from the hub.
14. Remove from the brake piston (10) the inner cyl-
inder (15).
15. Remove O-rings (16) and (17) from the brake

piston (10).
WB93R-8 50-131
16. Remove O-ring (18) from inner cylinder (15).
17. Remove and replace O-Ring (19).

1. Install a new O-Ring (19) onto hub (2).
2. Install O-ring (18) onto inner cylinder (15).
3. Install O-rings (16) and (17) onto brake piston

(10)
50-132 WB93R-8
4. Lubricate O-Rings (16), (17) e (18) and mount

inner cylinder (15) into brake piston (10).
2 O-Ring: Tecnolube POLYMER 400
5. Lubricate the brake cavity of the hub housing (2)

and mount pins (7).
2 Hub housing: Tecnolube POLYMER 400
6. Place the brake piston (10) and remove the pins

(7).
7. Place the adjuster bushing (14) with tapered

edge facing up into special tool (A).
8. Place pin of special tool (A) into adjuster bushing
(14).
9. Mount spring clips (13) taking care to rotate them

90° clockwise respect to the one mounted
before.
WB93R-8 50-133
10. Drive the spring clips (13) onto the adjuster bush-
ing (14) until they are seated against the special
tool (A).
REMARK
Repeat the same operations for assembly the
other kits.
11. Insert the adjuster (12) into the brake piston,

make sure that the chaffered side is up.
12. Install the snap rings (11) into the self adjuster
(12) bore.
NOTICE
Snap ring (11) orientation.
13. Place spring washers (9) onto shouldered bolt (8)

facing as shown.
50-134 WB93R-8
14. Mount the shouldered bolts (8) and spring wash-

ers (9) and tighten to the requested torque.
3 Shouldered bolts: 15.3 Nm
15. Note: make sure the all belleville springs are well
aligned before tightening the bolt
16. Put the half shaft (4) and brake separator plate
pins (7) into the axle housing.
17. Using the reference mark made during disas-

sembly, place the inner brake separator plate (5)
into the axle housing (3).
18. Place the inner brake disk (6) and the second
brake separator (5). Note: If using new brake
disks (6) they must besoaked in oil for 24 hours
prior to installation.
19. Place the outer brake disk (6) and make sure the
slots of the inner and outer brake disks are
aligned with each other.
WB93R-8 50-135
20. Attach lifting equipment to hub assembly (2) and

insert it into the axle beam (3).
k Check that the wheel hub (2) is properly
supported.
REMARK
Use a piece of rope and lift and rotate the half
shaft while pushing the hub onto the axle.
21. Mount screws (1) applying a film of the pre-

scribed adhesive and tighten to the requested
torque.
3 Screws: 226 Nm
2 Screws: Loctite 278
22. Refill axle with the prescribed oil.
50-136 WB93R-8
WHEEL HUB AND REDUCTION GEAR

Tools to be used when disassembling and assembling wheel hub and reduction gear
New/Redesign
Necessity
Sketch
Q'ty
A CA715026 Driver q 1 For bearing cup

B CA716057 Driver q 1 For wheel hub seal
C CA716135 Driver q 1 For bearing

1. Remove the wheel hub group from the axle. For
detail see "BRAKES GROUP".
WB93R-8 50-137
2. Remove the half shaft (s) and brakes group from

the wheel hub. For detail see "BRAKES
GROUP".
3. Support the wheel hub assembly (without half

shaft) with proper lifting equipment and assemble
the whole group to the axle beam.
k Check that the wheel hub is properly sup-
ported.
NOTICE
The half shaft must not be present to allow the
removal of the planetary carrier.
Secure the group to the axle beam using at
least 4 bolts (8). Tighten the bolts (8) to the
requested torque.
3 Screws: 226 Nm
2 Screws: Loctite 278
4. Remove the cover (1).
5. Remove the bolts (3) fastening the planetary car-

rier (15) to the wheel hub (5).
50-138 WB93R-8
6. Lubricate and assemble a high strength (12.9)

bolt (v) M22x2.5 (minimum length 140 mm) in the
indicated hole.
7. Screw in the bolt (v) by hand until contact with

the planetary carrier.
8. Lock the wheel, then tighten the bolt (v) with a

wrench to completely release the planetary car-
rier.
REMARK
It's recommended the use of a wrench with a
long handle.
9. Remove the bolt (v).

Check that the wheel hub is properly supported
then remove the fastening bolts (8).
10. Detach the wheel hub and reduction gear group

from the axle beam by leveraging in the appropri-
ate seats.
WB93R-8 50-139
11. Place the group on a work bench and lift the

complete planetary carrier, using a special hook
or a bearings puller.
• Planetary carrier special hook.
REMARK
A bearing puller can be used to hook (under the
gears) the planetary carrier.
12. Place the planetary carrier (15) on the work

bench. To disassemble a gear, remove the rela-
tive snap ring.
13. Using a suitable puller, remove gear (17) com-

plete of bearing (16).
REMARK
It's not possible to separate the bearing (16)
from the gear (if one of two has to be replaced,
replace both).
50-140 WB93R-8
14. Support the wheel hub carrier (9) with proper lift-
ing device and place it on solid work bench.
15. To extract the wheel hub (5), lift a bit the wheel
hub carrier (9) and beat with a soft metal pad on
the wheel hub.
16. Remove the wheel hub carrier.
17. Collect the bearing cone (13).
18. Remove from hub housing (9) the seal ring (6).
REMARK
This is a destructive operation for the seal; the
WB93R-8 50-141
19. Remove from hub carrier (9) the bearing cup (7).
In the same way, overturn the hub carrier (9) and
remove the bearing cup (13).
20. Remove the bearing cone (7) from wheel hub (5),
using suitable puller.
21. Remove the seal ring (6).

REMARK
This is a destructive operation for the seal; the

1. Place the wheel hub carrier (9) on suitable work
bench.
2. Install the bearing cups (7) and (13) using the
special tools (A) with a press or a hammer block.
3. Using special tool (B) install the hub seal (6) on

wheel hub carrier (9).
50-142 WB93R-8
• Special tool (B) usage.
4. Using an appropriate tool, install the bearing

cone (7) on wheel hub (5).
5. Attach lifting equipment to hub carrier (9) and

carefully install on wheel hub (5).
REMARK
Clean accurately all sealing surfaces.
NOTICE
Take care not to damage the hub seal (6).
6. Install inner bearing (13) with an appropriate

driver.
7. Assemble the gears to the planetary carrier (15).

For details see "METHOD FOR ASSEMBLING
PLANETARY GEARS".
WB93R-8 50-143
8. Assemble the bushes (14) to the planetary car-

rier (15) using a press.
9. Attach lifting equipment to planetary carrier (15)

and place it into hub (9).
REMARK
It's recommended the use of special hook or a
bearing puller to hook (under the gears) the plan-
etary carrier.
10. Assemble a new O-Ring (2) in the shown seat.
11. Assemble the fastening bolts (3) and tighten to

the prescribed torque.
3 Bolts: 230 Nm
50-144 WB93R-8
12. Assemble the cover (1).

2 Cover: Loctite 518
13. Assemble a new O-Ring (12) in the shown seat.
14. Assemble the brakes group and half shaft (s) to

wheel hub group For detail see "BRAKES
GROUP".
METHOD FOR ASSEMBLING PLANETARY GEARS

1. Place the gear (17) on a workbench.
2. Place over the special tool (C) the bearing (16)
complete of rollers containment ring.
3. Assemble the bearing (16) with tool (C).
• Tool (C) use.
WB93R-8 50-145
4. Install the gears (17) on planetary carrier (15).

REMARK
Check that rounded side of bearing (16) is
facing toward planetary carrier (15).
5. Assemble the snap ring (18) on gear shaft.
50-146 WB93R-8
PARKING BRAKE
Tools to be used when disassembling and assembling parking brake
New/Redesign
Necessity
Sketch
Q'ty
A CA715550 Driver q 1 For central body seal

1. Loosen the two nuts (1).
WB93R-8 50-147
2. Unscrew the two screws (2).

k To operate with care to avoid damages to
the brake pads. Remove the brake caliper
(3).
3. Remove the snap ring (4) and the input flange

(5).
REMARK
Collect the shim (6) and the O-ring (7).
4. Unscrew and remove the fastening screws (8) of

the brake caliper support (9).
5. Remove the brake caliper support (9) from the
central body.
6. Remove the seal (10) from the central housing

(11) with a puller.
REMARK
This is a destructive operation for the seal.

1. Introduce a new seal (10) into in the central body
using special tool (A).
50-148 WB93R-8
2. Insert the dowel pin (12) and the brake caliper

support (7) on the central body (9).
3. Screw and tighten the fastening screws (8) to the
requested torque.
3 Screw: 120 Nm
4. Grease the O-Ring (7) to maintain it in position.

5. Insert the washer (6) on the splined pinion end, a
new O-Ring (7), the input flange (5) and the lock
ring (4).
6. Position the brake caliper (3) on the flange disc

(5).
k Proceed with care, in order to avoid dam-
aging the brake pads.
7. Screw in the bolts (2) and tighten the nuts (1) to

the prescribed torque.
3 Nuts: 115 Nm
8. After tightening the nuts, make sure that is pre-
sent a space of R between the nuts (1) and the
caliper as shown in figure; if necessary adjust the
position of the nuts.
• R= 1.0±0.5 mm
WB93R-8 50-149
PARK BRAKE MECHANICAL CALIPER

1. Loosen the two nuts (1).
2. Unscrew the two screws (2).
REMARK
To operate with care to avoid damages to the
brake pads.
3. Remove the two screws (2).
50-150 WB93R-8
4. Remove the brake caliper (3) from the brake disc

(4). Only if necessary remove the two brake pads
(5).
k Do not invert the brake pads position if
the brake pads are not replaced; the brake
efficiency would be compromised.

1. Position the brake caliper (3), with relative pads
(5), on the flange disc (4).
REMARK
Proceed with care, in order to avoid damaging
the brake pads.
k Do not invert the brake pads position if
the brake pads are not replaced; the brake
efficiency would be compromised.
2. Assemble the two screws (2) and tighten the nuts

(1) to the prescribed torque.
3 Nuts: 115 Nm
3. After tightening the nuts, make sure that is pre-

sent a space of R between the nuts (1) and the
caliper as shown in figure; if necessary adjust the
position of the nuts.
• R= 1.0±0.5 mm
WB93R-8 50-151
DIFFERENTIAL SUPPORT GROUP

Tools to be used when disassembling and assembling differential support group
New/Redesign
Necessity
Sketch
Q'ty
A CA716640 Wrench q 1 For pinion splined end

For differential support ring
B CA715900 Wrench q 1
nuts
C CA715391 Driver q 1 For differential bearing cups
D CA716394 Tool q 1 For preload measurement

50-152 WB93R-8
2. Remove all screw (1).
3. Separate from axle (2) the differential housing (3)

using pry bars in slots.
4. Attach lifting eyes to differential housing (3) and

remove it.
5. Measure and write down the total rolling torque

MT0 of the bearings (pinion-crown bevel gear sys-
tem), using a torque wrench and special tool (A).
Note the value MT0 that is necessary in the bear-
ing reassembly.
REMARK
The rolling torque have to be included in the
field.
6. Instead of proceeding with step 5 measure the

starting total preloading FT0 of the bearings (pin-
ion-crown gear system), using a dynamometer
whose cord is wound on the pinion splined end.
Note the value FT0 that is necessary in the bear-
ings reassembly.
WB93R-8 50-153
7. Remove the bolts (4) securing the ring nuts (5)

and (6).
8. Unscrew the adjuster ring nuts (5) and (6) using

the special tool (B).
9. Remove the differential housing (7).

10. The bearing cups (8) and (9) are removed
together with the differential housing.
k Do not invert the bearing cone if the bearings

are not replaced.
11. If necessary, remove bearing cone (8) and (9)

from adjuster ring nuts (5) and (6).
50-154 WB93R-8

1. Assemble the bearing cups (8) and (9) on the dif-
ferential housing (7) with the special tool (C).
REMARK
Do not invert the bearing cones if the bearings
are not replaced; respect the marks made on
disassembly.
2. Assemble bearing cone (8) and (9) onto adjuster

ring nuts (5) and (6).
3. Position the complete differential box with bear-

ings on the differential carrier (3).
REMARK
Ensure that the bevel crown gear is on the
right side. Insert the adjuster ring nuts (5) and
(6).
4. Assemble and tighten both adjuster ring nuts (5)

and (6) in the differential support with special tool
(B), till the backlash is eliminated and the differ-
ential bearings are slightly preloaded.
REMARK
Check that the differential bearings are well
settled; if necessary, knock slightly with a soft
hammer, in order to properly set the bearings
in position.
5. Position a magnetic-base dial gauge on the dif-

ferential support, so that the feeler stylus touches
the surface of one tooth of the crown gear with a
90° angle.
WB93R-8 50-155
6. Lock the pinion and move the crown gear alter-

natively and note the pinion-ring gear backlash,
measured with the comparator.
7. Repeat this operation on two or more teeth and
calculate the average of measured backlash val-
ues.
8. Check if the average backlash value is within the
requested range:
Gmin < Gm < Gmax
• Gmin: 0.20 mm
• Gmax: 0.35 mm
9. If this condition is verified go to the step 14, if not
carry out the backlash adjustment as follows.
10. Adjust the ring nuts (5) and (6) by using the spe-
cial tool (B).
REMARK
Unscrew/screw the adjuster ring nuts, as indi-
cated in the next step, both of about 30
degrees at once then check the backlash.
11. Adjust the ring nuts (5) and (6), remembering

that:
(A)- if the measured backlash is less than the
nut on the crown side and screw in the ring nut
on the other side of the same measure;
(B)- if the measured backlash is greater than the
given tolerance range, screw in the adjuster ring
nut on the crown side and unscrew the ring nut
on the other side of the same measure.
12. Repeat the whole sequence of the above men-

tioned operations till the indicated conditions are
reached.
50-156 WB93R-8

established, if the bearings have been not
replaced, measure the total preloading FTm of the
bearings (pinion-crown bevel gear system), using
a dynamometer whose cord is wound on the pin-
ion splined end.
NOTICE
Do not use this method with new bearings, if
the bearings have been replaced see next
step.
14. The measured value FTm should be within the fol-
lowing range (see METHOD FOR DISASSEM-
BLING DIFFERENTIAL SUPPORT GROUP step
6):
FT0 < FTm < ( FT0+ 10) [N]
established, if the bearings have not been
replaced and instead proceeding with step 11
measure the total rolling torque (M Tm ) of the
bearings (pinion- crown bevel gear system) with
a torque meter and the special wrench (A).
16. The measured value MTm should be the same of
the starting:
MTm= MT0
(see METHOD FOR DISASSEMBLING DIFFER-
ENTIAL SUPPORT GROUP step 5)
17. If the bearings have been replaced, measure the
total preloading F T m of the bearings (pin-
ion-crown bevel gear system), using a dynamom-
eter whose cord is wound on the special tool (D)
inserted on the pinion splined end.

ment) of the special tool (B) and diameter of the
R= Dm/DP
19. The measured value of total preloading FTm must
be within the following range:
FTmin/R < FTm < FPmax/R [N]
• FTmin: FP + 33.4 N
• FPmax: FP + 50.2 N
WB93R-8 50-157

measure the total preloading FTm, the reference
diameter is the diameter of pinion shaft splined
end.
The measured value should be within the follow-
ing range:
FTmin < FTm < FTmax [N]
• FTmin: FP + 33.4 N
• FTmax: FP + 50.2 N
REMARK
With new bearings this way give inaccurate
result and it's not recommended.
established, if the bearings have been replaced
and instead proceeding with step from 15 to 19
measure the total rolling torque (M Tm ) of the
bearings (pinion-crown bevel gear system) with a
torque meter and the special wrench (A).
• MTmin
• MTmax
REMARK
All the preloads must be measured without
the seal installed.
22. The total rolling torque MTm must be within the
following range:
MTmin < MTm < MTmax [N]
• MTmin: MP + 0.58 N
• MTmax: MP + 0.87 N
23. If the measurement is not within the requested

range, check well the assembly of each compo-
nent and operate on the adjuster ring nuts (5)
and (6) of the differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (5) and (6)
by the same measure, keeping the pinion-ring
gear backlash value unchanged;
(B)- if the total preloading is greater than the
given range, unscrew both adjuster ring nuts (5)
and (6) by the same measure, keeping the pin-
ion-ring gear backlash value unchanged.
50-158 WB93R-8
24. Secure in position ring nuts (5) and (6) tightening

bolts (4) to the requested torque.
3 Bolts: 10 Nm
25. Before matching surfaces, make sure that they

are perfectly clean, degrease and clean them
with appropriate detergents.
Spread a film of adhesive on the contact surface
between the axle (2) and the differential housing
(3).
2 Loctite 510

1. Assembly the differential housing (3) to the axle
(2).
2. Tighten bolts (1) to the requested torque.

3 Bolts: 80 Nm
WB93R-8 50-159

To test the marks of the bevel gear teeth, paint the ring
gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides.
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the teeth
surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in order
to adjust the backlash.
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in
order to adjust the backlash.
Movements to correct:
1. move the pinion for type X contact adjustment.
2. move the pinion for type Z contact adjustment.
50-160 WB93R-8
DIFFERENTIAL LOCKING GROUP

Tools to be used when disassembling and assembling differential locking group
New/Redesign
Necessity
Sketch
Q'ty
A CA716244 Snap ring pusher q 1 -

B CA716863 Driver q 1 For lock ring

1. Loose plug (1) but do not remove it.
WB93R-8 50-161
2. Hold the differential lock fork (2) down to catch a

block inside of the housing, remove the plug (1).
3. Insert the special tool (A).
4. Remove the snap ring (5).

Remove special tool (A).
5. Remove the bushing (6).
6. Remove the spring (4).
50-162 WB93R-8
7. Remove the shaft (3) from differential housing.
8. Remove the fork (2), spring (7) and bushing (8)

from the shaft (3).
9. Remove O-Ring (9) from plug (1) and O-rings

(11) and (12) from the piston (10).

1. Install new O-rings (11) and (12) on the piston
(10) and O-Ring (9) on plug (1). Lubricate the
O-rings.
2 O-ring: Tecnolube POLYMER 400
2. Lubricate the shaft (3).

2 Tecnolube POLYMER 400
3. Install the fork (2) on the shaft (3) like shown in
figure. Install spacer (8) and spring (7) onto shaft.
REMARK
Mount the spacer (8) with the chamfer towards
the snap ring (13).
WB93R-8 50-163
4. Insert in the differential housing the shaft (3)

complete.
5. Install the spring (4).
6. Place the bushing (6) on the shaft, make sure the

chamfer in the bushing is facing out.
7. Insert the special tool (A).
8. Using special tool (B), install the snap ring (5).

Remove the special tools (A) and (B).
50-164 WB93R-8
9. Push the fork (2) into the carrier and lock it

behind the block inside of the carrier.
10. Hand screw the plug (1).
11. Tighten plug (1) to the requested torque.

