Wa600-3 Sebd013216 PDF

SEBM013216
MACHINE MODEL SERIAL NUMBER
WA600-3 50001 and up

WA600-3D (TBG SPEC.) 50001 and up
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• WA600-3 mounts the SA6D170E-2 or SAA6D170E-3 engine.

For details of the engine, see the 6D170-2 or 6D170-3 Series Engine Shop Manual.
© 2005 1
All Rights Reserved 00-1
Printed in Japan 06-05(02) (16)
CONTENTS
01 GENERAL ............................................................................................................ 01-1
10 STRUCTURE AND FUNCTION ........................................................... 10-1
20 TESTING AND ADJUSTING ................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
40 MAINTENANCE STANDARD ............................................................... 40-1
90 OTHERS ............................................................................................................... 90-1
00-2 WA600-3
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LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
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20-391 (6) 20-432-1 (11) 20-624 (6) 20-705 (1) 20-825 (3)
20-392 (6) 20-433 (11) 20-625 (6) b 20-706 (16) 20-826 (6)
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20-907 (3) 30-16-1 (13) 30-55 (2) 30-96 (2) 30-150 (2)
20-908 (3) 30-17 (2) 30-56 (2) 30-97 (2) 30-151 (2)
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20-912 (3) 30-21 (2) 30-60 (2) 30-101 (2) 30-152-3 (7)
20-913 (3) 30-22 (2) 30-61 (2) 30-102 (2) 30-152-4 (7)
20-914 (3) 30-23 (2) 30-62 (2) 30-103 (2) 30-152-5 (7)
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20-958 (4) 30-40 (7) 30-67 (2) 30-121 (2) 30-160 (2)
20-960 (4) 30-41 (2) 30-68 (2) 30-122 (2) 30-161 (2)
20-961 (4) 30-42 (7) 30-69 (2) 30-123 (2) 30-162 (2)
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20-968 (6) 30-47-2 (9) 30-76 (2) 30-130 (2) 30-169 (2)
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30-3 (2) 30-47-7 (15) 30-81 (2) 30-135 (2) 30-174 (2)
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30-175 (2) 30-229 (7) 40-21 (10) 90-3 (6)

30-176 (2) b 30-230 (16) 40-22 90-5 (6)
30-177 (2) 30-231 (2) 40-23 90-7 (6)
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30-179 (2) 30-233 (2) 40-23-2 (6) 90-11 (6)
30-180 (2) 30-234 (7) b 40-24 (16) 90-13 (6)
30-181 (2) 30-235 (7) 40-25 90-15 (6)
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30-183 (2) 30-235-2 (9) c 40-25-2 (16) 90-19 (6)
30-184 (2) 30-236 (2) 40-26 90-21 (6)
30-185 (2) 30-237 (2) 40-27 90-23 (6)
30-186 (2) 30-238 (2) 40-28 90-25 (6)
30-187 (2) 30-239 (2) 40-29 90-27 (6)
30-188 (7) 30-240 (2) 40-30 90-29 (6)
30-189 (7) 30-241 (2) 40-31 90-31 (6)
30-189-1 (7) 30-242 (7) 40-32 90-33 (6)
b 30-189-2 (16) 30-243 (2) 40-33
30-190 (7) 30-244 (2) 40-34
30-191 (2) b 30-245 (16) b 40-35 (16)
30-192 (2) 30-246 (2) b 40-36 (16)
30-193 (2) b 30-247 (16) 40-37 (6)
30-194 (2) 30-248 (2) c 40-37-1 (16)
30-195 (2) 30-249 (2) c 40-37-3 (16)
30-196 (2) 30-250 (14) c 40-37-4 (16)
30-198 (2) (30-250-1) b 40-38 (16)
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30-205 (2) c 30-256 (16) 40-42
30-206 (2) 40-44 (6)
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30-211 (2) 40-3 (6) (40-45-1)
30-212 (2) 40-4 (6) (40-45-2)
30-213 (2) 40-4-1 (6) (40-45-3)
30-214 (2) 40-4-2 (6) 40-46
b 30-215 (16) 40-4-3 (6) 40-47
b 30-216 (16) 40-6 40-48
b 30-217 (16) 40-7 (6) 40-50 (6)
b 30-218 (16) 40-8 40-51 (6)
b 30-219 (16) 40-10 40-52
b 30-220 (16) 40-11 40-53
b 30-221 (16) 40-12 (6) 40-54
30-222 (2) 40-13 (6) 40-55
30-223 (2) 40-14 40-56
30-224 (2) 40-15 (6) 40-57 (6)
30-225 (2) 40-16 40-58 (6)
30-226 (2) 40-17 40-59 (6)
b 30-227 (16) 40-18
30-228 (14) 40-20 90-1 (6)
WA600-3 00-2-5
(16)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