3 Plug: 180 Nm
WB93R-8 50-165
DIFFERENTIAL
Tools to be used when disassembling and assembling differential
New/Redesign
Necessity
Sketch
Q'ty
A CA715391 Bearing cup driver q 1 -

1. If differential bearing have to be replaced,
remove bearing cups (1) and (2).
2. Remove sleeve (3).
50-166 WB93R-8
3. Remove the locking ring (4).
4. Remove the differential housing cover (5),

remove the anti rotation pin (6) and the thrust
washer (7).
5. Remove the planetary gear (8).
6. Remove plugs (9).
7. Remove the pins (10).
WB93R-8 50-167
8. Remove the ring gear cap screws (11) and bevel

gear crown (12). Use a special spray solvent to
remove all residual sealant from the threaded
holes.
REMARK
If necessary, to remove any contamination
use a tapper M12x1.75 into the crown gear
holes; clean with compressed air the threaded
holes.
9. Push the pin (13) towards the flat surface side.

REMARK
The pin (13) can be pushed in only one direc-
tion.
10. Remove the spider gear (14) and thrust washer.

(15).
11. Push the pin (13) out of the housing and remove
the spider gear (16) and thrust washer (17).
12. Push the short spider pins (18) out of the spacer
(19) by pushing them through the hole in the
spacer (19).
50-168 WB93R-8
13. Remove pins (18), spider gears (20) and thrust

washers (21).
14. Remove the planetary gear (22) and thrust

washer (23) from the housing.
15. Remove the differential locking pins (25) from the

housing (24).

1. Install and lubricate new O-rings (26) on the pins
(25).
2 O-ring: Tecnolube POLYMER 400
2. Install the pins (25) in the differential housing

(24).
WB93R-8 50-169
3. Lubricate and install the gear (22) and thrust

washer (23) with clean hydraulic oil.
4. Lubricate and install the gears (20) and thrust

washers (21) with clean hydraulic oil.
5. Install pins (18) far enough to hold the thrust
washer and spider.
REMARK
Orientate the flats on the pins (18) facing up.
6. Install the spacer (19) as shown and push the

pins (18) into the spacer.
7. Make sure to install the pins (19) so that the
dowel pin hole aligns with the dowel pin hole in
the housing.
8. Lubricate and place the spider gear (16) and

thrust washer (17) into the housing.
9. Insert and push the pin (13) in as far as possible.
REMARK
Orientate the flat on the pin (13) facing up.
10. Lubricate and place the spider gear (14) and

thrust washer (15) into the housing.
11. Completely insert the pin (13) and make sure that
the dowel pin hole aligns with the dowel pin hole
in the housing (24).
50-170 WB93R-8
12. Mount bevel gear crown (12).

13. Apply the prescribed adhesive on the screws
(11) thread. Assemble the screws (11) to the
requested torque.
3 Screw: 165 Nm
2 Screw: Loctite 270
14. Install pins (10) and tighten plugs (9) to the

requested torque.
3 Screw: 25 Nm
15. Place the gear (8) into the housing.
16. Apply a light coat of grease to the thrust washer

(7) to hold it in place on the differential housing
cover (5).
17. When installing the differential housing cover (5),

place the pin (6) in the slot of the cover (5) and
align it into the grove in the housing during
assembly.
WB93R-8 50-171
18. Lock cover (5) with the locking ring (4).
19. Install the differential lock ring (3) onto the hous-
ing.
REMARK
If it is difficult to push down, reach through
the housing and rotate the spider gears until
the differential lock ring will go down.
20. Use the special tool (A) and a hammer to install

the bearing cups (1) and (2).
REMARK
Take care not to mix the bearing cups.
50-172 WB93R-8
PINION GROUP
Tools to be used when disassembling and assembling pinion group
New/Redesign
Necessity
Sketch
Q'ty
A CA716640 Wrench q 1 For pinion splined end

B CA716518 Wrench q 1 For pinion nut
C CA715128 False pinion q 1 -
D CA716394 Tool q 1 For preloading measurement
E CA119198 False differential box q 1 -
F CA715092 Driver q 1 For bearing cup
G CA119225 Driver q 1 For pinion bearings
H CA715167 Driver q 1 For bearing cone

1. Measure the starting preloading FP0 of the pinion
bearings using a dynamometer whose cord is
wound on the pinion splined end.
REMARK
Note the value FP0 that is necessary in the
bearings reassembly. For details see
"METHOD FOR ASSEMBLING" step 16.
WB93R-8 50-173
2. Instead of proceeding with step 1, if there is no

need to replace the bearings, the rolling torque
MP0 of bearing (7) and (8), using special tool (A)
and a torque wrench.
REMARK
Note the valve MP0 that is necessary in the
bearing reassembly. For details see "METHOD
FOR ASSEMBLING" step 17.
3. Lock the differential carrier with a vise.

Unscrew the lock nut (1) using special tools (B)
and (A).
REMARK
Note this operation will irretrievably damage
the lock nut (1).
4. Remove the ring nut (1) and collect its retaining

washer (2).
5. Tap the shaft with a soft hammer to remove the

bevel pinion (3).
REMARK
Take care not to drop the bevel pinion (3).
6. Collect the washers (4) and (5), the collapsible
spacer (6) and the inner ring (7).
7. Remove the bearing cup (7) and (8) from the dif-
ferential carrier (9) using a drift and a hammer.
50-174 WB93R-8
8. To remove the inner ring of the tapered roller

bearing (8) of the bevel pinion (3), use a standard
extractor.
9. Collect the inner ring of the tapered roller bearing
(8) and the underlying shim (10).
10. Check all pinion components for wear.

REMARK
The ring nut (1) and the collapsible spacer (6)
must be replaced when reassembling the unit.

1. Place the differential support (9) on a workbench.
Fit the bearing cups (7) and (8) using the special
drift (F) and (G) and a hammer.
2. Insert the baring cone (7) and (8) in their hous-

ings. Assemble the false pinion (C) and its ring
nut (1).
Tighten without exceeding the ring nut, till the
backlash is eliminated.
3. Install special tool (E) to the differential group

supports (9).
WB93R-8 50-175
4. Use a depth gauge to measure distance "X" (dis-

tance between the axis of the differential bear-
ings and the point at which the pinion head is
supported, or base of the bearing).
5. To adjust bevel gear/pinion measure the distance

"A" with a depth gauge.
Calculate the value "X" as follows:
• X = (A+C) - B mm
where "B" and "C" are known.
6. In order to determine the necessary thickness

value (S) between the pinion and the bearing,
subtract the value (V), stamped on the pinion
head (V= requested distance), from the meas-
ured value (X).
• S = X - V mm
7. Select the shim (10) of thickness value (S)

among the range of available shims.
SHIMS RANGE
Thickness
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
(mm)
Quantity - - - - - - - - - -
8. Remove the special tool (E) to the differential

group supports (9). Remove the ring nut (10), the
false pinion (C) and the bearing cones (7) and
(8).
50-176 WB93R-8
9. Once you have chosen the suitable shim (2),

insert it on the pinion shaft with the chamfer
against the pinion head, as shown in figure.
10. Force the inner rind of bearing (8) into the pinion
(3) with the special tool (H) under a press, mak-
ing sure that it is well set.
11. Install the washers (4) and (9) and a new collaps-
ible spacer (6) on the pinion gear (3).
REMARK
Use always a new collapsible spacer (6).
12. Check the right assembly sequence.
13. Insert the inner ring of bearing (7) on the pinion

shaft.
In order to force the bearing (8) into position, use
the special tool (H) and a hammer.
WB93R-8 50-177
14. Insert the ring nut washer (2) and screw a new
lock ring nut (1) on the pinion end.
REMARK
Lubricate with oil the ring nut (1) contact
sirface with the washer (2).
15. Screw the ring nut (1) in, using the wrench for
ring nut (B) and for pinion retainer (A).
k The torque setting is given by the pre-
loading measurement on bearings (7) and
(8); tighten the ring nut (1) gradually.
REMARK
If the tightening is excessive, the elastic
spacer (6) must be replaced and the proce-
dure repeated. When you check the
preloading, it is advisable to beat slightly both
pinion ends (3) with a soft hammer, so as to
help setting the bearings (7) and (8).
16. If the bearings have been not replaced, to meas-
ure the preloading FPm of the pinion taper roller
bearings (7) and (8), use a dynamometer whose
cord is wound on the end of pinion shaft (3).
k Do not use this method with new bear-
ings, if the bearings have been replaced
see next step.
The measured value should be within the
following range. (For details see "METHOD FOR
DISASSEMBLING" step 1).
FPm= FP0 ÷ (FP0+10) N
17. If the bearings have not been replaced and
instead of proceding with step 16 measure the
rolling torque M Pm of bearing (7) and (8), use
special tool (A) and a torque wrench.
k Do not use this method with new bearing,
if the bearings have been replaced see
next step.
All preloadings must be measured without the
seal rings. The measured value must be the
starting value. (For details see "METHOD FOR
DISASSEMBLING" step 2).
MPm = MP0
50-178 WB93R-8
new, to measure the preloading FPm of the bear-
ings, use a dynamometer whose cord is wound
on the special tool (D) inserted on the end of pin-
ion shaft.

ment) of the special tool (D) and diameter of the
R= Dm/DP
• Dp = 34.8 mm
The measured value of preloading must be within
the following range:
FPmin/ R < FPm < FPmax/ R [N]
• FPmin = 114.9 N
• FPmax = 137.9 N
measure the pinion bearing preloading, the refer-
ence diameter is the diameter of pinion shaft
splined end.
FPmin/ R < FPm < FPmax
• FPmin = 114.9 N
• FPmax = 137.9 N
new, and instead proceeding with step 18, 19
and 20 measure the pinion shaft bearings rolling
torque MPm with a torque meter and the special
wrench (A).
REMARK
All the preloads must be measured without
the seal ring.
22. The measured value MP must be within the fol-

lowing range:
MPmin < MP < MPmax [Nm]
• MPmin = 2.0 Nm
• MPmax = 2.4 Nm
WB93R-8 50-179
23. Once the requested preloading value is

achieved, caulk the ring nut (1), using a hammer
and a chisel.
TESTING AFTER ASSEMBLY

PRESSURE TEST
Perform a pressure test on the complete assembled
axle and check the whole system to find any possible
leakage.
k The maximum test total pressure must be
always lower then 1500 mbar (1.5 bar).
Stop every leak before assembling the axle to the
vehicle.
TESTING METHODS
1. With engine off, lift the axle so that the tyres get
away from the ground.
REMARK
If present, disable the negative parking
brakes.
2. Engage the gear so that the pinion gets locked.
3. With the help of another person standing on the
opposite side, begin the assembly testing by
rotating as much as possible both the wheels for-
ward. (Both the wheels should get locked after a
while).
4. Keeping the pinion locked, free the right wheel
and rotate the left one in the line of march. Rotate
the right wheels in the opposite direction.
The wheel will move freely without difficulty and
the right wheel will move in the opposite direction
if the assembly has been carried out correctly.
Repeat the same operation in the opposite direc-
tion (reverse gear).
IF ONE WHEEL DOES NOT ROTATE FREELY IN

BOTH DIRECTIONS, then check step by step all
assembly operations.
Check and see that the brakes are regulated correctly
and functioning properly.
50-180 WB93R-8
REMOVAL AND INSTALL TRANSMISSION

Tools to be used when removing and installing transmission assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Special key q 1 q See schetch

Commercially
B Jack q 5
available
Commercially
C Lifting tool q 1
available
D - Support q 1 q See schetch
E - Threaded bar q 1 M10 x 80mm
METHOD FOR REMOVING TRANSMISSION

rear outrigger (1).
2. Position two stands “B” under the machine.
1
B 1
RKAD5400
3. Raise the machine using front work equipment

until the machine is levelled.
4. Position two stand “B” under the machine.
RKAD5261
WB93R-8 50-181

k Release the remaining pressure in all circuit by referring to 30 TESTING AND ADJUSTING.


7. Remove hydraulic pump (For details, see “”)
8. Drain the transmission oil.
6 Transmission oil: approx 18 l
3
2
RKAD5420
9. Disconnect the rear shaft (4) from rear axle (5).

[*2]
RKAD5470
10. Disconnect front drive shaft (6) from front axle

(7). [*2]
RKAD5530
50-182 WB93R-8
RKAD4841
12. Use special tool “A” inserted into the cranckshaft

pulley to rotate the engine and loosen bolts (9)
locking engine flywheel to torque converter. [*3]
RKAD4871
13. Place a jack “B” under the engine flywheel hous-

ing (10) and force in raising.
10
RKAD5540
11
RKAD3703
WB93R-8 50-183
12
RKAD3714
16. Remove front floor cover (13) and disconnect

connector PD1 (14) and K14 (15) of accelerator
pedal.
13
RKAD3724
14
15
RKAD5042
50-184 WB93R-8
17. Disconnect hydraulic differential lock hose (16).

NOTICE
16 19
rities.
18. Disconnect connectors: 18
• FWD solenoid connector X108 (17)
• RVS solenoid connector X203 (18)
• differential lock solenoid connector X94 (19) 17
• 4WD solenoid connector X106 (20)
• transmission oil temperature sensor connector RKAD5550
X105 (21)
• 4th gear switch connector X104 (22)
20
21
22
RKAD6330
19. Disconnect the hoses (23), (24) and plug them.

NOTICE
rities.
24
RKAD6340
20. Remove bolt (25) and disconnect transmission oil

level pipe (26) from the engine. [*4]
25
26
RKAD4791
WB93R-8 50-185
21. Loosen bolts (27) and remove transmission oil

level pipe (26). [*5]
26
27
RKAD5560
22. Loosen and remove upper bolts (28) (6 pieces).

[*6] 28
23. Loosen and remove lower bolts (29) (6 pieces). 28
NOTICE
• Leave in position the 2 upper bolts (28) for
safety.
29
RKAD4881
24. Loosen nuts (30). [*7]

25. Loosen bolt (31) and remove supports (32).
32 32
30 30
31 31
RKAD5570
26. Install support “D” and place the lifting tool under
it.
NOTICE
• Ensure that the lifting tool “C” can lower
the transmission of about 600 mm. D
D
C
RKAD5580
50-186 WB93R-8
27. Remove the two upper bolts (28) left in place and
move the transmission backward until it is disen-
gaged from the engine.
28. Remove the transmission assembly(33). [*8]
4 Transmission assembly: 250 kg

33
RKAD5590
METHOD FOR INSTALLING TRANSMISSION

[*1]
3 Nuts (2): 400-550 Nm {40,79-56,08 kgm}
[*2]
30.4-41.8 Nm {3.1-4.3 kgm}
[*3]
3 Bolt (9): 52-71,5 Nm {5,3-7,29 kgm}
[*4]
3 Bolt (25): 72-99 Nm {7,4-10,1 kgm}
[*5]
3 Bolt (27): 28-38,5 Nm {2,9-3,9 kgm}
[*6]
3 Bolt (28) and (29): 39,2-53,9 Nm {4-5,5 kgm}
2 Bolt (28) and (29): Loctite 262
[*7]
3 Nuts (30): 156-214,5 Nm {15,9-21,9 kgm}
WB93R-8 50-187
[*8]
a In order to help centering of torque converter with
the flywheel, install a threaded bar “E” (M10
thread with lenght approx 80 mm). A
RKAD5600
50-188 WB93R-8
DISASSEMBLY AND ASSEMBLY TRANSMISSION

PLUGS AND FILTERS

1. Remove the drain plug (5) and drain the oil from
the transmission.
2. Remove the two cap screws (1) which fasten the

cover for the oil screen.
Remove the cover (2).
WB93R-8 50-189
3. Remove the oil screen (4) and the O-ring (3).

Filter handling and wash according to the rules in
force. In case of replacement, use only author-
ized disposal procedures and, in case of doubt,
refer to the authorized bodies.
4. Remove the oil filter (6).

REMARK
Filter handling and disposal according to the
rules in force. Use only authorized disposal
procedures and, in case of doubt, refer to the
authorized bodies.
5. Remove the connector for the oil filter (7).
6. Remove the spool (8).
50-190 WB93R-8
8. Use a puller to remove the regulator pressure

valve (10).
REMARK
The four-wheel drive priority valve is adjusted
at the factory. DO NOT try to disassemble or
adjust the four-wheel drive priority valve. If
any of the parts are damaged, use a new regu-
lator pressure valve.
k Do not remove the plug unless the plug is

leaking.
The plug is sealed with Loctite 542 and is dif-
ficult to remove. If removal is necessary,
clean all oil from the threads and apply Loc-
tite 542 before installation.
9. It is not necessary to remove the port plugs (12)

and (15), the breather (14), or the oil temperature
sensor (11) unless these parts are leaking or
damaged.

1. Assemble the port plugs (12) and (15), the
breather (14) and the oil temperature sensor
(11).
3 Plugs (12), (15): 23 Nm
2 Breather (14): Loctite 638
3 Oil temperature sensor (11): 30 Nm
2 Oil temperature sensor (11): Loctite 510
2. Assemble valve (10).
WB93R-8 50-191
3. Assemble spring (9).
4. Assemble spool (8).
5. Assemble connector (7).

3 Connector (7): 50 Nm
6. Assemble a new filter (6).

REMARK
Put a thin coat of oil or grease on the filter
gasket, turn clockwise until the gasket makes
contact with the base, continue to turn the
filter 2/3 turn.
7. Assemble filter (4) and O-ring (3) after having

washed or replaced it.
50-192 WB93R-8
8. Assemble cover (2) and screws (1).

3 Screws (1): 23 Nm
9. Assemble plug (5).

3 Plug: 80 Nm
WB93R-8 50-193
CONVERTER AND OIL PUMP

Tools to be used when disassembling and assembling converter and oil pump
New/Redesign
Necessity
Sketch
Q'ty
A CA716443 Driver q 1 For hydraulic pump seal

1. Drain oil from transmission hydraulic circuit.
2. Remove torque converter (1) from vehicle.
50-194 WB93R-8
3. Remove screws (2).

k Mark the pump position with respect to
the bellhousing before untightening the
screws.
4. Remove the pump by means of two levers.
5. Remove the oil pump (3).

k Oil pump seal ring can be damaged dur-
ing this operation.
6. If replacement is necessary, remove O-ring (4).

k Do not open/disassemble the pump or its
operation may be compromised.
Special tools from the manufacturer are
required for reassembly.
7. If replacement is necessary, remove seal ring

(5).
WB93R-8 50-195

1. Clean the outer diameter of seal ring (5) and the
pump (3) housing bor from oil and dust.
Apply a thin film of Loctite 480 on the outer diam-
eter of seal ring (5).
2. Assemble seal ring (5) on oil pump (3). Use tool

(A).
3. Lubricate the seal ring (5) lips with grease Poly-

mer 400L.
4. Fit O-ring (4).
50-196 WB93R-8
k Before oil pump assembly (if new), check that

o i l pa s s a g e h o l e s b e t w e e n p u m p a n d
half-case or the visual marks coincide.
5. Grease the ring to keep it centred/coaxial with

respect to the shaft slot centre line and to make
the introduction onto the pump easier.
6. Apply a thin film of grease on the coupling seat

with the front half-case. Assemble the oil pump
(3).
7. Fit screws (2).

3 Screws: 23 Nm
k Carefully check that marks on the oil
pump and on the bellhousing coincide.
8. In order to avoid damage to the pump seal ring, it

is recommended to fit the converter on the TLB
transmission by hand (the two teeth of the pump
driving converter can cut the seal ring lip).
Match the transmission and the converter to the
vehicle engine flywheel with the screws of the
converter driving disc of engine SAE3 bellhous-
ing.
Fit converter (1). Turn the torque converter until
engaging the relative splined shafts.
WB93R-8 50-197
PIPES

1. Drain oil from transmission hydraulic circuit and
remove screws (1) and (2).
2. Remove pipe (3).
3. Collect gaskets (4).

1. Assemble pipe (3), screws (1) and (2).
k Replace gaskets (4).
3 Screws: 40 Nm
50-198 WB93R-8
HYDRAULIC CONTROL VALVE

1. Disconnect all electrical wires and drain the
hydraulic oil from the transmission.
2. Remove the screws (13) and remove the control
valve (53).
3. Remove the gasket (49).
WB93R-8 50-199
4. Remove the screws (48) and the plate (50).
6. Lock the control valve (53) with a clamp.

8. Remove the O-Ring (2).
9. Push down the piston (4) then remove the snap

ring (3).
10. Remove the piston (4)and the spring (5).
50-200 WB93R-8
11. Check the wear conditions of removed parts.
k Do not remove from control valve (47) piston

(8). It piston (8) is removed the control valve
body (47) has to be replaced with a new one.
k It piston (8) has to be replaced, order the con-
trol valve body kit (47).

15. Remove the thrust washer (10).
WB93R-8 50-201
16. Turn the control valve (47).

17. Remove the screws (33).
18. Remove the valve cover (34).
19. Remove the plate gasket (35).
20. Remove the plate (36).
21. Remove the outward piston (38), the springs

(39),(40),(41), the pin (42) and the inward piston
(43).
50-202 WB93R-8
23. Remove the plate gasket (37).
24. Remove the ball (26).

WB93R-8 50-203
28. Remove the solenoid (30). Remove the O-Ring

(29).
29. Remove the solenoid (28). Remove the O-Ring

(27).
30. Unscrew the solenoid tube (24).
31. Remove the solenoid pipe (24) with spool (21).
32. Disassemble the spool (21) from the solenoid

tube (24).
50-204 WB93R-8
33. Remove the spring (23) and the thrust washer

(22). Check the wear conditions of removed
parts.
34. Unscrew the nut (20).

36. Remove the solenoid (18).
38. Unscrew the solenoid tube (18).
39. Remove the O-Rings (17).
WB93R-8 50-205

1. Assemble the O-Rings (17).
2. Assemble the solenoid tube (18).

3 Solenoid tube: 25-30 Nm
3. Assemble the O-Ring (17).

4. Assemble the solenoid (18).
6. Assemble the nut (20).

3 Nut: 5-7 Nm
50-206 WB93R-8
7. Assemble the solenoid tube (24) and spring (23)

at the spool (21) and thrust washer (22).
8. Assemble the solenoid pipe (24) with spool (21)

to the control valve.
9. Screw the solenoid tube (24).

3 Solenoid tube: 21.5-24.5 Nm


WB93R-8 50-207
14. Assemble the O-Ring (31) on the plug. Assemble

the plug (32).
3 Plug: 7-10 Nm
15. Assemble the spring (25).
16. Position the ball (26).
17. Assemble the plate gasket (37).
18. Preassemble the components.
50-208 WB93R-8
19. Assemble the outward piston (38), the springs

(39), (40), (41), the pin (42) and the inward piston
(43).
20. Assemble the plate (36).
21. Assemble the plate gasket (35).
22. Assemble the valve cover (34).
23. Assemble the screws (33).

3 Screws: 9.8-11.8 Nm
WB93R-8 50-209
24. Turn the control valve (47).

25. Assemble the thrust washer (10).
26. Assemble the spring (9).
27. Assemble the O-Ring (7) on the plug.

28. Assemble the plug (6).
29. Assemble the piston (4) and the spring (5).
30. Push down the piston (4) then assemble the

snap ring (3) in its seat.
50-210 WB93R-8
31. Assemble the O-Ring (2) on the plug.

32. Assemble the plug (1).
33. Assemble the gasket (51) on the transmission.
34. Assemble the plate (50) and the screws (48).

3 Screws: 23 Nm
35. Assemble the gasket (49).
36. Assemble the control valve (53) and the screws

(13).
3 Screws: 28 Nm
WB93R-8 50-211
4WD SOLENOID VALVE

1. Disconnect all electrical wires and drain the
hydraulic oil from the transmission.
2. Remove screws (1) and remove housing (2).
3. Remove nut (8).

4. Remove solenoid (7).
50-212 WB93R-8
5. Remove cartridge (6) from housing.

6. Remove O-rings (5) from the cartridge.
8. Remove valve (3).

k Do not try to disassemble the valve (3).
There are no serviceable parts. If there is
a problem, use a new check valve.

1. Assemble valve (3) to the housing.
2. Assemble O-rings (5) into the cartridge (6).

3. Assemble cartridge (6) in the housing.
3 Cartridge: 26-29 Nm
WB93R-8 50-213
4. Assemble the 4WD solenoid valve (7).

5. Assemble nut (8).
3 Nut: 4.8-6.8 Nm
6. Assemble new gasket (4).
7. Assemble the housing (2) and screws (1).

3 Screws: 23 Nm
50-214 WB93R-8
TRANSMISSION HOUSING
Tools to be used when disassembling and assembling converter and oil pump
New/Redesign
Necessity
Sketch
Q'ty
A CA715406 Hook q 1 For front half housing lifting

B CA715354 Driver q 1 For cover seal
C CA716750 Protection q 1 For teflon seal ring
D CA716456 Pusher q 1 For teflon seal ring
E CA716489 Gauger q 1 For teflon seal ring
F CA715501 Driver q 1 For seal
WB93R-8 50-215

1. Remove bearing snap ring (1).
2. Untighten and remove flange retaining screw (2).

3. Use a screwdriver and two screws to avoid
flange rotation.
4. Remove washer (3).
5. Remove flange (5) and O-ring (4).
6. Remove the three cap screws (6).
50-216 WB93R-8
7. Remove the cover (7).
8. Remove the O-ring (8) from the cover (7).
9. Remove the seal (9) from the cover (7).
10. Untighten and remove flange retaining screw

(10).
11. Use a screwdriver and two screws to avoid
flange rotation.
12. Remove washer (11).
WB93R-8 50-217
13. Remove flange (12) and O-ring (13).
14. Remove the three cap screws (14).
15. Remove the shift tower assembly (15) and the

O-ring (16).
16. Remove the O-ring (43).

17. Remove the six cap screws (17) and the two cap
screws (42) which fasten the rear cover (18) to
the rear half housing.
18. Use a prybar to loosen the rear cover from the

housing.
19. Remove the rear cover (18).
50-218 WB93R-8
20. Remove the seal (19) from the rear cover.
21. Use a punch to remove the pins (20) which fas-

ten the shift collars to the shift rods and centering
pins (41).
22. Remove the shift collars (21).
23. Remove the two screws (22) which hold the plate
between the two shift rods.
24. Remove the plate (23).
WB93R-8 50-219
25. Remove the two detent balls (24) from the

groove between the two shift rods.
26. Untighten and remove screws (25) and washers

(26).
27. Remove springs (27).
28. Remove balls (28).
29. Pull the secondary shaft to the rear so that there

is clearance between the snap ring and the rear
housing. Remove the snap ring (29).
50-220 WB93R-8
30. Remove transmission shaft PTO (30) by pushing

lightly on the opposite side.
31. If to replaced, remove teflon seal ring (31) by cut-

ting it.
32. Remove snap ring (32).
33. Extract bearing (33) using a suitable driver.
WB93R-8 50-221
36. Use lever to remove the front half housing (36).
37. Lift the front half housing by means of special

tool (A) or with two hooks.
38. The outer rings of the bearings for the primary

shaft (37) and for the secondary shaft (38) can
stay with either the shafts or the front housing.
39. Remove the two bearings.
40. Remove bearing (40).
50-222 WB93R-8
41. Replace O-rings (39) if necessary.

1. Push the secondary shaft toward the rear of the
rear housing so that there is clearance between
the snap ring groove and the rear housing.
2. Install the snap ring (29).
3. Assemble the O-Rings (39).
4. Apply a thin film of sealant on the edge of the

rear half-housing.
2 Rear half-housing: Loctite 510
5. Use clean transmission oil to lubricate the bear-

ing for the primary shaft (37) and the bearing for
the secondary shaft (38).
6. Install the bearings.
WB93R-8 50-223
7. Install the front half housing (36) on the rear half

housing with special tool (A) or with two hooks.
Make sure that the bearings on the shafts go
straight into the bores in the front half housing.
Push the front half housing all the way down on
the rear half housing.
8. Assemble screws (34).

3 Screws: 50 Nm

3 Screws: 50 Nm
10. Use clean transmission oil to lubricate the bear-

ing for the 4WD shaft. Install the bearing (40) on
the 4WD shaft.
11. Use a suitable driver.
12. Use the (B) special tool to install a new seal (9) in
the cover (7). Push just until the seal stops mov-
ing.
k Do not use excessive force. Fill the cavity
under the lip of the seal with high temper-
ature wheel bearing grease.
50-224 WB93R-8
14. Install the cover (7) in the front housing.
15. Install the three cap screws (6) which fasten the
cover to the front housing.
3 Screws: 23 Nm
16. Install a new O-ring (4) in the four-wheel drive

flange. Use clean transmission oil to lubricate the
O-ring.
17. Install the four-wheel drive flange (5) on the

four-wheel drive shaft.
WB93R-8 50-225
18. Install the washer (3).
19. Assemble screw (2).

20. Use screwdriver to avoid flange rotation.
3 Screw: 139 Nm
21. Assemble snap ring (1).
22. Assemble ball (28).

REMARK
In steps 22 through 24 the photos show the
installation of lower detent parts 1st and 2nd
speed pipe. It is necessary for you to install
both the upper detent parts 3rd and 4th speed
pipe and the lower ones 1st and 2nd speed
pipe according to the instructions in the
procedure. Make sure that you start with both
shift rods in the NEUTRAL position.
23. Assemble spring (27).
50-226 WB93R-8
24. Assemble washer (26) and screw (25).

3 Screw: 80 Nm
25. Repeat steps 22 through 24 to install the upper

detent ball and spring. Assemble screw (25) and
washer (26).
3 Screw: 80 Nm
26. Assemble bearing (33) on transmission shaft

PTO (30).
28. For the assembly of teflon seal ring (31) follow

operations from step 20 to step 22 (see
"SHAFTS A - D" - METHOD FOR ASSEM-
BLING) using respectively the tools (C), (D) and
(E).
WB93R-8 50-227
29. Insert transmission shaft PTO (30) to the stroke.
30. Grease the balls.

31. Install the two detent balls (24).
32. Install the plate (23).
33. Apply sealant to the threads of the two Allen

head screws. Install the two Allen head screws
(22) to fasten the plate in position.
2 Screw: Loctite 242
3 Screw: 50 Nm
34. Install shift collars (21) on the shift rods.
50-228 WB93R-8
35. Install the pins (20) to fasten the shift collars to

the shift rods, and the centering pins (41).
36. Use the special tool (F) to install a new seal (19)
in the rear cover. Push the seal just until the seal
makes contact with the lip in the bore.
37. Put the rear cover (18) in position. Make sure

that the pin (41) is correctly installed both in the
rear housing and through the hole in the rear
cover. Install the six cap screws (17) and the two
cap screws (42) to fasten the cover to the rear
half housing. If necessary, tap the rear cover with
a soft faced hammer to close the gap between
the rear half housing and the rear cover before
tightening the cap screws.
3 Screw: 50 Nm
38. Assemble the O-ring (43).
39. Install a new O-ring (16) on the shift tower
assembly (15).
40. Use clean oil to lubricate the O-ring and assem-
bly it on the rear housing.
41. Install the three Allen head screws (14) to fasten

the shift tower assembly to the rear cover.
3 Screw: 23 Nm
WB93R-8 50-229
42. Install a new O-ring (13) in the output flange (12).

43. Use clean oil to lubricate the O-ring.
44. Install the washer (11).
45. Use a prybar between the two cap screws to hold

the output flange while you tighten the cap screw
(10) in the secondary shaft.
3 Cap screw: 139 Nm
50-230 WB93R-8
SHAFTS A - D
Tools to be used when disassembling and assembling shafts A - D
New/Redesign
Necessity
Sketch
Q'ty
A CA716450 Tool kit q 1 For clutch disassembly

B CA715499 Protection q 1 For piston input shaft
F CA715743 Protection q 1 For teflon seal ring
G CA716500 Pusher q 1 For teflon seal ring
H CA716449 Gauger q 1 For teflon seal ring
WB93R-8 50-231

1. Grasp with pliers the input shaft assembly A.
Remove with shaft assembly D and lift.
SHAFT A
1. If to be replaced, remove the teflon seal ring (1).
3. Install a bearing separator under the gear as

shown (do not install the bearing separator
between the gear and the bearing).
Use a puller on the bearing separator and insert
a shaft protector between the puller and the end
of the input shaft.
By means of puller which operates between
bearing separator and shaft protector pull only
until the bearing is free.
Pulling further can damage the parts.
50-232 WB93R-8
5. Remove spacer (4).
6. Remove gear (5).
7. Remove needle cage (6).
8. Remove thrust washer (7).
WB93R-8 50-233
9. Remove split pin (8).
10. Remove lock ring (9).
11. Use prybars to lift and to remove the clutch plate

lock ring (10) evenly.
12. Remove the clutch plates (11) and the clutch

drive plates (12).
13. Place a mark below the groove on the friction

bell.
50-234 WB93R-8
14. Place a mark on each clutch plate lock ring (10),

clutch plate (11) and clutch drive plate (12).
REMARK
These marks will be used for reference during
the reassembly procedure.
15. Lower lock spring cover (14). Use tool (A).
17. Loosen the handles of the threaded rods to

release the tension from the spring.
18. Remove the top piece of the (A) special tool.
19. Remove lock spring cover (14) and spring (15).
WB93R-8 50-235
21. Remove clutch piston (17) by blowing in com-

pressed air through the delivery hole.
22. If to be replaced, remove teflon seal ring (18) and

relevant inner O-ring from outer seat of piston
and teflon seal rings (19) and relevant inner
O-ring from inner of piston. To remove the rings it
is necessary to cut them.
23. Turn the shaft (20).

24. If to be replaced, remove teflon seal rings (21) by
cutting them.
50-236 WB93R-8
26. Remove bearing (23) by means of an extractor.
27. Remove bearing (23) and thrust washer (24).
28. Remove gear (25) and needle cage (26).
29. For the disassembly of the other parts, repeat the

operations from step 8 to step 20.
30. Check the sealing ring grooves (large and small)
for wear and damage if necessary.
Use new parts as required.
31. Check on the output shaft for wear and damage.
Check oil passages in the output shaft to be sure
that the passages are open and free of foreign
material.
32. Check the ball bearings and the needle bearings
for flat areas, pitting, and other damage.
WB93R-8 50-237
33. If the clutch discs are to be used again, keep the

clutch packs in the same previous assembly
order separate and record which clutch pack
goes with each clutch.
34. At each disassembly, verify with a caliper that the

total thickness of the clutch kit is within the wear
limit (see table). If not, replace the clutch kit (18)
with a new one.
Verify that all the clutch plates do not appear
burned or that the friction material it is not dam-
aged and that splines are well traced.
Verify also that all the clutch drive plates (17) are
perfectly plane and inspect for pitting or scoring.
In the case that at least one of the above prob-
lems occurs, replace the complete clutch kit with
a new one.
If using a new clutch kit soak the clutch plates in
clean transmission oil for at least an hour before
assembly.
In any case lubricate the contact surfaces of
clutch drive plates with clean transmission oil
before assembly.
35. Inspect the bore of the shaft in the input shaft

housing for damage that will cause leakage when
the clutch is assembled.
Check the slots in the side of the input shaft
housing for damage from the tangs on the steel
discs.
Use new parts as required during assembly.
FWD-RVS GEAR CLUTCH

Number of clutch plate (each side) 6
Number clutch steel plate (each side) 6
Nominal clutch plate thickness 2.40±0.05 mm

Nominal clutch kit thickness 29.00–29.20 mm (Under load of 163 kg)
Maximum clutch plate wear (each side) 0.25 mm
Maximum clutch kit wear 3.0 mm
50-238 WB93R-8
SHAFT D
36. Remove bearing (40) of shaft D (41) by means of
an extractor.
37. Remove bearing (42) of shaft D (41) by means of

an extractor.
SHAFT A
1. Assemble new teflon ring (18) and relevant inner
O-rings, new teflon ring (19) and relevant inner
O-rings respectively into the piston outer and
inner seats.
2. Apply a thin film of grease on the sealing rings

just inserted.
WB93R-8 50-239
3. Insert clutch piston (17) with special tool (a) (B)

as protection of seal rings (19).
4. Assemble sleeve (16).
5. Assemble spring (15) and lock spring cover (14).
6. Lower lock spring cover (14). Use tool (A).
7. Insert lock ring (13).
50-240 WB93R-8
8. Remove tool (A) and assemble split pin (8).
9. Insert thrust washer (7).
10. Insert needle cage (6).
11. To assemble the clutch pack start with the gear

(5) on the bench. Install the clutch plate lock ring
(10) so that the reference mark on top of the
plate made during disassembly is facing towards
the gear.
12. Assemble clutch plates (11) and clutch drive

plates (12) on the gear (5).
REMARK
The assembled clutch pack must contain
seven clutch drive plates and six clutch
plates.
k Leave the clutch pack immersed in oil for
at least an hour before mounting it.
WB93R-8 50-241
13. Locate the pack assembly by means of two

screwdrivers.
14. Assemble lock ring (10).
15. Assemble washer (4).
16. Heat the bearing (3) to 80-100 °C.

17. Assemble bearing (3). Use a suitable driver.
18. Install the snap ring (2).

REMARK
For clarity of the Teflon sealing ring installa-
tion procedure the following photos do not
show the clutch pack, gear, spacer, bearing,
and snap ring installed on the input shaft.
50-242 WB93R-8
19. Using two pry bars lift the bearings toward the
snap ring to have clearance between gear and
bearing.
20. Insert the teflon seal ring (1) as follows.
1) Install the (C) spacer (lenght 102.5 mm) onto

the input shaft with the chamfered end facing
in.
2) Slide the (C) expander/protector onto the

i n p u t s h a ft a n d o v e r t h e s pa c e r. T h e
expander/protector will stop in the correct
position to install the seal ring in the groove.
3) Heat the Teflon seal ring to 60°-80°C for 5

minutes. Install the teflon seal ring onto the
expander/protector.
WB93R-8 50-243
21. Install the (D) pusher over the expander/protector

and slide the seal ring until it reaches the groove
in the shaft. Remove the pusher, expander/pro-
tector, and spacer from the shaft.
22. Install the special tool (E) (seal compressor) on

the shaft seal ring. Leave the compressor tool in
position for at least 15 minutes until the seal ring
has cooled while maintaining the correct size.
k Remove the seal compressor shortly
before assembling the shaft in the trans-
mission.
23. Overturn the shaft and execute the operations

from step 1 to step 14.
24. Use clean transmission oil to lubricate the thrust
washer (24).
25. Install the thrust washer so that the notch in the
inner edge fits over the pin.
REMARK
Make sure that the side with the oil grooves is
upwards.
26. Heat the bearing (23) to 80-100 °C.