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

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
k Slinging with one rope may cause turning

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

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
! The adapter can be pushed in about 3.5
mm.
! Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
! Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
! Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
! When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
! For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

! In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

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

! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 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
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
! Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
General assembly drawing .......................... 01- 2

Specifications ............................................... 01- 5
Weight table .................................................. 01-11
List of lubricant and coolant ........................ 01-14
WA600-3 01-1
(16)
GENERAL GENERAL ASSEMBLY DRAWING
WA600-3D (TBG SPEC.) Unit: mm

Serial No. : 50001 – 52000
01-2-2 WA600-3
0
WA600-3D (TBG SPEC.)

Serial No. : 52001 – 53000
WA600-3 01-3
0
WA600-3D (TBG SPEC.)

Serial No. : 53001 and up
01-4 WA600-3
0
GENERAL SPECIFICATIONS
SPECIFICATIONS
WA600-3
Machine model WA600-3
Serial No. 50001 – 52000 52001 and up
Operating weight kg 43,950 45,180

Weight
Distribution (front) kg 20,970 21,960
Distribution (rear) kg 22,980 23,220
Bucket capacity (piled) m3 6.1
Rated load kg 10,980
Travel speed FORWARD 1st km/h 7.4 6.4
FORWARD 2nd km/h 12.7 11.1
FORWARD 3rd km/h 21.0 18.8
FORWARD 4th km/h 33.5 30.3

Performance
REVERSE 1st km/h 8.2 7.1
REVERSE 2nd km/h 13.9 12.2
REVERSE 3rd km/h 23.0 20.5
REVERSE 4th km/h 35.2 32.7
Max. rimpull FORWARD kN {kg} 323.6 {33,000} 333.4 {34,000}
REVERSE kN {kg} 291.3 {29,700} 300.1 {30,600}
Gradeability deg 25 25
Min. Center of outside wheel mm 6,980

turning
radius Outside portion of chassis
(with tooth) mm 8,265
Overall length (with tooth) mm 10,775 10,840

Overall width (chassis) mm 3,570 3,570
Bucket width (with tooth) mm 3,685 3,685
Overall height (top of ROPS canopy) mm 4,250 4,250
(Bucket raised) mm 7,165 7,165
Wheelbase mm 4,100 4,100
Dimensions
Tread mm 2,650 2,650

Min. ground clearance mm 495 495
Height of bucket hinge pin mm 5,155 5,155
Dumping clearance (tip of edge) mm 3,805 3,805
Dumping reach (tip of edge) mm 1,610 1,610
Bucket dump angle deg 45 45
Bucket tilt angle (travel posture) deg 49.5 49.5
Digging depth (10° dump) (with tooth) mm 440 440
WA600-3 01-5
0
Serial No. 50001 – 52000 52001 and up

Model SA6D170E-2 SAA6D170E-3
4-cycle, water-cooled, in-line, 4-cycle, water-cooled, in-line,
Type 6-cylinder, direct injection, with 6-cylinder, direct injection, with
turbocharger, and after-cooler turbocharger, and after-cooler
No. of cylinders - bore x stroke mm 6 – 170 x 170 6 – 170 x 170
Piston displacement ¬ {cc} 23.15 {23,150} 23.15 {23,150}
Flywheel horsepower kW/rpm {HP/rpm} 328/2,000 {440/2,000} 357/2,000 {478/2,000}