27. Use a suitable driver to drive the bearing (23)
onto the input shaft until the bearing makes con-
tact with the thrust washer.
50-244 WB93R-8
29. Using two pry bars lift the bearings toward the
snap ring to have clearance between gear and
bearing.
30. Install the (F) spacer (lenght 3.40 mm) onto the
input shaft (20) with the chamfered end facing in.
31. Slide the expander/protector (F) onto the input

shaft and over the spacer. The expander/protec-
tor (F) will stop in the correct position to install the
seal ring in the groove.
32. Heat the Teflon seal ring to 60°-80°C for 5 min-

utes. Assemble the teflon seal ring onto the
expander/protector.
33. Install the (G) pusher over the expander/protec-

tor and slide the seal ring until it reaches the
gr o ov e i n t he s h af t. Re mo v e th e p us he r ,
expander/protector, and spacer from the shaft.
WB93R-8 50-245
34. Install the special tool (H) (seal compressor) on

the shaft seal ring. Leave the compressor tool in
position for at least 15 minutes until the seal ring
has cooled while maintaining the correct size.
k Remove the seal compressor shortly
before assembling the shaft in the trans-
mission.
35. For the introduction of the other three teflon

rings, repeat the operations from step 30 to step
34, using the following spacer rings:
• for the 2nd teflon ring: length 19.4 mm
• for the 3rd teflon ring: length 35.4 mm
• for the 4th teflon ring: length 52.25 mm
36. Carry out the end float-check procedure of the
clutch pack on the both sides of the FWD-RVS
GEAR CLUTCH.
37. In order to eliminate the end float, position the
shaft on a suitable support (s) and push the
clutch counterdisc (10) towards the clutch kit with
a suitable driver (t), as indicated in figure.
38. In order to verify the end float feed the piston (17)
and (37) chamber with compressed air at 6 bar
and check with a dial gauge located as shown in
the photo the real stroke “X”. Measure the end
float X (see next figure).
39. Check the stroke of the piston (17) and (37). The
end float value must be:
• X= 1.60 - 2.45 mm
If the distance is not within the range specified the
clutch could be assembled wrongly. Turn the
clutch and repeat the same operation for the other
clutch pack (steps 36, 37, 38 and 39).
50-246 WB93R-8
1. Lubrication oil passage

2. Forward clutch passage
3. Reverse clutch passage
4. Forward gear
5. Forward clutch pack
6. Reverse clutch pack
7. Reverse gear
8. Input shaft
9. Apply compressed air of approximately 6 bar to the forward clutch passage. Listen to hear the forward
piston moving to lock the forward clutch pack.
Try to move the forward gear. The forward gear must not turn on the input shaft. Try to move the reverse
gear. The reverse gear must turn freely on the input shaft.
If the clutches do not work correctly, disassemble the clutches to find the problem.
10. Apply compressed air of approximately 6 bar to the reverse clutch passage. Listen to hear the reverse
piston moving to lock the reverse clutch pack. Try to move the reverse gear. The reverse gear must not
turn on the input shaft. Try to move the forward gear.
The forward gear must turn freely on the input shaft. If the clutches do not work correctly, disassemble
the clutches to find the problem.
WB93R-8 50-247
SHAFT D
11. Using a suitable driver assemble bearing (40)
onto D shaft (41).
12. Using a suitable driver assemble D shaft bearing

(42).
13. Lubricate with oil the shaft seat A.
14. Fit shaft assembly D and shaft assembly A.

REMARK
The operation is correct only if the two shafts
are fitted at the same time.
50-248 WB93R-8
SHAFTS B - C
Tools to be used when disassembling and assembling shafts B - C
New/Redesign
Necessity
Sketch
Q'ty
A CA716446 Hook q 1 For secondary shaft
WB93R-8 50-249

1. Remove the shafts B and C with special tool (A).
2. Remove the gear control forks. For disassembly

see "SPEED CONTROLS".
SHAFT C
2. Remove thrust washer (2) and third speed gear

(3).
50-250 WB93R-8
3. Remove third/fourth speed synchronizer assem-

bly (4).
REMARK
• The transmissions can be equipped with two
type of synchronizer.
The two type of synchronizer are interchange-
able as assembly, whilst their single compo-
nents are not.
For more detailed information check the
spare parts catalogue.
• The synchronizer assembly component parts
are serviced as a complete unit. The synchro-
nizer assembly may be disassembled for
inspection and cleaning. If any of the parts
are damaged, the entire synchronizer assem-
bly must be replaced. Use new parts as
required.
4. Remove the clutch ring (5) from each side of the

synchronizer assembly.
REMARK
The synchronizer assembly component parts
are serviced as a complete unit. The synchro-
nizer assembly may be disassembled for
inspection and cleaning. If any of the parts are
damaged, the entire synchronizer assembly
must be replaced. Use new parts as required.
5. Use a feeler gauge to measure the clearance

between the bottom of the teeth on the synchro-
nizer ring and the edge of the sleeve on the out-
side of the synchronizer assembly.
This clearance should be approximately 1.0 mm
with used parts in good condition.
If the clearance is 0.5 mm or less, use a new syn-
chronizer assembly. Repeat the measurement
for the opposite side of the synchronizer assem-
bly before disassembly. Repeat the measure-
ment for the opposite side of the synchronizer
assembly before disassembly.
WB93R-8 50-251
6. Remove the tapered friction ring (6) from each

side of the synchronizer assembly.
7. Remove the sleeve (7) from the synchronizer

hub.
When the sleeve is removed from the synchro-
nizer hub the spring plates, hub pins and hub
springs will be released from the synchronizer
hub.
k Do not lose any of these parts.
8. This image shows the relationship between the

plates (8), the balls (9), the hub springs (10), and
the synchronizer hub (11).
The synchronizer hub contains 3 plates (8), 3
balls (9), and 3 hub springs (10).
9. Remove fourth speed gear (12).
10. Turn the shaft. Remove the outer race bearing

(15).
50-252 WB93R-8
11. Remove the inner race bearing (15) with a suita-

ble extractor.
REMARK
Do not try to remove the bearing pulling the
gear since it is locked by snap ring (16).
13. Remove the shims (20) and the thrust washer

(17).
14. Remove split pin (19).
15. Remove second speed gear (18).
WB93R-8 50-253
16. Remove the spacer (21).
17. Remove the first/second speed synchronizer

assembly (23).
18. Remove synchronizer ring (22).
19. Remove the steel ring (24) and the sintered ring
(25) together. Install the synchronizer ring on top
of the synchronizer assembly. Use a feeler
gauge to measure the clearance between the
bottom of the teeth on the synchronizer ring and
the edge of the sleeve on the outside of the syn-
chronizer assembly.
20. This clearance should be approximately 1.0 mm

with used parts in good condition.
If the clearance is 0.5 mm or less, use a new syn-
chronizer assembly. Repeat the measurement
for the opposite side of the synchronizer assem-
bly before disassembly.
21. Remove the tapered friction ring (26).
50-254 WB93R-8
22. Turn the synchronizer assembly (23) over and

remove the synchronizer ring (27) from the other
side.
23. Remove the steel ring (28) and the sintered ring
(29) together.
24. Remove the tapered friction ring (30).
25. Support the sleeve on blocks. Push down on the

hub while you use a punch to push the detent
assemblies out of the sleeve and hub.
26. Remove the sleeve (31) from the hub.
27. This image shows the relationship between the

balls (32), the plates (33), the springs (34), and
the hub (35).
WB93R-8 50-255
28. Remove spacer (36).
29. Remove first speed gear (37).
31. Remove the 4WD gear (14).
32. Remove the snap ring (13).
50-256 WB93R-8
SHAFT B
33. Remove the inner race bearing (39) with an
extractor.

SHAFT C
1. Put the secondary shaft on the bench so that the
first-second gear end is up. You can use a vise
with soft jaws to hold the secondary shaft in posi-
tion.
2. Install the snap ring (13) as shown.
3. Assemble 4WD gear (14).
WB93R-8 50-257
4. Assemble the snap ring (38).
5. Assemble the first speed gear (37).
6. Assemble spacer (36).
7. Assemble the first/second speed synchronizer

(23).
This image shows the correct positions of the
hub (35), the sleeve (31), the springs (34), the
plates (33), and the balls (32) prior to final
assembly.
The springs are installed in the hub, and the
plates are on the springs. The plates are not yet
pushed down into the sleeve and are holding the
hub up out of the sleeve. The balls are loose in
the recesses of the plates.
8. Use a punch or screwdriver to push the balls (32)
into the plates and to push the plates down so
that the balls are on the flat faces of the teeth, but
not into the detent grooves. When all the balls
are in position, push the hub and the plates down
until the balls move into the detent groove.
50-258 WB93R-8
9. Install the tapered friction ring (30) on the syn-

chronizer assembly.
10. Use clean transmission oil to lubricate the sin-

tered ring (29) and the steel ring (28).
11. Install the sintered ring (29) and the steel ring
(28) as shown.
12. Install the synchronizer ring (27) as shown. The

flat sides of the teeth must be up.
13. Turn the synchronizer assembly over and install

the tapered friction ring (26) on the other side.
WB93R-8 50-259
14. Use clean transmission oil to lubricate the sin-

tered ring (25) and the steel ring (24). Install the
sintered ring (25) and the steel ring (24) as
shown.
Install the top synchronizer ring on the synchro-
nizer assembly. Make sure that the teeth on the
top synchronizer ring are aligned with the teeth
on the inside of the sleeve. Push the sleeve up
until the sleeve engages the teeth on the top syn-
chronizer ring.
To do this, you must use enough force to over-
come the strength of the detent springs and balls.
When the synchronizer ring and the sleeve are
completely engaged, the detent must hold the
sleeve in this position.
Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and
repeat the procedure with the bottom synchro-
nizer ring.
If the sleeve does not engage the teeth smoothly
or does not stay in position when moved to any of
the three positions, the synchronizer assembly
has damaged parts or was not assembled cor-
rectly.
Disassemble the synchronizer assembly to find
the problem.
15. Install the top synchronizing ring (22) so that the
flat sides of the teeth are up.
16. Install the first/second speed synchronizer
assembly (23).
17. Install the spacer (21) on the second speed gear

(18).
The teeth in the inside diameter of the spacer
must engage the teeth on the bottom of second
s pe ed g ea r b ef or e s ec o nd s p ee d ge ar is
installed.
50-260 WB93R-8
18. Assemble the second speed gear (18).
19. Assemble split pin (19).
20. Assemble thrust washer (17) and shims (20).

22. Measure the backlash X between gear (18) and
thrust washer (17): the value must be between
0.2-0.42 mm.
23. Check with a dial gauge positioned as shown in

the photo the real backlash X.
WB93R-8 50-261
24. If backlash X is more than the value prescribed

remove the snap ring and the washer from their
seat and, using the shims shown in the chart
reach the prescribed value. Assemble shims (20)
between thrust washer (17) and snap ring (16).
SHIMS RANGE
Thick. - mm 0.05 0.1 0.3 0.5
Q.ty - - -
25. Heat the inner race of the bearing (15) to

80-100°C. Assemble the inner race of the bear-
ing (15).
Use a suitable driver.
26. Assemble the outer race of the bearing (15).
27. Turn the shaft. Assemble the fourth speed gear

(12).
28. Assemble the third/fourth speed synchronizer

(4.)
This image shows the correct positions of the
hub (11), the sleeve (7), the springs (10), the
plates (8), and the balls (9) prior to final assem-
bly. The springs are installed in the hub, and the
plates are on the springs. The plates are not yet
pushed down into the sleeve and are holding the
hub up out of the sleeve. The balls are loose in
the recesses of the plates.
50-262 WB93R-8
29. Install the 3 sets of hub springs (8), hub pins (9),
and spring plates (10) into the synchronizer hub
(11).
Use a punch or screwdriver to push the spring
plates as the synchronizer hub is installed into
the sleeve (7).
Be sure that the spring plates are aligned with
the grooves in the sleeve.
30. Install the tapered friction ring (6) on each side

the synchronizer assembly.
31. Use clean transmission oil to lubricate and install

the clutch ring (5) on each side of the synchro-
nizer assembly.
Install the top synchronizer ring on the synchro-
nizer assembly.
Make sure that the teeth on the top synchronizer
ring are aligned with the teeth on the inside of the
sleeve.
Push the sleeve up until the sleeve engages the
teeth on the top synchronizer ring.
To do this, you must use enough force to over-
come the strength of the detent springs and balls.
When the synchronizer ring and the sleeve are
completely engaged, the detent must hold the
sleeve in this position.
Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and
repeat the procedure with the bottom synchro-
nizer ring. If the sleeve does not engage the
teeth smoothly or does not stay in position when
moved to any of the three positions, the synchro-
nizer assembly has damaged parts or was not
assembled correctly.
Disassemble the synchronizer assembly to find
the problem.
WB93R-8 50-263
32. Install the third/fourth speed synchronizer

assembly (4) onto the shaft.
33. Use clean transmission oil to lubricate the thrust

washer (2). Assemble third speed gear (3) and
the thrust washer (2) onto the shaft.
34. Heat the bearing (1) to 80-100°C.

Assemble bearing (1).
35. Check with a dial gauge positioned as shown in

the image that the backlash Z is between
0.2-0.42 mm.
If the backlash is not within these value, it is not
possible to adjust it and will be necessary to ver-
ify the procedure used to assembly all the com-
ponents, taking particular care to the
synchronizer.
SHAFT B
36. Heat the inner race of the bearing (39) to
80°-100°C. Assemble the inner race of the bear-
ing (39).
50-264 WB93R-8

Heat the bearing to 80-100°C.
Assemble bearing (40). Use a suitable driver.
38. Reposition shaft assemblies B and C into the half

box. Use tool (A).
k Install shaft assemblies with pins and
forks.
Fit the preassembled forks 3rd and 4th
speed and 1st and 2nd as shown in the
image.
REMARK
For preassembly see "SPEED CONTROLS".
39. Position the group with care paying attention to

the location of fork pins in their seats.
WB93R-8 50-265
SHAFT E
Tools to be used when disassembling and assembling shafts E
New/Redesign
Necessity
Sketch
Q'ty
A CA716446 Hook q 1 For secondary shaft

B CA716450 Tool kit q 1 For clutch disassembly
F CA715499 Protection q 1 For teflon seal ring
G CA716750 Protection q 1 For teflon seal ring
H CA716456 Pusher q 1 For teflon seal ring
I CA716489 Gauger q 1 For teflon seal ring
50-266 WB93R-8

1. Remove the shafts B and C with special tool (A).
2. Remove shaft E.
3. If necessary, remove the teflon seal rings (1)

from the shaft.
REMARK
Destructive operation for seal rings (1).
4. Remove the lock ring (2), spacer (3) and thrust

washer (4).
5. Remove the spring pin (5).
WB93R-8 50-267
6. Remove gear (6).
7. Remove needle bearing (7) and thrust washer

(8).
8. Remove the spring pin (9).
9. Remove the spacer (10) and lock ring (11).
10. Slightly press thrust plate (12).

11. Remove lock ring (13) and remove thrust plate
(12) by means of two screwdrivers.
50-268 WB93R-8
12. Remove disc (14) and counterdiscs (15) pack.
13. Lower the spring (17) retaining washer (16). Use

tool (B).

release the tension from the spring.
16. Remove the top piece of special tool (B).
17. Remove the washer (16) and spring (17).
WB93R-8 50-269
19. Remove clutch piston (20) by blowing in com-

pressed air through the delivery hole.
20. If to be replaced, remove teflon seal ring (21) and

relevant inner O- ring from outer seat of piston
and teflon seal rings (22) and relevant inner
O-ring from inner of piston. To remove the rings it
is necessary to cut them.
21. Remove the teflon seal ring (23).1

REMARK
This is a destructive operation for the teflon
seal rings (23).

23. Check the sealing ring grooves (large and small)
for wear and damage if necessary.
24. Check on the output shaft for wear and damage.
Check oil passages in the output shaft to be sure
that the passages are open and free of foreign
material.
25. Check the ball bearings and the needle bearings
for flat areas, pitting, and other damage.
50-270 WB93R-8
26. If the clutch discs are to be used again, keep the

clutch packs in the same previous assembly
order separate and record which clutch pack
goes with each clutch.
27. At each disassembly, verify with a caliper that the

total thickness of the clutch kit is within the wear
limit (see table page 187). If not, replace the
clutch kit with a new one.
28. Verify that all the clutch plates do not appear
burned or that the friction material it is not dam-
aged and that splines are well traced.
29. Verify also that all the clutch drive plates (15) are
perfectly plane and inspect for pitting or scoring.
In the case that at least one of the above prob-
lems occurs, replace the complete clutch kit with
a new one.
If using a new clutch kit soak the clutch plates in
clean transmission oil for at least an hour before
assembly.
30. In any case lubricate the contact surfaces of
clutch drive plates with clean transmission oil
before assembly.
31. Inspect the bore and the shaft in the input shaft
housing for damage that will cause leakage when
the clutch is assembled.
32. Check the slots in the side of the input shaft
housing for damage from the tangs on the clutch
drive plates.
Use new parts as required during assembly.
4WD GEAR CLUTCH

Number of clutch plate 11
Number clutch steel plate 11
Nominal clutch plate thickness 2.40±0.05 mm
Minimum groove depth 0.40 mm
Nominal clutch kit thickness under load of 163 kg 47.30-47.50 mm
WB93R-8 50-271

1. Assemble bearing (24) using a suitable driver.
2. Assemble new teflon seal ring (23).

For the introduction of the teflon ring, follow the
operations from step 30 to step 35 (see
"SHAFTS A - D" - METHOD FOR ASSEM-
BLING) using special tools (C), (D) e (E).
3. Assemble new teflon ring (21) and relevant inner

O-ring, new teflon ring (22) and relevant inner
O-rings respectively into the piston outer and
inner seats.
4. Apply a thin film of grease on the seal rings just

inserted.
5. Insert clutch piston (20) with tool (a) (F) as pro-

tection of seal rings (22).
50-272 WB93R-8
6. Assemble the sleeve (19).
7. Assemble spring (16) and washer (17).
8. Lower the spring (16) lock washer (17) using

special tool (B).
9. Insert snap ring (18).