Engine
Performance
Maximum torque Nm/rpm {kgm/rpm} 2,060/1,400 {210/1,400} 2,373/1,400 {242/1,400}
Fuel consumption ratio g/kW•h {g/HP•h} 209 {156} 221 {167}
High idle speed rpm 2,150 2,175
Low idle speed rpm 700 750
Starting motor 24V, 7.5kW x 2
Alternator 24V, 50A
Battery (12V, 200Ah) x 2
Torque converter 3-element, 1-stage, 3-element, 1-stage,

single-phase single-phase
(TCA45-2B) (TCA43-7B)
Planetary gear, constant-mesh Planetary gear, constant-mesh
Transmission multiple-disc, hydraulically multiple-disc, hydraulically
Power train
actuated, pressure rised actuated, pressure rised

lubrication, modulation type lubrication, modulation type
Spiral bevel gear, splash Spiral bevel gear, splash
Reduction gear lubrication lubrication
Differential Straight bevel gear Straight bevel gear
Final drive Planetary gear single stage, Planetary gear single stage,
splash lubrication splash lubrication
Drive type Front/rear-wheel drive
Front axle Fixed-frame, full-floating

Axle, wheel
Rear axle Center pin support type, full-floating
Tire 35/65 x 33 – 24 PR (L4)
Wheel rim 28.00 x 33 WTB
Inflation pressure Front tire kPa {kg/cm2} 392 {4.0}

2
Rear tire kPa {kg/cm } 343 {3.5}
Main brake Front/rear wheel braking, separate front/rear wheel,

Brakes
wet disc, hydraulically actuated
Parking brake Drive shaft, dry caliper type disc brake,

Hydraulically released spring type
01-6 WA600-3
(16)
Serial No. 50001 – 52000 52001 and up

Steering
Type Articulated type

system
Structure Fully hydraulically power steering
Work equipment pump ¬ /min 496 (Gear type: SAR(4) 140 + 125) 492(Gear type: SAL(4) 125 + 125)
Hydraulic Switch pump ¬ /min 187 (Gear type: SAR(3) 100) 199(Gear type: SAL(4) 100)
pump
Delivery Steering pump ¬ /min 232 (Gear type: SAR(4) 125) 246 (Gear type: SAL(4) 125)
PPC pump ¬ /min 59 (Gear type: SAR(1) 32) 63 (Gear type: SAL(1) 32)
Main control valve 2-spool type

Hydraulic system
2
Control Set pressure MPa {kg/cm } 20.6 {210}
valve
Steering valve Orbitroll + spool valve type
2
Set pressure MPa {kg/cm } 20.6 {210}
Steering cylinder Reciprocating piston
No. – bore x stroke mm 2 – 130 x 529
Lift cylinder Reciprocating piston

Cylinder
No. – bore x stroke mm 2 – 225 x 1,130
Bucket cylinder Reciprocating piston

equipment
Work
Link type Single link
Bucket edge type Flat edge with tooth
WA600-3 01-7
(16)
WA600-3D
Machine model WA600-3D
Serial No. 50001 – 52000 52001 – 53000 53001 and up
Operating weight kg 44,850 45,740 46,110

Weight
Distribution (front) kg 21,635 22,020 21,490
Distribution (rear) kg 23,215 23,720 24,620
Bucket capacity (piled) m3 6.1
Rated load kg 10,980
Travel speed FORWARD 1st km/h 7.4 6.4
FORWARD 2nd km/h 12.7 11.1
FORWARD 3rd km/h 21.0 18.8
FORWARD 4th km/h 33.5 30.3

Performance
REVERSE 1st km/h 8.2 7.1
REVERSE 2nd km/h 13.9 12.2
REVERSE 3rd km/h 23.0 20.5
REVERSE 4th km/h 35.2 32.7
Max. rimpull FORWARD kN {kg} 323.6 {33,000} 333.4 {34,000}
REVERSE kN {kg} 291.3 {29,700} 300.1 {30,600}
Gradeability deg 25 25
Min. Center of outside wheel mm 6,980

turning
radius Outside portion of mm 8,265
chassis (with tooth)
Overall length (with tooth) mm 10,775 10,840

Overall width (chassis) mm 3,570 3,570
Bucket width (with tooth) mm 3,685 3,685
Overall height (top of ROPS canopy) mm 4,250 4,250
(Bucket raised) mm 7,165 7,165
Wheelbase mm 4,100 4,100
Dimensions
Tread mm 2,650 2,650

Min. ground clearance mm 495 495
Height of bucket hinge pin mm 5,155 5,155
Dumping clearance (tip of edge) mm 3,805 3,805
Dumping reach (tip of edge) mm 1,610 1,610
Bucket dump angle deg 45 45
Bucket tilt angle (travel posture) deg 49.5 49.5
Digging depth (10° dump) (with tooth) mm 440 440
01-8 WA600-3
0
Serial No. 50001 – 52000 52001 – 53000 53001 and up

Model SA6D170E-2 SAA6D170E-3
Type 4-cycle, water-cooled, 4-cycle, water-cooled,

in-line, 6-cylinder, in-line, 6-cylinder,
direct injection, with direct injection, with
turbocharger, and turbocharger, and
after-cooler after-cooler
No. of cylinders – bore x stroke mm 6 – 170 x 170 6 – 170 x 170
Piston displacement ¬ {cc} 23.15 {23,150} 23.15 {23,150}
Flywheel horsepower kW/rpm {HP/rpm} 328/2,000 {440/2,000} 357/2,000 {478/2,000}

Engine
Performance
Maximum torque Nm/rpm {kgm/rpm} 2,060/1,400 {210/1,400} 2,373/1,400 {242/1,400}
Fuel consumption ratio g/kW•h {g/HP•h} 209 {156} 221 {165}
High idle speed rpm 2,100 2,175
Low idle speed rpm 700 700
Starting motor 24V, 7.5kW x 2

Alternator 24V, 50A
Battery (12V, 200Ah) x 2
Torque converter 3-element, 1-stage, 3-element, 1-stage,

single-phase single-phase
(TCA45-2B) (TCA43-7B)
Planetary gear, con- Planetary gear, con-
Transmission
stant-mesh multple- stant-mesh multple-
disc, hydraulically
Power train
disc, hydraulically
actuated, pressure actuated, pressure
rised lubrication, rised lubrication,
modulation type modulation type
Reduction gear Spiral bevel gear, Spiral bevel gear,
splash lubrication splash lubrication
Differential Straight bevel gear Straight bevel gear
Final drive Planetary gear Planetary gear
single stage, splash single stage,
lubrication splash lubrication
Drive type Front/rear-wheel drive

Front axle Fixed-frame, full-floating
Axle, wheel
Rear axle Center pin support type, full-floating

Tire 35/65 x 33 – 24 PR (L4)
Wheel rim 28.00 x 33 WTB
Inflation pressure Front tire kPa {kg/cm2} 392 {4.0}
2
Rear tire kPa {kg/cm } 343 {3.5}
Main brake Front/rear wheel braking, separate front/rear wheel,

Brakes
wet disc, hydraulically actuated
Parking brake Drive shaft, dry caliper type disc brake,

Hydraulically released spring type
WA600-3 01-9
(16)
Serial No. 50001 – 52000 52001 – 53000 53001 and up

Steering
Type Articulated type

system
Structure Fully hydraulically power steering
Work equipment ¬ /min 496 (Gear type: 492 (Gear type:

pump SAR (4) 140 + 125) SAL (4) 125 + 125)
Hydrau- Switch pump ¬ /min 187 (Gear type: 199 (Gear type:
lic pump SAR (3) 100) SAL (4) 100)
Delivery Steering pump ¬ /min 232 (Gear type: 246 (Gear type:
SAR (4) 125) SAL (4) 125)
PPC pump ¬ /min 59 (Gear type: 63 (Gear type:
SAR (1) 32) SAL (1) 32)
Hydraulic system
Main control valve 2-spool type