REMARK
Ensure that the snap ring (18) is well fitted.

release the tension from the spring. Remove the
top piece of the (B) special tool.
WB93R-8 50-273
11. To assemble the clutch pack start with the gear

(6) on the bench. Install the clutch plate lock ring
(13) so that the reference mark on top of the
plate made during disassembly is facing towards
the gear.
12. Assemble clutch plates (14) and clutch drive

plates (15) on the gear (6).
k Leave the clutch pack immersed in oil for
at least an hour before mounting it.
13. Locate the pack assembly by means of two

screwdrivers.
14. Assemble lock ring (12).
15. Apply compressed air at low pressure in hole in

order to push the thrust plate (13) against the
retaining ring (12).
50-274 WB93R-8
k Carefully remove gear (6) paying attention

not to move clutch plates (14).
16. Assemble lock ring (11) and spacer (10).
17. Assemble pin (9).
18. Insert thrust washer (8) and roller bearing (7).
19. Correct installation of thrust washer (8) with the

lubricating groove facing upwards.
WB93R-8 50-275
20. Assemble gear (6) paying attention it completely

fit in its seat.
21. Assemble spring pin (5).
22. Assemble the thrust washer (4), spacer (3) and

lock ring (2).
23. Correct installation of thrust washer (4) with the

lubricating groove facing the gear.
24. Measure the clutch discs clearance for each

clutch assembly.
The clutch plate lock ring must be all the way up
against the lock ring. Use a feeler gauge to
measure the distance between the clutch plate
lock ring and the first clutch plate (11). The dis-
tance must be 2.00 to 2.90 mm. If the distance is
not within specification, the clutch is probably
assembled wrong.
50-276 WB93R-8
1. 4WD speed clutch oil passage

2. 4WD speed gear
3. 4WD clutch pack
4. Output shaft
5. 4WD lubricant oil passage
See the illustration above.

Try to rotate the 4WD gear. The 4WD gear must turn
freely on the input shaft.
Apply compressed air of approximately 6 bar to the
4WD gear clutch passage. Hear the 4WDgear piston
moving to lock the 4WD gear clutch pack.
Try to move the 4WD gear. The 4WD gear must not
turn on the input shaft. If the clutch does not work
correctly, disassemble the clutch to find the problem.
25. Insert teflon seal (1) and (2).

For the introduction of the rings, follow the opera-
tions from step 30 to step 35 (see "SHAFTS A -
D" - METHOD FOR ASSEMBLING) using special
tools (G), (H) e (I).
WB93R-8 50-277
26. Insert shaft E.
27. Lift the three shafts B-C at the same time and
insert into the half- housing using special tool (A).
50-278 WB93R-8
SPEED CONTROLS

1. Untighten and remove screws (1).
k For the disassembly of the two half boxes
it is necessary to remove the shift tower
assy.
2. Remove shift tower assy (2) and O-ring (3).
WB93R-8 50-279
3. Use side cutters as shown to release the catch

on the band which fastens the boot. Remove the
band (4).
4. Remove the boot (5).
5. Remove the two pins (7).
6. Remove the snap ring (8) from the shift lever.
7. Remove the bushing (9) from the shift lever.
50-280 WB93R-8
9. Remove the shift lever (6).
10. If disassembly is required, remove the pins (11)

and separate the shift forks from the shift rods.
Make sure that you remember how the parts are
assembled and which parts go together. Except
for the pins, none of the parts are interchangea-
ble.
11. Inspect all parts for burrs and excessive wear.
Assembly is the reverse of disassembly.
WB93R-8 50-281

1. Apply grease to the ball of the shift lever. Install
the shift lever (6).
2. The image shows the correct position of the lever

(6) respect to the cover (2):
the cavity (A) of the lever must be toward the (B)
side of the cover;
the slots (C) must be aligned with the holes (D) of
the cover.
3. Install the spring (10).
4. Install the bushing (9).
5. Put the snap ring (8) on the shift lever.
50-282 WB93R-8
6. Install the pins (7) through the holes in the cover

flange so that the pins engage the slots in the
shift lever.
7. Install the boot (5) so that the end of the boot fits
over the ends of the pins.
k Be careful so that the pins do not fall out
during this step.
8. Install the band (4) on the boot as shown.

Use the side cutters to engage the catch on the
band.
9. Install a new O-ring (3) into flange cover seat.

Use clean oil to lubricate the O-ring.
Put the shift tower assy into position on the rear
cover.

3 Screws: 23 Nm
WB93R-8 50-283
11. Fit the two pins (11) to lock gear control fork 3rd
and 4th speed (13) and gear control fork 1st and
2nd speed (14).
50-284 WB93R-8
REMOVAL AND INSTALL HYDRAULIC PUMP ASSEMBLY
HYDRAULIC SYSTEM
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY

rear outrigger (1).
2. Position two stands “B” under the machine.
1
B 1

RKAD5400

k Release the remaining pressure in all circuit by referring to 30 TESTING AND ADJUSTING.


5. Remove hydraulic pump (For details, see “”)
6. Drain the transmission oil.
6 Transmission oil: approx 18 l
3
2
RKAD5420
7. Disconnect the rear shaft (4) from rear axle (5).

[*2]
RKAD5470
WB93R-8 50-285
6
RKAD3701
RKAD3713
10. Remove front floor cover (8) and disconnect con-

nector PD1 (9) and K14 (10) of accelerator pedal.
8
RKAD3723
9
10
RKAD5041
50-286 WB93R-8
11. Disconnect from hydraulic pump (11):

• delivery hose (12) (P1) 16
• pump pressure hose (13) (P1L)
• load sensing pressure hose (14) (PLS) 15
• PC mode change hose (15) (PM)
13 11
• drain hose (16) (Pd3)
NOTICE
14 12
re-assembling.
• Plug all hoses to prevent entry of any impu- RKAD5480
rities.
12. Loosen bolts (17) [120]and clamps (18).

13. Remove hose assembly (19). [*3]
17
18
19
17
RKAD5490
14. Loosen nuts (20) and remove hydraulic pump

(11). [*4]
4 Hydraulic pump: 40 kg
11 20
20
RKAD5500
15. Remove O-Ring (21), spacer (22) and O-Ring

(23). [*5]
NOTICE
21
• Replace O-Ring with new ones. 22
23
RKAD5510
WB93R-8 50-287
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY

[*1]
3 Nuts (2): 400-550 Nm {40,79-56,08 kgm}
[*2]
30.4-41.8 Nm {3.1-4.3 kgm}
[*3]
2 Hose (19): LG-9 THREEBOND 1206D
[*4]
3 Nuts (20): 240-330 Nm {24,5-33,7 kgm}
2 Nuts (20): Loctite 262
[*5]
2 Stud (24): Loctite 262
24
24
RKAD5520
• Refilling with hydraulic oil.

• Bleed air from hydraulic circuit (For detail see “30 TESTING AND ADJUSTING” - “BLEEDING AIR
FROM HYDRAULIC CIRCUIT”).
• Run the engine to circulate the oil through the system. Then, check the oil level again.
50-288 WB93R-8
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE

ASSEMBLY
RKA84260
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY

REMARK
2 different types of springs with different mounting load are installed to springs and (6) and (7). Check the
mounting position (hydraulic port) to prevent any wrong installation.
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY

• Carefully clean and inspect the parts to prevent failure due to dust, rust, and scratch, etc., and then take
extreme care when assembling them.
• Plugs (2) and (3) are not supplied.
• When assembling piston (8), apply grease (G2- L1) to the piston periphery and inner periphery of body
(1) hole.
• When installing spring (5), install the end surface of the smaller end turn diameter to shim (4) side.
• End turn diameter of spring (inside diameter):
Small diameter side: 4.9 mm
Large diameter side: 5.55 mm
• As springs (6) and (7), different springs are used for hydraulic ports. Check it before installing.
• Installed height:
Spring (6) (P1): 30.6 mm
Spring (6) (P2): 31.6 mm
Spring (6) (P3): 31.9 mm
Spring (7) (P4): 31.9 mm
• Load at installed height
Spring (6) (P1): 41.2 N {4.20 kg}
Spring (6) (P2): 39.1 N {3.99 kg}
Spring (6) (P3): 38.5 N {3.09 kg}
Spring (7) (P4): 63.9 N {6.52 kg}
WB93R-8 50-289
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
3 Bolt (11): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}

• When installing joint (12) to body (1), apply Loctite according to the following procedure.
1. When installing the joint, apply 1 drop (approxi-
mately 0.02g) of Loctite 648 to the female
threaded part (A) (2 places) of the body. Before
installing, thoroughly degrease and dry the male
thr eaded par t of th e jo int a nd the femal e
threaded part of the body by using Drysol.
2. The positions where a drop of Loctite is applied
are as follows.
2 Female threaded part of body (A):
Loctite 648
3 Joint (12): 39 to 49 Nm {4 to 5 kgm}
• Apply grease (G2-LI) to the contact surfaces of

disc (13) and piston (8).
3 Application amount: Grease (G2-LI)
Joint sliding surface: 0.3 to 0.8 cc/entire circumference
Contact portions of disk and piston: 0.3 to 0.8 ml/1 place
• When assembling disc (13), adjust play of the lever end so that the play is within the range from 0.5 to 3
mm at the point of 200 mm from the rotation center. (For detail see “30 TESTING AND ADJUSTING” -
“ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVES”).
3 Nut (14): 69 to 88 Nm {7 to 9 kgm}
50-290 WB93R-8
REMOVAL AND INSTALL LOADER WORK EQUIPMENT ASSEMBLY
WORK EQUIPMENT
k Loosen the hydraulic tank cap to release the pressure inside the hydraulic tank (For details, see
“30 TESTING AND ADJUSTING” - “RELEASING REMAINING PRESSURE FROM HYDRAULIC CIR-
CUIT”).
METHOD FOR REMOVING LOADER WORK EQUIPMENT ASSEMBLY
1. Remove engine hood (For details, see “

REMOVE AND INSTALL ENGINE HOOD”).
2. Loosen locking bolts (1) on both side.
NOTICE
• Leave in place bolts (2).
3. Start the engine and lower the work equipment to
the ground in a stable posture.
4. Turn the starting switch to OFF position to stop
the engine.
5. For machine with return to dig specification

Remove bolt (3), disconnect return to dig sensor
support (4).[*1]
NOTICE 4
• Mark the position of support (4).
RKAD4640
WB93R-8 50-291
6. Disconnect hoses (5) from cylinder (6).

7. Remove bolt (7) and disconnect clamp (8).
NOTICE
6
re-assembling. 8
rities.
5
7
RKAD4650
8. Disconnect hoses (9) from cylinder (10).
9. For machine with ECSS specification
Disconnect connector X302 (11) on the R.H. side
and X301 on the L.H. side.
NOTICE 11
re-assembling.
rities.
9
RKAD4660
10. Remove bolts (2) locking the loader arm cylinder
pins (12).
11. Using a fabric belt “A” sling the cylinders (10) and
extract both side pins (12). 12
12. Repeat the procedure for the loader arm cylin-
ders.[*2]
NOTICE
Install a service bolt (A) and nut (B) to help
extraction of pins with their rotation.
REMARK
10
• Notate the position of spacer and quantity of RKAD4670
shims between snap ring and cylinder.
13. Using fabric belts “B” and wooden blocks “C” to

lock the bucket loader cylinder and fabric belts
“D” with wooden blocks “E” to lock bucket rota- C
tion.
E
RKAD4680
50-292 WB93R-8
14. Sling the front work equipment assembly (13).
13
RKAD4690
15. Remove bolts (2) locking the loader arm pins
(14).
16. Extract pins (14) from both side.[*3]
14 17
17.
REMARK
• Notate the position of spacer (15) and the
quantity of shims (16) between snap ring and
arm.
18
RKAD4700
18. Sling the front work equipment assembly (13).
4 Front work equipment assembly: 1050 kg 13
RKAD4710
WB93R-8 50-293
METHOD FOR INSTALLING LOADER WORK EQUIPMENT ASSEMBLY

• To install, reverse the removal procedure.
[*1]
1. Adjust the position of the return to dig sensor
(For details, see “30 TESTING AND ADJUSTING
- RETURN TO DIG SENSOR ADJUSTMENT”).
[*2]
NOTICE
• Use the procedure described below to
2 Sliding surface of mounting pin (When

install loader arm and bucket cylinders
assembling): Hyper white grease (G2-T)

k When aligning the pin holes, never insert
your fingers in them.
1. Install pins (12) and lock them in position with
bolts (2) and nuts (1)
3 Bolt (2): 96 - 132 Nm {9,8 - 13,5 kgm}
2. Install shims (18), spacer (19) and snap ring (20).
• Adjust the shims so that clearance between snap
ring and cylinders will be 1.0 mm or less.
Shim thickness: t = 1.0 mm
2 Mounting pin (Greasing after assembly):
Hyper white grease (G2-T)
[*3]
2 Inside bushings: Hyper white grease (G2-T)
1. Position the loader work equipment (13) and

align pin holes.
2 Sliding surface of mounting pin (When
assembling): Hyper white grease (G2-T)
k When aligning the pin holes, never insert
your fingers in them.
2. Install pins (14) and lock them in position with
bolts (2) and nuts (1)
3 Bolt (2): 96 - 132 Nm {9,8 - 13,5 kgm}
3. Install shims (15), spacer (16) and snap ring (17).
• Adjust the shim (16) so that clearance “a”
between arm (17) and frame (16) will be 1.0 mm
or less.
Shim (16) thickness: t = 1.0 mm
2 Mounting pin (Greasing after assembly):
Hyper white grease (G2-T)
50-294 WB93R-8
REMOVAL AND INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY

k Place the machine on a level ground, lower the outrigger fully extend backhoe work equipment.
k The bucket is needed to be installed to carry out this procedure safely.
METHOD FOR REMOVING BACKHOE WORK EQUIPMENT ASSEMBLY
1. Place a stand “A” under boom (1).
RKAD5610
2. Position a lifter “B” under boom fulcrum pin.
RKAD5990
3. Remove pins (2) and disconnect tie-rod (3) from
levers(4).
4
RKAD5620
WB93R-8 50-295
4. Remove snap ring (5), shims (6) and lever (4) of

both side.
6 5
RKAD5640
6. Loosen bolt (8).
8
7
RKAD5650
7. Sling boom cylinder (9), remove pin (10) and col-
lect shims (11). [*1] [*2]
9 11
8. Start the engine and fully retract boom cylinder
(9).
k Loosen the hydraulic tank cap to release the
pressure inside the hydraulic tank (For
details, see “30 TESTING AND ADJUSTING” - 7 10
“RELEASING REMAINING PRESSURE FROM RKAD5670
HYDRAULIC CIRCUIT”).
9. Disconnect all the hoses (12) from boom (1).
NOTICE
re-assembling.
12
rities.
RKAD6310
50-296 WB93R-8
10. Disconnect hoses (12) from boom cylinder (9).

NOTICE 9
rities.
11. Lower boom cylinder (9).
12
RKAD5690
12. Loosen bolt (14) and remove pin (15) on both
sides.[*1] [*3]
15
14
RKAD6271
13. Collect shims (16) installed between boom (1)
and boom swing support (17).
14. Sling the backhoe work equipment assembly and
remove it. 16
17
4 Backhoe work equipment assembly:
• with standard arm: 900 kg
• with telescopic arm: 1200 kg
• with side digging boom and standard arm:
1050 kg
• with side digging boom and telescopic arm: RKAD6300
1300 kg
METHOD FOR INSTALLING BACKHOE WORK EQUIPMENT ASSEMBLY

[*1]
k When aligning the positions between hole and pin, run the engine at minimum idling. Do not
insert fingers in the holes to check the alignment.
[*2]
• Adjust the shim so that clearance between boom cylinder (9) head and boom swing support (17) will be
1.0 mm or less.
[*3]
WB93R-8 50-297
• Adjust the shim so that clearance between boom (1) and boom swing support (17) will be 1.0 mm or
less.

50-298 WB93R-8
REMOVAL AND INSTALL BACKHOE BOOM CYLINDER

TESTING AND ADJUSTING” - “HANDLING BATTERY DISCONNECT SWITCH”).
CUIT”).
METHOD FOR REMOVING BACKHOE BOOM CYLINDER
RKAD5610
levers (4).
4
RKAD5620
3. Remove snap ring (5), shims (6) and lever (4) of
both side.
6 5
RKAD5640
WB93R-8 50-299

5. Loosen bolt (8).
8
7
RKAD5650
6. Sling boom cylinder (9), remove pin (10) and col-
lect shims (11). [*1] [*2]
9 11
7 10
RKAD5670
7. Place a block “B” between boom (1) and arm cyl-
inder (12).
12
B
RKAD5660
8. Disconnect hoses (13) from boom cylinder (9).
NOTICE 9
rities.
13
RKAD5691
50-300 WB93R-8
14
RKAD5680
10. Remove pin (15) and collect spacers (16) and
shims (17). [*1] [*3]
16
11. Sling the boom cylinder (9). 17
4 Boom cylinder: 95 kg
15
RKAD5700
METHOD FOR INSTALLING BACKHOE BOOM CYLINDER

• Carry out installation in the reverse order to removal.
[*1]
k When aligning the positions between hole and pin, do not insert fingers in the holes to check the
alignment.
[*2]
• Adjust the shim so that clearance between boom cylinder (9) head and boom swing support will be 1.0
mm or less.
[*3]
• Adjust the shim so that clearance between boom (1) and boom cylinder (9) will be 1.0 mm or less.
• Insert spacer (16) between boom cylinder bottom and arm cylinder bottom.
Spacer thickness: t = 2.5 mm

WB93R-8 50-301
REMOVAL AND INSTALL BACKHOE ARM CYLINDER

CUIT”).
METHOD FOR REMOVING BACKHOE ARM CYLINDER
RKAD5610
2. Place a block “B” between boom (1) and boom
cylinder (2).
1 2
B
RKAD5710
3. Loosen bolt (3)
4. Sling arm cylinder and disconnect hoses (4) from
arm cylinder (5).
NOTICE 3 6 5
rities.
5. Remove clamp (6).
4
RKAD5720
50-302 WB93R-8
6. Remove pin (7) and collect shims (8). [*1] [*2]
8
RKAD5740
RKAD5681
8. Remove pin (10) and collect spacers (11) and
shims (12). [*1] [*3]
11
9. Sling the arm cylinder (5). 12
4 Arm cylinder: 75 kg
10
RKAD5701
WB93R-8 50-303
METHOD FOR INSTALLING BACKHOE ARM CYLINDER

[*1]
alignment.
[*2]
• Adjust the shim (7) so that clearance between arm cylinder (2) head and arm will be 1.0 mm or less.
[*3]
• Adjust the shim (12) so that clearance between boom (1) and boom cylinder (2) will be 1.0 mm or less.
• Insert spacer (11) between boom cylinder bottom and arm cylinder bottom.

50-304 WB93R-8
REMOVAL AND INSTALL BACKHOE TELESCOPIC ARM CYLINDER

k Place the machine on a level ground, lower the outrigger fully extend backhoe work equipment
and telescopic arm.
METHOD FOR REMOVING BACKHOE TELESCOPIC ARM CYLINDER
1. Place a stand “A” under the fixed arm (1) and a

stand “B” under the sliding arm (2). 4
2. Remove snap ring (3) and extract pin (4). [*1]
1
3. Start the engine a fully retract telescopic arm cyl-
inder (5). 3
stop the engine. 2
position, and remove the key. (For details, see A
“30 TESTING AND ADJUSTING” - “HAN-
DLING BATTERY DISCONNECT SWITCH”). B
RKAD5930

details, see “30 TESTING AND ADJUSTING” -
“RELEASING REMAINING PRESSURE FROM
4. Sling the telescopic cylinder (5).
RKAD5940
5. Disconnect hoses (6).
NOTICE 7
rities.
7. Sling the telescopic cylinder (5).
6
4 Telescopic cylinder: 45 kg
8
RKAD6320
METHOD FOR INSTALLING BACKHOE TELESCOPIC ARM CYLINDER

[*1]
WB93R-8 50-305
alignment.