Control
Set pressure MPa {kg/cm2} 20.6 {210}
valve
Steering valve Orbitroll + spool valve type
Set pressure MPa {kg/cm2} 20.6 {210}
Steering cylinder Reciprocating piston

Cylinder
Lift cylinder Reciprocating piston
No. – bore x stroke mm 2 – 225 x 1,130
Bucket cylinder Reciprocating piston

equipment
Work
Link type Single link
Bucket edge type Flat edge with tooth
01-10 WA600-3
(16)
GENERAL WEIGHT TABLE
WEIGHT TABLE
WA600-3
¤ This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WA600-3 Machine model WA600-3
Serial Number 50001 – 52000 52001 and up Serial Number 50001 – 52000 52001 and up
Engine assembly 2,750 2,900 Steering and switch pump — 39
Radiator assembly 415 545 Torque converter charging

and PPC pumps — 24
Torque converter assembly 157 220 Hydraulic pumps — 41
Transmission assembly 1,400 1,400 Lift cylinder (1 piece) 404 404
Upper drive shaft 29.5 31 Bucket cylinder 524 524
Center drive shaft 64 64 Engine hood 116.5 116.5
Front drive shaft 64 64 Front frame 3,390 3,390
Rear drive shaft 48.2 48.2 Rear frame 3,450 3,630
Front axle assembly 2,996 2,996 Bucket link (with bushing) 147 147
Rear axle assembly 2,898 2,898 Bellcrank (with bushing) 897 897
Front differential assembly 499 499 Lift arm (with bushing) 3,262 3,262
Rear differential assembly 508 508 Bucket (with teeth) 4,250 4,250
Planetary carrier assembly

(1 piece) 115 115 Counterweight 2,820 2,820
Wheel hub (1 piece) 195 195 Fuel tank 405 405
Axle pivot (front/rear) 136/153 136/153 Battery (1 piece) 59 59
Wheel (1 piece) 466 466 Cab assembly 439 456
Tire (1 piece) 990 990 Air conditioner unit 23 23
Steering valve 48 48 Operator's seat 54 54
Orbit-roll valve 5.2 5.2 Floor frame 180 184
Steering cylinder (1 piece) 77 77
Hydraulic tank 414 414
Hydraulic, Steering and

PPC Pumps 72 —
Torque converter charging 30 —

and switch pumps
Main control valve 90 90
WA600-3 01-11
(16)
WA600-3D
¤ This weight table is a guide for use when transporting or handling components. Unit: kg
Serial Number 50001 – 52000 52001 – 53000 53001 and up
Engine assembly 2,750 2,900 2,900
Radiator assembly 415 545 630
Torque converter assembly 157 220 220
Transmission assembly 1,400 1,400 1,400
Upper drive shaft 29.5 31 31
Center drive shaft 64 64 64
Front drive shaft 64 64 64
Rear drive shaft 48.2 48.2 45.2
Front axle assembly 2,996 2,996 2.996
Rear axle assembly 2,898 2,898 2,898
Front differential assembly 499 499 499
Rear differential assembly 508 508 508
Planetary carrier assembly switch

(1 piece) 115 115 115
Wheel hub (1 piece) 195 195 195
Axle pivot (front/rear) 136/153 136/153 136/153
Wheel (1 piece) 466 466 466
Tire (1 piece) 990 990 990
Steering valve 48 48 48
Orbit-roll valve 5.2 5.2 5.2
Steering cylinder (1 piece) 77 77 77
Hydraulic tank 414 414 414
Hydraulic, Steering and PPC Pumps 72 — —
Torque converter charging and

switch pumps 30 — —
Main control valve 90 90 90
Steering and switch pump — 39 39
01-12 WA600-3
0
Unit: kg
Serial Number 50001 – 52000 52001 – 53000 53001 and up
Torque converter charging and PPC

pumps — 24 24
Hydraulic pumps — 41 41
Lift cylinder (1 piece) 404 404 404
Bucket cylinder 524 524 524
Engine hood 200 200 200
Front frame 3,390 3,390 3,390
Rear frame 3,450 3,630 3,670
Bucket link (with bushing) 147 147 147
Bellcrank (with bushing) 897 897 897
Lift arm (with bushing) 3,262 3,262 3,262
Bucket (with teeth) 4,250 4,250 4,250
Counterweight 2,820 2,820 2,820
Fuel tank 405 405 405
Battery (1 piece) 59 59 59
Cab assembly 439 456 456
Air conditioner unit 23 23 23
Operator's seat 54 54 54
Floor frame 180 184 184
WA600-3 01-13
(16)
GENERAL LIST OF LUBRICANT AND COOLANT
LIST OF LUBRICANT AND COOLANT
AMBIENT TEMPERATURE CAPACITY

RESER- KIND OF
VOIR FLUID –22 –4 14 32 50 68 86 104 122°F
Specified Refill
–30 –20 –10 0 10 20 30 40 50°C
SAE 30 61 ¶ 43 ¶
Serial No. : Serial No. : 
Engine oil
SAE 10W
50001 – 5200050001 – 52000
pan SAE 10W-30 62 ¶ 47 ¶
Serial No. : Serial No. : 
SAE 15W-40  52001 and up 52001 and up
Engine
oil
Transmis- SAE 30
120 ¶ 110 ¶
sion case
SAE 10W
Hydraulic SAE 10W 500 ¶ 345 ¶

system
Axle
(Front and 124 ¶ 124 ¶
rear) See Note 1
(each)
Pins Grease NLGI No. 2 – –
Diesel ASTM D975 No. 2

Fuel tank 670 ¶ –
fuel
ª
137 ¶
Serial No. : 
50001 – 52000
142 ¶
Cooling
system
Coolant Add antifreeze Serial No. :  –
52001 – 53000
160 ¶
Serial No. : 
53001 and up
ª ASTM D975 No. 1
Note 1:
For axle oil, use only recommended oil as follows.
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBIL AND SUPER UNIVERSAL
It is possible to substitute engine oil CLASS-CD
SAE30 for axle oil.
If noise comes from the brake, it is no problem of
durability.
01-14 WA600-3
(16)
GENERAL LIST OF LUBRICANT AND COOLANT
REMARK:
• When fuel sulphur content is less than 0.5 %,
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table if
fuel sulphur content is above 0.5 %.
Change interval of
Fuel sulphur content oil in engine oil pan
0.5 to 1.0 % 1/2 of regular interval
Above 1.0 % 1/4 of regular interval
• When starting the engine in an atmospheric

temperature of lower than 0°C, be sure to use
engine oil of SAE10W, SAE10W-30 and
SAE15W-40 even though an atmospheric tem-
perature goes up to 10°C more or less in the
day time.
• Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
• There is no problem if single grade oil is mixed
with multigrade oil (SAE10W-30, 15W-40), but
be sure to add single grade oil that matches
the temperature in the table.
• We recommend Komatsu genuine oil which
has been specifically formulated and ap-
proved for use in engine and hydraulic work
equipment applications.
Specified capacity: Total amount of oil including

oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill sys-
tem during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
WA600-3 01-15
(16)
10 STRUCTURE AND FUNCTION
Power train .................................................... 10- 2 Spring cylinder ........................................... 10-105