50-306 WB93R-8
REMOVAL AND INSTALL OUTRIGGER CYLINDER

k Place the machine on a level ground, set the backhoe work equipment with arm in vertical posi-
tion.
METHOD FOR REMOVING OUTRIGGER CYLINDER
1. Lower the outrigger cylinders of about 100 mm

and stop the engine.
stop the engine.
“30 TESTING AND ADJUSTING” - “HAN-
DLING BATTERY DISCONNECT SWITCH”).
RKAD5760
2. Place a lifter “A” under the outrigger foot (1) and
lightly force in raising.
A
RKAD5770
3. Disconnect pipes (2).
NOTICE
• Plug all pipes to prevent entry of any impu- 2
rities.
RKAD6280
WB93R-8 50-307
3
4
RKAD5790
5. Raise the outrigger cylinder (5) using lifter “A”
and sling it.
RKAD5800
6. Loosen bolt (6) and remove pin (7) and foot (8).
[*1]
6
7. Sling the cylinder (5)
4 Outrigger cylinder: 35 kg
1 7
RKAD5810
METHOD FOR INSTALLING OUTRIGGER CYLINDER

[*1]
alignment.

50-308 WB93R-8
REMOVAL AND INSTALL BACKHOE BOOM SWING CYLINDERS

k Place the machine on a level ground, lower the outrigger and set the backhoe work equipment
with arm in vertical position.
CUIT”).
METHOD FOR REMOVING BACKHOE BOOM SWING CYLINDERS
1. Loosen bolts (1) (2 pieces) and disconnect clamp

(2). [*1]
1
NOTICE
• Do not loose the central bolt (2)
RKAD5830
2. Loosen bolts (3) (4 pieces). [*2]
RKAD5840
3. Sling the hoses assembly (4).
RKAD5850
WB93R-8 50-309
4. Remove upper support (5).
RKAD5860
5. Disconnect hoses (6) from boom swing cylinders
(7). 6
NOTICE
6
rities.
7
RKAD5870
6. Loosen bolt (8) and remove pin (9). [*3]
7. Rotate the cylinder (7) to disengage the cylinder 9
heads from the boom swing support (10) and
sling the boom swing cylinder (7) 8
4 Boom swing cylinder: 40 kg
10
RKAD5880
50-310 WB93R-8
METHOD FOR INSTALLING BACKHOE BOOM SWING CYLINDERS

[*1]
k When aligning the positions between hole

and pin, do not insert fingers in the holes to
check the alignment. 9
8
• Start the engine and using the boom swing con-
trol lever extend or retract the boom swing cylin-
ders to center the pin hole.
• Install the pins (9) and lock them in position with
bolt (8).
RKAD5881
[*2]
3 Bolts (3): 900-1100 Nm {91,8-112,2 kgm}
[*3]
IMPORTANT
• DO NOT install pins (9) at this step

WB93R-8 50-311
REMOVAL AND INSTALL BACKHOE BUCKET CYLINDER

k Place the machine on a level ground, lower the outrigger fully extend backhoe work equipment
and lower them with the back of the bucket on the ground.
CUIT”).
METHOD FOR REMOVING BACKHOE BUCKET CYLINDER
1. Sling bucket cylinder (1).
RKAD5890
RKAD5900
2. Loosen ring nut (2), remove pin (3). [*1] [*2]
RKAD5910
50-312 WB93R-8
3. Disconnect hoses (4) from bucket cylinder (1).

NOTICE
4 5
rities.
4. Remove snap ring (5) and remove pin (6). [*1]
[*2]
5. Sling the bucket cylinder (1). 1
4 Bucket cylinder: 55 kg
6
RKAD5920
METHOD FOR INSTALLING BACKHOE BUCKET CYLINDER

[*1]
alignment.
[*2]

WB93R-8 50-313
REMOVAL AND INSTALL BACKHOE BOOM LOCK CYLINDER

k Place the machine on a level ground, lower the outrigger and fully extend backhoe work equip-
ment.
CUIT”).
METHOD FOR REMOVING BACKHOE BOOM LOCK CYLINDER

levers (3).
RKAD6290
3
RKAD5621
2. Remove nut (4) and lever (5).
5
5 4
RKAD5970
50-314 WB93R-8
3. Disconnect hose (6) from boom lock cylinder (7).

NOTICE
• Plug hose to prevent entry of any impuri-
ties. 7
4. Loosen bolts (8) and remove boom lock cylinder
(7). 6
RKAD5980
METHOD FOR INSTALLING BACKHOE BOOM LOCK CYLINDER

WB93R-8 50-315
REMOVAL AND INSTALL BACKHOE BOOM

METHOD FOR REMOVING BACKHOE BOOM
1. Remove backhoe arm cylinder (For details, see

“REMOVAL AND INSTALL BACKHOE ARM
CYLINDER”).
2. Start the engine and fully lower boom (1) on
stand “A”.
1
“RELEASING REMAINING PRESSURE FROM A
RKAD6000
3. Remove backhoe arm.
4. Remove backhoe boom cylinder (For details, see
“REMOVAL AND INSTALL BACKHOE BOOM
CYLINDER”).
5. Disconnect all the hoses (2) from boom (1).

NOTICE
re-assembling.
2
rities.
RKAD6311
6. Loosen bolt (3) and remove pin (4) on both
sides.[*1] [*2]
50-316 WB93R-8
7. Collect shims (5) installed between boom (1) and

boom swing support (6). 1
8. Sling the backhoe work equipment assembly and 6
remove it.
4 Backhoe boom (1): 270 kg
5
RKAD6060
METHOD FOR INSTALLING BACKHOE BOOM

[*1]
k When aligning the positions between hole and pin, run the engine at minimum idling. Do not
insert fingers in the holes to check the alignment.
[*2]
• Adjust the shim so that clearance between boom (1) and boom swing support (6) will be 1.0 mm or less.

WB93R-8 50-317
REMOVAL AND INSTALL BACKHOE ARM ASSEMBLY

tion.
CUIT”).
METHOD FOR REMOVING BACKHOE ARM ASSEMBLY
1. Loosen bolt (1) and sling arm cylinder (2).
1 2
RKAD5721
3. Lower arm cylinder (2) on a block “A”.
2
4
RKAD5741
4. Disconnect all the hoses (5) from arm (6).

NOTICE
rities. 5
6
5
RKAD6321
50-318 WB93R-8
5. Loosen bolt (7) and sling arm (6).

6. Remove pin (8) and collect shims (9) and spac-
ers (10). [*1] [*4] 8
7. Sling arm assembly (6). 6 7
4 Arm assembly: 230 kg

9
10
RKAD6080
METHOD FOR INSTALLING BACKHOE ARM

[*1]
alignment.
[*2]
[*3]
• Adjust the shim (4) so that clearance between arm cylinder (2) head and arm (6) will be 1.0 mm or less.
[*4]
• Adjust the shim (9) so that clearance between boom (11) and arm (6) will be 1.0 mm or less.
• Insert spacer (10) between boom (11) and arm (6) one per side.

WB93R-8 50-319
REMOVAL AND INSTALL BACKHOE TELESCOPIC ARM ASSEMBLY

tion and lock the movable arm with the safety pin.
CUIT”).
METHOD FOR REMOVING BACKHOE TELESCOPIC ARM ASSEMBLY
1. Loosen bolt (1) and sling arm cylinder (2).
1 2
RKAD5721
3. Lower arm cylinder (2) on a block “A”.
2
4
RKAD5741
4. Disconnect all the hoses (5) from arm (6).

NOTICE
rities. 5
6
5
RKAD6321
50-320 WB93R-8
5. Loosen bolt (7) and sling telescopic arm (6).

6. Remove pin (8) and collect shims (9) and spac-
ers (10). [*1] [*4] 8
7. Sling telescopic arm assembly (6). 6 7
4 Arm telescopic assembly: 460 kg

9
10
RKAD6080
METHOD FOR INSTALLING BACKHOE TELESCOPIC ARM

[*1]
alignment.
[*2]
[*3]
• Adjust the shim (4) so that clearance between arm cylinder (2) head and arm (6) will be 1.0 mm or less.
[*4]
• Adjust the shim (9) so that clearance between boom (11) and arm (6) will be 1.0 mm or less.
• Insert spacer (10) between boom (11) and arm (6) one per side.

WB93R-8 50-321
REMOVAL AND INSTALL BACKHOE BOOM SWING BRACKET

ment.
METHOD FOR REMOVING BACKHOE BOOM SWING BRACKET
1. Remove backhoe work equipment assembly (For

details, see “REMOVAL AND INSTALL BACK-
HOE WORK EQUIPMENT ASSEMBLY”).
2. Remove backhoe boom lock cylinder (For
HOE BOOM LOCK CYLINDER”).
3. Loosen bolts (1) and remove pins (2) of both cyl-
inders. [*1]
2
1
RKAD5882
4. Sling boom swing bracket (3).
5. Loosen bolts (4) and (5) and remove pins (6) and 6
(7).
3
4
7
5
RKAD6160
50-322 WB93R-8
6. Sling swing bracket (3) and collect spacers (8).
4 Swing bracket: 160 kg

8
8 RKA84320
METHOD FOR INSTALLING BACKHOE BOOM SWING BRACKET

[*1]

• Start the engine and using the boom swing con- 2
ders to center the pin hole. 1
bolt (1).
check the alignment.
RKAD5882

WB93R-8 50-323
REMOVAL AND INSTALL BACKHOE SLIDING BRACKET

ment.
METHOD FOR REMOVING BACKHOE SLIDING BRACKET

HOE WORK EQUIPMENT ASSEMBLY”).
2. Remove backhoe boom lock cylinder (For
HOE BOOM LOCK CYLINDER”).
3. Remove backhoe boom swing bracket (For
HOE BOOM SWING BRACKET”).
4. Disconnect hose (1). [*1]
RKAD6170
5. Disconnect hoses (2) from swing cylinders (3).
RKAD6180
50-324 WB93R-8
6. Fully loosen and remove bolts (4).

7. Loosen without removing bolts (5). [*2]
4
5
4
5
RKAD6190
8. Sling sliding bracket (6) and remove bolts (5).
9. Collect spacers (7) and sliding block (8). 7
6
7
5
8
RKAD6200
10. Sling sliding bracket (4).
4 Sliding bracket: 300 kg

8
8 RKA84320
WB93R-8 50-325
METHOD FOR INSTALLING BACKHOE SLIDING BRACKET

[*1]
2 Sliding guide: Hyper white grease (G2-T)
[*2]
•Tighten bolts (4) and (5) following the order in fig-

ure.
3 Bolts (4) and (5):
1200-1650 Nm {122,4-168,3 kgm}
2 Bolts (4) and (5): Loctite 242
• Start the engine and using the boom swing con-

ders to center the pin hole.
bolt (1).
check the alignment.
50-326 WB93R-8
REMOVAL AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON
REMOVAL AND INSTALL BACKHOE SLIDING BRACKET LOCKING

PISTON
ment.
CUIT”).
METHOD FOR REMOVING BACKHOE SLIDING BRACKET LOCKING PISTON

HOE SLIDING BRACKET”).
2. Remove pipes (1) and (2).

3. Plug union (3) and inlet air compressed air
through union (4) to remove upper piston (5). [*1]
k Use low pressure air compressed (max 0.2
MPa {2 kg/cm2}.
k The the piston may be ejected suddenly and
provide damage to things or persons. Always 1 5
use a proper safety device to hold it. 4
3
2
RKAD6220
4. Inlet air compressed air through union (6) to

remove lower piston (7). [*1]
k Use low pressure air compressed (max 0.2
MPa {2 kg/cm2}.
k The the piston may be ejected suddenly and
provide damage to things or persons. Always
use a proper safety device to hold it.
7
6
RKAD6230
5. Remove from dust seal (8), guide ring (9) and

packing (10). [*2] 9 10
8
10
RKAD6240
WB93R-8 50-327
REMOVAL AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON
METHOD FOR INSTALLING BACKHOE SLIDING BRACKET LOCKING PISTON

[*1]
•Install pistons (5) and (7) using a seal compres-

sion ring “A”.
2 Pistons (5) and (7): hydraulic oil
5
7
RKAD6250
RKAD6260
[*2]
• Install dust seal (8), guide ring (9) and packing

(10) taking care to correctly orientate packing
(10).
NOTICE 8 9 10
• Be careful not to damage the dust seal and

the packing.
RKA84330
• Start the engine and using the boom swing control lever extend or retract the boom swing cylinders to
center the pin hole.
50-328 WB93R-8
REMOVAL AND INSTALL OPERATOR'S CAB ASSEMBLY
CAB AND ITS ATTACHMENTS

k Place the machine on a level ground, lower the work equipment to the ground, and stop the
engine.
k Release the residual pressure in the hydraulic circuit. For details, see “30 TESTING AND
ADJUSTING - RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT”.
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY
1. Remove the bolts (1), and remove front mask (2)

2
1
1500±50 g
NOTICE
• Never release the refrigerant to the atmos-
3
phere.
• Ask a qualified person for collecting, add-
RKAD4020
ing and filling operations of the refrigerant.
(Only qualified persons can work.)
4. Disconnect the upper air conditioner hose (4)

from the air conditioner drier (5). [*2]
NOTICE 4
3
• Fit a plug or flange in the place where the
hose is disconnected to prevent dust and
• Remove O-ring. Do not reuse it. (O-ring is
deformed and deteriorated if it is used even
once.)
RKAD4090
WB93R-8 50-329
5. Remove bolt (6) and clamp (7).
7
6
RKAD5020
6. Connect hose (4) to a 4 mt long cable A that will

be used during reassembly.
A 4
RKAD5030
7. Disconnect hose (7) from compressor (8). [*3]

NOTICE
• Fit a plug or flange in the place where the
hose is disconnected to prevent dust and 7
8
• Remove O-ring (9). Do not reuse it. (O-ring
is deformed and deteriorated if it is used
even once.)
8. Remove all clamps fixing hoses (4) and (7) to the
frame.
RKAD4951
RKAD4961
50-330 WB93R-8
9. Remove the exhaust pipe (For details, see

“REMOVE AND INSTALL EXHAUST PIPE”).
10. Remove engine controller assembly (For details,
see “REMOVE AND INSTALL ENGINE CON-
TROLLER ASSEMBLY”).
10
RKAD3712
12. Remove front floor cover (11) and disconnect

connector PD1 (12) and K14 (13) of accelerator
pedal.
11
RKAD3722
12
13
RKAD5040
13. Disconnect hoses (14) from steering unit (15).

NOTICE 15
re-assembling.
rities.
14
RKAD4130
WB93R-8 50-331
14. Remove bolts (16) and disconnect support (17)

from cab frame.
15. Disconnect brake piping (18). 17
NOTICE
• Mark the position to avoid errors when 18
re-assembling.
rities. 16
RKAD4140
16. Remove fuse box cover (19).
19
RKAD5130
17. Disconnect connector X16 (20).
20
RKAD5050
18. Disconnect ground cable (21), connectors BH02,

BH03 and BH04 (22) from fuse box.
21
22
RKAD5060
50-332 WB93R-8
19. Disconnect connectors EH02 (23) and X11 (24)

from fuse box.
23
24
RKAD5070
20. Disconnect connectors RDTS (25), X8 (26) and

EH01 (27) from fuse box.
26
25
27
RKAD5080
21. Loosen bolts (28) and remove rear equipment

pedal (29).
NOTICE
• Depending on the specification of the 29
machine, rear equipment pedals can be one
or two. Remove all of them.
28
RKAD5140
22. Remove rear cover (30).
30
RKAD5150
WB93R-8 50-333
23. Remove rear floor cover (31).
31
RKAD5160
24. Disconnect hoses (32) (4 pieces upper side and

4 pieces lower side) from control valve (33).
NOTICE 32
• Mark the position to avoid errors when 32
re-assembling.
33
rities.
RKAD4150
25. Disconnect hoses (34) (port P2) and (35) (port

UL) from solenoid valve (36).
NOTICE 34
36
re-assembling.
rities.
RKAD4170
26. Disconnect hoses (37) and (38) from T-Block

(39).
NOTICE
• Plug all hoses to prevent entry of any impu- 37 38
rities.
39
RKAD4180
50-334 WB93R-8
27. Disconnect parking brake cable (40) from sup-

port proceeding as follow.
1. Remove safety spring (a) end pin (b) and dis- 40
connect parking brake cable (40) from park- d
ing brake. b
2. Compress spring (c) and remove snap ring
(d). c
3. Disconnect parking brake cable (40) from
support.
a
RKAD5310
28. Disconnect connector SLD (41).

29. Loosen bolt (42) and remove lever assembly
(43).
41
43
42
RKAD4190
30. Remove L.H: and R.H. covers (44).
44
RKAD5170
31. Remove mounting bolts (45) on the front side of

the operator's cab (46). [*4]
45
46
RKAD5090
WB93R-8 50-335
32. Remove mounting bolts (47) at the rear side of

the operator's cab (48). [*4]
47
48
RKAD5100
33. Loosen bolts (49) and remove protection (50).

34. Sling the operator’s cab (46) and raise it of about
25 cm.
k Place under the cab 4 blocks for safety, and
lower the cab over them.
50
49
RKAD5110
35. Disconnect ground cables (51) from frame.

NOTICE
• Extract the wiring harness from inside the
cab.
51
RKAD5120
36. Loosen clamp (52) and disconnect heater hoses

(53).
NOTICE
re-assembling. 53
rities.
37. Sling operator's cab assembly (46), and remove
it.
a Check that all the wiring and piping are dis-
connected, and remove it. 52
4 Operator's cab assembly (46): 600 kg

RKAD5180
50-336 WB93R-8
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY

removal.
[*1]
• Refill with the air conditioner compressor oil.
[*2]
• Connect the air conditioner hose (4).
NOTICE
not enter the hose.
2 O-ring:
orated.

(DENSO: ND-OIL8)
3 Hoses (10) and (11):
20 - 27,5 Nm {2,04 - 2,8 kgm}
[*3]
• Connect the air conditioner hose (4).
NOTICE
not enter the hose.
2 O-ring:
orated.

(DENSO: ND-OIL8)
3 Hoses (10) and (11):
20 - 27,5 Nm {2,04 - 2,8 kgm}
3 Bolt (45) and (47):

[*4]
240-330 Nm {24,47-33,65 kgm}
WB93R-8 50-337
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
ELECTRICAL SYSTEM
posture.
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY

2. Remove bolt (3) and protection (4).
RKAD4970
RKAD4980
3. Remove bolts (5) (4 pieces) fixing operator’s seat

and move it aside so that it does not hinder the
work.
RKAD4990
50-338 WB93R-8
4. Disconnect cable (6) opening clips (7) (2 pieces).

5. Remove bolts (8) and disconnect engine control- 8
9
ler (9).
7
6
11
10
RKAD5000
6. Disconnect the connectors CE01 (10) and CE02
(11) according to the following procedure.
1) Move the yellow slider (a) in the direction of
the arrow.
2) Tilt the lever (b) in the direction of the arrow.
3) Disconnect the connectors CE01 (10) and
CE02 (11).
NOTICE
• Pull the connectors CE01 (10) and CE02
(11) out straight. a
b
RKAD5010
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY

removal.
WB93R-8 50-339
REMOVE AND INSTALL FRONT PANEL

posture.
k Do not remove or install the connector forcibly, otherwise the pin may be deformed.
METHOD FOR REMOVING FRONT PANEL
1. Using a small screwdriver remove cover (1).
1 1
RKAD5190
2. Loosen nut (2) and remove steering wheel (3).
3
RKAD5200
3. Remove plugs (5) and loosen screws (6).
4
5
RKAD5210
50-340 WB93R-8
4. Disconnect the connectors PA63A (7) and

PA63B (8).
6
NOTICE
Pull the connectors PA63A (7) and PA63B (8)
out straight.
5. Press locking springs (9) and remove the front 7
panel (10). [*1]
RKAD5220
METHOD FOR INSTALLING FRON PANEL

removal.
[*1]
a If the front panel needs to be replaced with a new
one, and the machine is Germany specification, it
has to be properly configured to show the correct
travelling speed (For details, see “30 TESTING
AND ADJUSTING - ADJUST FRONT PANEL
SETTINGS”)
WB93R-8 50-341
REMOVAL AND INSTALL STEERING COLUMN SWITCHES

posture.
k Do not remove or install the connector forcibly, otherwise the pin may be deformed.
METHOD FOR REMOVING STEERING COLUMN SWITCHES
1. Using a small screwdriver remove cover (1).
1 1
RKAD5190
2. Loosen nut (2) and remove steering wheel (3).
3
RKAD5200
3. Remove plugs (5) and loosen screws (6).
4
5
RKAD5210
50-342 WB93R-8
4. Disconnect connectors PA63A (7) and PA63B

(8).
6
NOTICE
• Pull the connectors PA63A (7) and PA63B
(8) out straight. 7
RKAD5220
5. Loosen bolt (9) and (10) and remove steering
column switched (11) and (12). [*1]
12
9
10
11
RKAD5230
6. Disconnect connectors S60 (13) and S57 (14).
13
12
14 11
RKAD5240
METHOD FOR INSTALLING STEERING COLUMN SWITCHES

removal.
[*1]
a Before tightening bolts (9) and (10) check that
dowel pin (15) is correctly inserted into steering
column (16). 16
15
RKAD5250
WB93R-8 50-343
REMOVAL AND INSTALL KOMTRAX TERMINAL ASSEMBLY

posture.
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY
1. Remove the screw covers (1) by unscrewing

them half to 1 turn.
RKAD3820
2. Remove switch panel (2) fixing screws (3) and

move the switch panel aside.
2
3
RKAD3830
3. Remove the cab wiring harness from KOMTRAX

terminal (4)
a Be sure to remove the cab wiring harness
before the antenna cable (described in pro-
cedure 5). 4
4. Remove the communication antenna cable and
GPS antenna cable from KOMTRAX terminal (4).
RKAD3811
50-344 WB93R-8
5. Remove all mounting bolts (5) and washers (6) of

the KOMTRAX terminal.
Reference: The mounting bolt size is M8.
a When handling the KOMTRAX terminal, take 6
care not to give an impact on it. 5 5
(Never hit it against another part or drop it.)
RKAD3841
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY

• Carry out installation in the reverse order to
removal.
• If KOMTRAX terminal has been replaced, per-
form start-up procedure.
REMARK
For the start-up procedure, see “30 TESTING
AND ADJUSTING” - “METHOD FOR STARTING
UP KOMTRAX TERMINAL”.
WB93R-8 50-345
50-346 WB93R-8
WB93R-8
HYDRAULIC EXCAVATOR
WB93R-8

60 MAINTENANCE STANDARD01-
WB93R-8 60-1
CONTENTS
CONTENTS
CONTENTS .............................................................................................................................................. 60-2

ENGINE MOUNT ................................................................................................................................. 60-10
COOLING SYSTEM............................................................................................................................. 60-12

TRANSMISSION.................................................................................................................................. 60-13
FRONT AXLE....................................................................................................................................... 60-16
REAR AXLE ......................................................................................................................................... 60-21
HYDRAULIC SYSTEM............................................................................................................................ 60-26

9-SPOOL CONTROL VALVE .............................................................................................................. 60-26
11-SPOOL CONTROL VALVE ............................................................................................................ 60-34
HYDRAULIC PUMP ............................................................................................................................. 60-42
PPC VALVE ......................................................................................................................................... 60-44
WORK EQUIPMENT............................................................................................................................... 60-50

FRONT WORKING EQUIPMENT........................................................................................................ 60-50
BACKHOE WORKING EQUIPMENT................................................................................................... 60-54
WORK EQUIPMENT CYLINDER ........................................................................................................ 60-56
60-2 WB93R-8
ABBREVIATION LIST
ABBREVIATION LIST
of the meaning.

Abbrevia-
tion
the tires rotate.
AISS Engine
reverse direction.
ARAC
ASR
BCV
not being used.
work tronic control
machine.
Crankcase Depres-
sion Regulator
WB93R-8 60-3
ABBREVIATION LIST

Abbrevia-
tion
than OLSS).
Electronic Control
Module
ECMV
Electronically Con-
System
EGR Engine
failure history).
portional Control
tive Structure
3449.
Forward-Neu-
tral-Reverse
60-4 WB93R-8
ABBREVIATION LIST

Abbrevia-
tion
Communication
Plus)
Communication
Plus)
System (D Series)
HST
(Same as IMV)
Unit
KCCV Engine
Komatsu Catalyzed
KCSF Engine gas.
Soot Filter
KDOC Engine
muffler.
ulate Filter
muffler.
WB93R-8 60-5
ABBREVIATION LIST

Abbrevia-
tion
KTCS
soft ground.
direction.
work tronic control
machine.
machine.
MMS Communication
NC Normally Closed
actuated.
NO Normally Open
actuated.
Open-center Load
Sensing System
less of the load.
PC Hydraulic system
tion sure.
PCCS
60-6 WB93R-8
ABBREVIATION LIST

Abbrevia-
tion
Pre-stroke Control
Valve

Motor (D, PC, etc)
ROPS Cab and canopy
structure)
3471 or ISO 12117-2.
SCR Urea SCR system
Le Systeme Interna-
principle applied.
energized.
TOPS Cab and canopy
12117.
direction of flow.
Variable Geometry
Turbocharger
is variable.
WB93R-8 60-7
ABBREVIATION LIST

Abbrevia-
tion
VHPC Engine control

HD: Dump truck
WA: Wheel loader

A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
60-8 WB93R-8
ABBREVIATION LIST

SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
WB93R-8 60-9

ENGINE MOUNT
2
1
2
1
2
4
1
RKA84630
60-10 WB93R-8
1 Tightening torque of bolt 156 - 214,5 Nm {15,9 - 21,9 kgm}
2 Tightening torque of bolt 72 - 99 Nm {7,3 - 10,1 kgm} with Loctite 262

Retighten
3 Tightening torque of bolt 39,2 - 53,9 Nm {4 - 5,5 kgm} with Loctite 262
4 Tightening torque of bolt 52 - 71,5 Nm {5,3 - 7,29 kgm} with Loctite 242
WB93R-8 60-11
COOLING SYSTEM
2
RKA84640
1 Tightening torque of clamp 4,7 - 6,5 Nm {0,5 - 0,7 kgm}
2 Tightening torque of clamp 4 - 5,5 Nm {0,4 - 0,6 kgm}

Retighten
3 Tightening torque of clamp 7,0 - 9,7 Nm {0,7-1 kgm}
4 Tightening torque of clamp 52 to 71,5 Nm {5,3 to 7,29 kgm} with Loctite 242
60-12 WB93R-8

TRANSMISSION
4.8-6.8 Nm 23 Nm
40 Nm 26-29 Nm
Loctite 542 7-10 Nm
A 30 Nm
Loctite 510 W
23 Nm
50 Nm
Y R
M M
G
E E
K F F
100 Nm G
Loctite 270 Y R
23 Nm
30 Nm
A 80 Nm
28 Nm
12 Nm
26-30 Nm 23 Nm 50 Nm
23 Nm 30 Nm
23 Nm
50 Nm
Loctite 270
View W
139 Nm
40 Nm
Loctite 518
Loctite 638 30 Nm
23 Nm A-A View K
Loctite 510
RKA84350
WB93R-8 60-13
50 Nm E-E
Loctite 542 20 Nm
G-G
30 Nm
L-L
50 Nm
F-F
M-M
80 Nm
23 Nm
R-R
Y-Y
RKA84360
60-14 WB93R-8
25-30 Nm
5-7 Nm
21.5-24.5 Nm
7 - 10 Nm
15-24.2 Nm
15-24.2 Nm 9.8-11.8 Nm
30-40 Nm
RKA84660
WB93R-8 60-15
FRONT AXLE
Differential
10 Nm
60 Nm Loctite 638
Loctite 510
169 Nm
3
RKA84670
60-16 WB93R-8
Unit: mm
Criteria
No. Check item Remedy
Standard clearance Clearance limit
Crown wheel and pinion back-
1 0.15 - 0.30 0.15 - 0.30 Adjust
lash
Pinion rotating force Standard value Limit value
(without sealing ring) measured
on pinion Ø 34.8 mm [*1] 91.80 - 137.60 N 91.80 - 137.60 N
2
Pinion-crown rotating force
(without sealing ring) measured (P + 37.3) - (P + 55.9) N [*2] (P + 37.3) - (P + 55.9) N [*2]
on pinion Ø 34.8 mm [*1] Adjust
Pinion rotating torque

1.60 - 2.40Nm 1.60 - 2.40Nm
(without sealing ring) [*1]
3
Pinion-crown rotating torque (T + 0.65) - (T + 0.98) Nm (T + 0.65) - (T + 0.98) Nm
(without sealing ring) [*1] [*3] [*3]
[*1]: value are valid when a new bevel gear is installed. If bevel gear and bearing are not replaced, the value
has to read before disassembly.
[*2]: P is the real pinion rotating force measured before assembly of differential.
[*3]: T is the real pinion rotating torque measured before assembly of differential.
WB93R-8 60-17
B B
95 Nm
Loctite 270
C-C 60 Nm C
220 Nm
13 Nm
B-B
RKA84680
60-18 WB93R-8
Final drive
350 Nm 190 Nm
Grease
Polimer 400
8 Nm
Grease
Polimer 400
Grease
Polimer 400
8 Nm
80 Nm
Loctite 278
RKA84690
WB93R-8 60-19
Steering cylinder
220 Nm 120 Nm
150 Nm
250 Nm 300 Nm
25 Nm
80 Nm
RKA84700
60-20 WB93R-8
REAR AXLE
Differential
165 Nm
Loctite 270
Grease
Polimer 400
B A
10 Nm
C C
A-A
2
A
3
25 Nm
E
E-E
Grease Grease B-B

Polimer 400 Polimer 400
180 Nm Loctite 638
H-H
C-C
RKA84710
WB93R-8 60-21
Unit: mm
Criteria
Standard clearance Clearance limit
Crown wheel and pinion back-
1 0.20 - 0.35 0.20 - 0.35 Adjust
lash
Pinion rotating force Standard value Limit value
(without sealing ring) measured
on pinion Ø 34.8 mm [*1] 114.90 - 137.90 N 114.90 - 137.90 N
2
Pinion-crown rotating force
(without sealing ring) measured (P + 33.4) - (P + 50.2) N [*2] (P + 33.4) - (P + 50.2) N [*2]
on pinion Ø 34.8 mm [*1] Adjust
Pinion rotating torque

2.00 - 2.40Nm 2.00 - 2.40Nm
(without sealing ring) [*1]
3
Pinion-crown rotating torque (T + 0.58) - (T + 0.87) Nm (T + 0.58) - (T + 0.87) Nm
(without sealing ring) [*1] [*3] [*3]
[*1]: value are valid when a new bevel gear is installed. If bevel gear and bearing are not replaced, the value
has to read before disassembly.
[*2]: P is the real pinion rotating force measured before assembly of differential.
[*3]: T is the real pinion rotating torque measured before assembly of differential.
60-22 WB93R-8
Final drive
80 Nm
Loctite 638 18 Nm
500 Nm
Loctite 518
230 Nm
Grease
Polimer 400
60 Nm
226 Nm 15.3 Nm
1 Loctite 270
Loctite 638 Grease

Polimer 400
RKA84720
Unit: mm
Criteria
Standard value limit value
1 Flange rotation torque 20 - 40 Nm 20 - 40 Nm Repair
WB93R-8 60-23
Central body and parking brake
10 Nm
30 Nm
Loctite 638
Loctite 510
80 Nm
80 Nm
Loctite 638
120 Nm
Clearance between
Grease
KLUBERPLUS brake disc and brake pads:
Polimer 400
S06-100 Min. 0.7 mm
Max 0.9 mm
169 Nm
115 Nm
45 Nm
80 Nm
RKA84730
60-24 WB93R-8
Brake disks
1
2
3
RKA85630
Unit: mm
Criteria
Standard size Repair limit
1 Friction disc thickness 6.73 ± 0.1 5.8 Replace
2 Separator plate 8.00 ± 0.1 mm 7.6 Replace
3 Separator plate 5.00 ± 0.1 mm 4.6 Replace
4 Piston wear - Max. 0.4 Replace
WB93R-8 60-25
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
9-SPOOL CONTROL VALVE
a Since the valve are single add-on type, they can be added and removed one by one stay time.
AC AC
9.8-12.7 Nm
AL AL
AB AB
AA AA
N N
M M
X
L L
K K
J J
9.8-12.7 Nm F F
E E
9.8-12.7 Nm
D
Z
29.4-34.3 Nm
View Z
58.8-73.5 Nm
RKA83340
60-26 WB93R-8
HYDRAULIC SYSTEM
(1/5)
WB93R-8 60-27
HYDRAULIC SYSTEM
(2/5)
49-58.8 Nm
39.2-49 Nm
39.2-49 Nm
39.2-49 Nm
6 39.2-49 Nm
39.2-49 Nm
5
39.2-49 Nm
9
137-157 Nm A-A
117.6-161.8 Nm
137-157 Nm
4
10
3
1
7
8
B-B
RKA83560
60-28 WB93R-8
HYDRAULIC SYSTEM
Unit: mm
Criteria Remedy
No. Check item Free
Installed Installed Free Installed
installed x
length load installed load
Øe
Spool return spring
1 (shovel arm raise 27.1x16.2 26.7 14.4N – 11.8N
control)
Spool return spring
2 (backhoe bucket 66.5x21.1 25.4 73.5N – 58.8N
boom control)
Spool return spring
3 27.2x16.6 26.7 30.38N – 34.3N
(shovel control)
Spool return spring Replace
4 42x20 25.4 75.5N – 59.6N
(boom swing control) spring
Spool return spring
5 65.4x22.1 26.5 73.5N – 58.8N
(arm control)
Spool return spring
6
(Hammer control)
Spool return spring
7 (shovel arm 19.4x17.6 19 14.7N – 11.8N
float control)
Spool return spring
8 (shovel arm 38.7x18 27.6 355.7N – 284.6N
lower control)
9 Priority valve spring 56.8x15.2 48.5 29.6N – 23.7N
10 Unloading valve spring 25.5x19.3 18 121.5N – 97.2N
WB93R-8 60-29
HYDRAULIC SYSTEM
(3/5)
AD
7 2
24.5-34.3 Nm
8
3
1
4
8
8
1
8 5
19.6-24.5 Nm
3
1
9
5
14.7-19.6 Nm
6 6 AD
1.3-1.7 Nm
D-D C-C
24.5-34.3 Nm
14.7-19.6 Nm
24.5-34.3 Nm
AD - AD AL - AL
RKA83360
60-30 WB93R-8
HYDRAULIC SYSTEM
Unit: mm
No. Check item Criteria Remedy
Free
installed
x Øe
spring
1 15.4x6 8 7.44N – 5.96N
(Shovel arm, backhoe bucket,
boom, shovel, boom swing)
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
Pressure compensation valve Replace
3 spring. 18.9x8.4 15 15.7N – 12.5N spring
(Boom swing, backhoe bucket)
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
WB93R-8 60-31
HYDRAULIC SYSTEM
(4/5)
3
65.7-82.3 Nm
2
1 2
1
1 2 E-E 1 K-K
2
F-F L-L
J-J M-M
RKA83370
Unit: mm
Free
installed
x Øe
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 13.0x8.8 11 3.92N – 3.1N
plate lock
60-32 WB93R-8
HYDRAULIC SYSTEM
(5/5)
34-44 Nm
39.2-49 Nm
AC - AC
N-N
65.7-82.3 Nm
AA - AA
AB - AB
AE - AE
RKA83380
Unit: mm
Free
installed Replace
x Øe spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-8 60-33
HYDRAULIC SYSTEM
11-SPOOL CONTROL VALVE

a Since the valve are single add-on type, they can be added and removed one by one any time.
Komatsu Ltd.
AC AC
AL AL
AB AB
AA AA
R R
X P P
N N
9.8-12.7 Nm
M M
L L
K K
J J
9.8-12.7 Nm
F F
E E
9.8-12.7 Nm
D
29.4-34.3 Nm Z
View Z
58.8-73.5 Nm
RKA83400
60-34 WB93R-8
HYDRAULIC SYSTEM
(1/5)
AE
C B A
C B A
AE
View X
RKA83410
WB93R-8 60-35
HYDRAULIC SYSTEM
(2/5)
49-58.8 Nm
137-157 Nm 39.2-49 Nm
117.6-161.8 Nm
117.6-161.8 Nm
10
39.2-49 Nm
4
3
39.2-49 Nm
1 39.2-49 Nm
11
39.2-49 Nm 39.2-49 Nm
12
7
8
B-B A-A
K-K J-J
RKA83420
60-36 WB93R-8
HYDRAULIC SYSTEM
Unit: mm
Free
installed
x Øe
Spool return spring
1 (shovel arm raise 27.1x16.2 26.7 14.4N – 11.8N
control)
Spool return spring
2 (backhoe bucket 66.5x21.1 25.4 73.5N – 58.8N
boom control)
Spool return spring
3 27.2x16.6 26.7 30.38N – 34.3N
(shovel control)
Spool return spring
4 42x20 25.4 75.5N – 59.6N
(boom swing control)
5 65.4x22.1 26.5 73.5N – 58.8N
(arm control) spring
Spool return spring
6
(Hammer control)
Spool return spring
7 (shovel arm 19.4x17.6 19 14.7N – 11.8N
float control)
Spool return spring
8 (shovel arm 38.7x18 27.6 355.7N – 284.6N
lower control)
9 Priority valve spring 56.8x15.2 48.5 29.6N – 23.7N
10 Unloading valve spring 25.5x19.3 18 121.5N – 97.2N
Spool return spring
11 29x17.5 28.5 22.5N – 18.0N
(Jig arm control)
Spool return spring
12 42.2x20 25.4 98.0N – 78.4N
(4 in 1 bucket control)
WB93R-8 60-37
HYDRAULIC SYSTEM
(3/5)
AD
7
2
24.5-34.3 Nm
8
3
1 4
8
1
8 5
8
3
1
19.6-24.5 Nm 5
6 AD C-C
6
D-D
24.5-34.3 Nm
17.4-19.6 Nm
24.5-34.3 Nm
AD - AD
RKA82841
60-38 WB93R-8
HYDRAULIC SYSTEM
Unit: mm
Free
installed
x Øe
spring
1 15.4x6 8 7.44N – 5.96N
(Shovel arm, backhoe bucket,
boom, shovel, boom swing)
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
Pressure compensation valve Replace
3 spring. 18.9x8.4 15 15.7N – 12.5N spring
(Boom swing, backhoe bucket)
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
WB93R-8 60-39
HYDRAULIC SYSTEM
(4/5)
3
65.7-82.3 Nm
2
1 2
1
1 2 E-E 1 K-K
2
F-F L-L
J-J M-M
RKA83370
Unit: mm
Free
installed
x Øe
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 13.0x8.8 11 3.92N – 3.1N
plate lock
60-40 WB93R-8
HYDRAULIC SYSTEM
(5/5)
34-44 Nm
34.3-44.1 Nm
AC- AC
N-N
65.7-82.3 Nm
AA - AA AL- AL
AB - AB
RKA83430
Unit: mm
Free
installed Replace
x Øe spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-8 60-41
HYDRAULIC SYSTEM
HYDRAULIC PUMP
19.5-24.5 Nm
View X
157-196 Nm
A A
68.6-83.4 Nm
Z
X
27.4-34.3 Nm
7.8-9.8 Nm
68.6-83.4 Nm 19.6-27.4 Nm
11.8-14.7 Nm
View Z
RKA83320
60-42 WB93R-8
HYDRAULIC SYSTEM
Z
27.4-34.3 Nm X 27.4-34.3 Nm
27.4-34.3 Nm 27.4-34.3 Nm
A-A
RKA83330
WB93R-8 60-43
HYDRAULIC SYSTEM
PPC VALVE
Loader work equipment PPC valve
Standard version
RKA84740
60-44 WB93R-8
HYDRAULIC SYSTEM
69 - 88 Nm
{7 - 9 kgm}
11.8 - 14.7 Nm 39 - 49 Nm
{1.2 - 1.5 kgm} {4 - 5 kgm}
2 4
3
1
P3 P4
A-A B-B
G2-LI
G2-LI
6 8
D-D
5 7
P1 P2
C-C
E-E
RKA84750
WB93R-8 60-45
HYDRAULIC SYSTEM
Unit: mm
Free
installed
x Øe
38.5N
1 Centering spring (for p3) 31.9
{3.93 kg}}
5.28N
2 Metering spring (for p3) 25.3
{0.538 kg}}
63.9N
{6.52 kg}} Replace
5.28N spring
{0.538 kg}}
39.1N
{3.99 kg}}
5.28N
{0.538 kg}}
41.2N
{4.20 kg}}
5.28N
{0.538 kg}}
60-46 WB93R-8
HYDRAULIC SYSTEM
Float and return to dig version
RKA84760
WB93R-8 60-47
HYDRAULIC SYSTEM
69 - 88 Nm
{7 - 9 kgm}
11.8 - 14.7 Nm 39 - 49 Nm
{1.2 - 1.5 kgm} {4 - 5 kgm}
2 4
3
1
P3 P4
C-C
B-B
G2-LI
G2-LI
6 8 D-D
5 7
P1 P2
A-A
RKA84770
60-48 WB93R-8
HYDRAULIC SYSTEM
Unit: mm
Free
installed
x Øe
38.5N
{3.93 kg}}
5.28N
{0.538 kg}}
64.9N
{6.62 kg}} Replace
5.28N spring
{0.538 kg}}
39.1N
{3.99 kg}}
5.28N
{0.538 kg}}
41.2N
{4.20 kg}}
5.28N
{0.538 kg}}
WB93R-8 60-49
WORK EQUIPMENT
WORK EQUIPMENT
FRONT WORKING EQUIPMENT
E
C E
C
D
B
B D
A
A
2 3
1
A-A B-B
C-C
5
4
D-D E-E
RKA83530
60-50 WB93R-8
WORK EQUIPMENT
Unit: mm
Criteria
No. Check item Standard Tolerance Standard Clearance Remedy

size Shaft Hole clearance limit
Clearance between mounting

– 0.050 + 0.240
1 pin and bushing of lift arm and 45 0.130–0.329 1.000
– 0.089 + 0.080
bucket

– 0.050 + 0.240
2 pin and bushing of link and 45 0.130–0.329 1.000
– 0.089 + 0.080
bucket

– 0.050 + 0.096
3 pin and bushing of link and 45 0.093–0.185 1.000 Replace
– 0.089 + 0.043
link

– 0.060 + 0.178
4 pin and bushing (of lift arm) 60 0.170–0.284 1.000
– 0.106 + 0.110
and link

– 0.050 + 0.240
5 pin and bushing of lift arm and 50 0.130–0.329 1.000
– 0.089 + 0.080
frame
WB93R-8 60-51
WORK EQUIPMENT
SWING BRACKET
B
A C D
D
A C
1 3 5
B-B
A-A
2
6
4
C-C
D-D
RKA83540
60-52 WB93R-8
WORK EQUIPMENT
Unit: mm
Criteria

Clearance between boom

– 0.010 + 0.034
1 swing cylinder bushing and 60 0.044–0.156 1.000
– 0.085 + 0.071
bushing on bracket

pin and bushing of swing – 0.060 + 0.228
2 65 0.207–0.334 1.000
bracket (lower) and sliding – 0.106 + 0.147
plate

pin and bushing of sliding – 0.060 + 0.228 Replace
3 65 0.210–0.334 1.000
plate (upper) and boom swing – 0.106 + 0.150 bushing
bracket and
Clearance between mounting pin
–0.030 +0.097
4 pin swing cylinder head and 55 0.068–0.173 1.000
–0.076 +0.038
bushing on swing bracket
Standard size Limit size

5 Upper shim thickness
2.50 --0 0.1 –
6 Central shim thickness 4.75 --0 0.1 –
7 Lower shim thickness 4.75 --0 0.1 –
WB93R-8 60-53
WORK EQUIPMENT
BACKHOE WORKING EQUIPMENT
C
C
D B
A A
3 3
2 2
1 1
4 4
A-A
B-B
5 6 6
D-D
C-C
RKA83550
60-54 WB93R-8
WORK EQUIPMENT
Unit: mm
Criteria


– 0.050 +0.240
– 0.089 +0.080
bucket

– 0.050 +0.240
2 pin and bushing of arm and 45 0.130–0.329 1.000
– 0.089 +0.080
bucket

– 0.050 +0.240
3 pin and bushing of arm and 45 0.130–0.329 1.000
– 0.089 +0.080
link
Replace
–0.050 +0.240
– 0.089 +0.080
link

– 0.050 +0.084
5 pin and bushing of boom and 50 0.087–0.173 1.000
– 0.089 +0.037
arm

– 0.060 +0.172
6 pin and bushing of boom and 60 0.167–0.278 1.000
– 0.106 +0.107
boom
WB93R-8 60-55
WORK EQUIPMENT
WORK EQUIPMENT CYLINDER

LOADER ARM CYLINDER
4
2 1 5 3
RKA83450
Unit: mm
Criteria

Clearance between piston – 0.025 + 0.152 0.020 –

1 50 0.516 Replace bushing
rod and bushing – 0.064 – 0.005 0.216
Clearance between piston

– 0.060 + 0.174 0.160
2 rod support shaft and bush- 60 1.000
– 0.106 + 0.100 –0.280
ing Replace pin and
Clearance between cylin- bushing
– 0.060 + 0.174 0.160
3 der bottom support shaft 60 1.000
– 0.106 + 0.100 –0.280
and bushing
Tightening torque of cylin-
4 677 ± 67.5 Nm {69.0 ± 6.9 kgm}
der head
Retighten
Tightening torque cylinder
5 1670 ± 170.0 Nm {170.3 ± 17.3 kgm}
piston
60-56 WB93R-8
WORK EQUIPMENT
LOADER BUCKET CYLINDER
2 4 1 5 3
RKA83440
Unit: mm
Criteria

Clearance between piston – 0.025 + 0.141 0.021–0.20

rod and bushing – 0.064 – 0.004 5

– 0.050 + 0.142 0.130
– 0.089 + 0.080 –0.231
ing Replace pin and
– 0.050 + 0.142 0.130
– 0.089 + 0.080 –0.231
and bushing
4 539 ± 54.0 Nm {55.0 ± 5.5 kgm}
der head
Retighten
5 1250 ± 130.0 Nm {127.5 ± 13.2 kgm}
piston nut
WB93R-8 60-57
WORK EQUIPMENT
LOADER BUCKET 4 IN 1
4 3
1
2
RKA83460
Unit: mm
Criteria

Clearance between –0.025 + 0.132 0.031 –

1 40 0.482 Replace
piston rod and head –0.050 + 0.006 0.132

–0.050 +0.100 0.100–0.18 Replace pin and
–0.089 +0.050 9 bushing
ing

3 690 ± 69.0 Nm {70.3 ± 7.0 kgm}
piston nut
Retighten
4 540 ± 54.0 Nm {55.0 ± 5.5 kgm}
der head
60-58 WB93R-8
WORK EQUIPMENT
BACKHOE BOOM
4 5
1 3
2
RKA83470
Unit: mm
Criteria

Clearance between – 0.030 + 0.151 0.035–0.22

piston rod and bushing – 0.076 + 0.005 7

– 0.060 + 0.174 0.160–0.28
– 0.106 + 0.100 0
ing Replace pin and
– 0.060 + 0.174 0.160–0.28
– 0.106 + 0.100 0
and bushing

4 981 ± 98.0 Nm {100.0 ± 10.0 kgm}
der head
Retighten
5 2740 to 2840 Nm {279.5 to 289.6 kgm} with Loctite 262
piston
WB93R-8 60-59
WORK EQUIPMENT
BACKHOE ARM
3
5
4
1
2
RKA83480
Unit: mm
Criteria


piston rod and bushing – 0.076 0 2

– 0.030 + 0.046 0.030–0.13
– 0.076 0 2
ing Replace pin and
– 0.050 + 0.142 0.130–0.23
– 0.089 + 0.080 1
and bushing

4 961 ± 96.0 Nm {98.0 ± 9.8 kgm}
der head
Retighten
5 2450 ± 240 Nm {250.0 ± 24.5 kgm}
piston
60-60 WB93R-8
WORK EQUIPMENT
BACKHOE BUCKET
4
5
2 1 3
RKA83490
Unit: mm
Criteria



– 0.050 + 0.142 0.130–0.23
– 0.089 + 0.080 1
ing Replace pin and
– 0.050 + 0.142 0.130–0.23
– 0.089 + 0.080 1
and bushing
• Step 1: Tighten 1175 to 1375 Nm {120 to 140 kgm}

• Step 2: loosen till torque 0 Nm {0 kgm}
Tightening torque of cylin- • Step 3: tighten to 390 Nm {40 kgm}
4
der head • Step 4: tighten with the turn tightening method (revolution of
3,5 to 4,5 mm on the outside diameter 110 mm of cylinder Retighten
head) {using the angle method of 4°± 0,5°}

5 1670 ± 170 Nm {170.0 ± 17.0 kgm}
piston
WB93R-8 60-61
WORK EQUIPMENT
BACKHOE BOOM SWING
4 1
2
RKA83500
Unit: mm
Criteria

Clearance between –0.030 + 0.164 0.037–0.2

piston rod and bushing –0.076 + 0.007 40
Replace
Clearance between pis-
–0.030 + 0.174 0.130–0.2 pin and
2 ton rod support shaft 55 1.000
–0.076 + 0.100 50 bushing
and bushing
Tightening torque of
3 785 ± 78.5 Nm {80.0 ± 8.0 kgm}
cylinder head
Tightening torque of
4 44.1 to 53.9 Nm {4.5 ± 5.5 kgm} Retighten
cushion
Tightening torque cylin-

5 735 ± 49 Nm {75.0 ± 5.0 kgm}
der piston
60-62 WB93R-8
WORK EQUIPMENT
BACKHOE OUTRIGGERS
2 3
1
RKA83510
Unit: mm
Criteria



2 539 ± 54 Nm {55.0 ± 5.5 kgm}
der head
Retighten
3 911 ± 91.1 Nm {93.0 ± 9.3 kgm} with Loctite 262
piston
WB93R-8 60-63
WORK EQUIPMENT
BACKHOE TELESCOPIC ARM

3
2
RKA83520
Unit: mm
Criteria


1 Jig arm 40 Replace bushing

2 539 ± 54 Nm {55.0 ± 5.5 kgm}
der head
Retighten
3 1080 ± 100 Nm {10.0 ± 10.0 kgm}
piston
60-64 WB93R-8
WB93R-8
HYDRAULIC EXCAVATOR
WB93R-8

90 DIAGRAMS AND DRAWINGS 01-
WB93R-8 90-1
CONTENTS
CONTENTS
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-10

SYMBOLS IN HYDRAULIC CIRCUIT DIAGRAM ............................................................................. 90-10
HYDRAULIC CIRCUIT DIAGRAM 1/3 .............................................................................................. 90-13
ELECTRIC CIRCUIT DIAGRAM ............................................................................................................. 90-19

SYMBOLS IN ELECTRIC CIRCUIT DIAGRAM ................................................................................ 90-19
ELECTRICAL CIRCUIT DIAGRAM (1/12) ........................................................................................ 90-23
ELECTRICAL CIRCUIT DIAGRAM (10/12) ...................................................................................... 90-41
90-2 WB93R-8
ABBREVIATION LIST
ABBREVIATION LIST
of the meaning.

Abbrevia-
tion
the tires rotate.
AISS Engine
reverse direction.
ARAC
ASR
BCV
not being used.
work tronic control
machine.
Crankcase Depres-
sion Regulator
WB93R-8 90-3
ABBREVIATION LIST

Abbrevia-
tion
than OLSS).
Electronic Control
Module
ECMV
Electronically Con-
System
EGR Engine
failure history).
portional Control
tive Structure
3449.
Forward-Neu-
tral-Reverse
90-4 WB93R-8
ABBREVIATION LIST

Abbrevia-
tion
Communication
Plus)
Communication
Plus)
System (D Series)
HST
(Same as IMV)
Unit
KCCV Engine
Komatsu Catalyzed
KCSF Engine gas.
Soot Filter
KDOC Engine
muffler.
ulate Filter
muffler.
WB93R-8 90-5
ABBREVIATION LIST

Abbrevia-
tion
KTCS
soft ground.
direction.
work tronic control
machine.
machine.
MMS Communication
NC Normally Closed
actuated.
NO Normally Open
actuated.
Open-center Load
Sensing System
less of the load.
PC Hydraulic system
tion sure.
PCCS
90-6 WB93R-8
ABBREVIATION LIST

Abbrevia-
tion
Pre-stroke Control
Valve

Motor (D, PC, etc)
ROPS Cab and canopy
structure)
3471 or ISO 12117-2.
SCR Urea SCR system
Le Systeme Interna-
principle applied.
energized.
TOPS Cab and canopy
12117.
direction of flow.
Variable Geometry
Turbocharger
is variable.
WB93R-8 90-7
ABBREVIATION LIST

Abbrevia-
tion
VHPC Engine control

HD: Dump truck
WA: Wheel loader

A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
90-8 WB93R-8
ABBREVIATION LIST

SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
WB93R-8 90-9
HYDRAULIC CIRCUIT DIAGRAM

(ALL-K512-012-K-00-A)
SYMBOLS IN HYDRAULIC CIRCUIT DIAGRAM
90-10 WB93R-8
WB93R-8 90-11
90-12 WB93R-8
90 Diagrams and drawings
HYDRAULIC CIRCUIT DIAGRAM 1/3
WB93R-8 90-13
WB93R-8 90-15
WB93R-8 90-16
WB93R-8 90-17
WB93R-8 90-18
ELECTRIC CIRCUIT DIAGRAM

SYMBOLS IN ELECTRIC CIRCUIT DIAGRAM
(ALL-K512-012-K-00-A)
(Rev. 2010/03)
WB93R-8 90-19
90-20 WB93R-8
WB93R-8 90-21
90-22 WB93R-8
ELECTRICAL CIRCUIT DIAGRAM (1/12)
WB93R-8 90-23
WB93R-8 90-25
WB93R-8 90-27
WB93R-8 90-29
WB93R-8 90-31
WB93R-8 90-33
WB93R-8 90-35
WB93R-8 90-37
WB93R-8 90-39
WB93R-8 90-41
WB93R-8 90-43
WB93R-8 90-45

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WENBM00171

Machine model Serial number

00 INDEX AND FOREWORD 0 -1

10 STRUCTURE AND FUNCTION

POWER TRAIN DESCRIPTION ............................................................................................................ 34

20 STANDARD VALUE TABLES

30 TESTING AND ADJUSTING

BLEEDING AIR FROM THE BRAKE LINES ......................................................................................... 21

CHECKS BEFORE TROUBLESHOOTING .............................................................................................. 21

50 DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALL KDOC ASSEMBLY ..................................................................................... 46

REMOVE AND INSTALL FRONT PANEL ........................................................................................... 340

90 DIAGRAMS AND DRAWINGS

ELECTRICAL CIRCUIT DIAGRAM (10/12) ........................................................................................... 41

FOREWORD, SAFETY AND GENERAL INFORMATION

IMPORTANT SAFETY NOTICE

General precautions knowledge of welding perform the work. When

Precautions for using mobile crane

• When installing wire ropes to an angular load,

Precautions for using overhead traveling crane Selecting wire ropes

• Before starting work, check the wire ropes, Nominal diameter

Manufacturer Part name

• When tightening nuts of the air conditioner

• When performing grinding or welding work

materials, ask the industrial waste treatment

HOW TO READ THE SHOP MANUAL

Composition of shop manual

Reading the symbols

Symbol Item Remark

Reading the signal word

Symbol Item Remark

Reading the unit

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

Standard dimension Tolerance

• The tolerance may be indicated in the text and

Repair limit and allowable value or allowable di-

HANDLING EQUIPMENT OF FUEL SYSTEM DEVICES

Use care for working environment

How to clean parts when dirt is stuck

Precautions for replacing fuel filter cartridge

HANDLING OF INTAKE SYSTEM PARTS

Be careful of working environment

HANDLING OF HYDRAULIC EQUIPMENT

Be careful of working environment

Disassembly and maintenance work in the field

Plugging of opening (prevention of flowing out

METHOD OF DISCONNECTING AND CONNECTING OF PUSH-PULL

HANDLING OF ELECTRICAL EQUIPMENT

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness Defec-

dry cloth or blow it with compressed air and

High-pressure water entering connector

Entry of water, mud or dirt when disconnecting

• Check that there is no oil, dirt or water stick

3. Action to take after removing connectors

• If the connector clamp is removed, be sure Drying wiring harness

Handling of Deutsch connector (DT8-pin, DT12-

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

3. Perform a continuity test on the connector.

Slide, lock type

a Lock (L2) is located in the back of connec-

a If the lock is located on the underside, use