Power train system ...................................... 10- 4 Parking brake solenoid valve .................... 10-106
Radiator, hydraulic oil cooler ...................... 10- 6 Hydraulic piping ......................................... 10-108
Radiator, hydraulic oil cooler Work equipment hydraulic circuit
(with suction fan) ...................................... 10-6-4 diagram ..................................................... 10-110
Torque converter and transmission Work equipment lever linkage .................. 10-112
piping .......................................................... 10- 7 Hydraulic tank ............................................. 10-113
Hydraulic circuit for power train ................. 10- 8 Accumulator (for PPC valve) ..................... 10-115
Hydraulic circuit diagram for power train ... 10-10 PPC valve .................................................... 10-116
Torque converter .......................................... 10-12 PPC reliev valve .......................................... 10-120
Torque converter regulator valve Cut-off valve ................................................ 10-121
(Serial No.: 52001 and up) ...................... 10-14-4 Main control valve ...................................... 10-124
Transmission ................................................ 10-15 Auto grease system ................................ 10-137-1
Transmission control valve ......................... 10-24 Lubrication of work equipment ................. 10-138
Torque converter oil cooler ......................... 10-44 Work equipment linkage ............................ 10-140
Torque converter oil filter ............................ 10-45 Bucket .......................................................... 10-142
Transfer ......................................................... 10-47 Bucket positioner and boom kick-out ....... 10-143
Drive shaft ..................................................... 10-48 Operation of proximity switch .................. 10-145
Center support .............................................. 10-49 Rops canopy ............................................... 10-149
Axle ................................................................ 10-50 Cab ............................................................... 10-150
Differential .................................................... 10-52 Cab heater ................................................ 10-150-1
Limited slip differential ............................. 10-54-1 Air conditioner ............................................ 10-151
Final drive ..................................................... 10-55 Electric circuit diagram .............................. 10-154
Axle mount ................................................... 10-58 Machine monitor system ........................... 10-158
Center hinge pin ........................................... 10-60 Main monitor .............................................. 10-159
Steering piping ............................................. 10-61 Maintenance monitor ................................. 10-164
Steering column ........................................... 10-62 Machine with joystick and automatic shift
Steering unit (orbit-roll valve) ..................... 10-63 control ...................................................... 10-165-1
Steering valve ............................................... 10-66 Engine starting circuit ................................ 10-166
Two-way restriction valve ............................ 10-77 Engine stop circuit ................................... 10-167-2
Stop valve ..................................................... 10-78 Auto priming system (APS)
Emergency steering piping ......................... 10-79 (Serial No. : 50001 – 52000) ..................... 10-169
Diverter valve (for emergency steering) ..... 10-80 Pre-heating circuit
Brake piping .................................................. 10-84 (Serial No. : 52001 and up) ................... 10-172-1
Brake circuit diagram ................................... 10-86 Electric transmission control ..................... 10-173
Brake valve .................................................... 10-88 Kick-down, hold switch .............................. 10-176
Charge valve ................................................. 10-93 Kick-down electrical circuit ........................ 10-177
Accumulator (for brake) ............................... 10-97 Electric parking brake control .................... 10-183
Slack adjuster ............................................... 10-98 E.C.S.S. (Electronically Controlled
Brake ............................................................ 10-101 Suspension System) ................................ 10-192
Parking brake .............................................. 10-103
WA600-3 10-1
(15)
STRUCTURE AND FUNCTION RADIATOR, HYDRAULIC OIL COOLER
1. After cooler SPECIFICATIONS

2. Coolant level sensor Radiator
3. Upper tank • Core model: PF2-7
4. Radiator core • Total heat dissipating area:
5. Fuel cooler 135.22 m2 (52001 – 53001)
6. Sub tank 166.80 m2 (53001 and up)
7. Lower tank (hydraulic oil cooler 7A, 7B) • Cross-sectional area of water flow:
217.01 cm2 (52001 – 53001)
A: After cooler outlet port 233.43 cm2 (53001 and up)
B: After cooler inlet port Hydraulic oil cooler
C: Coolant inlet port
D: Hydraulic oil cooler inlet port Oil cooler 7A Oil cooler 7B
E: Hydraulic oil cooler outlet port Core type PTO-OL PTO-OL
F: Coolant outlet port
Heat 1.396 m2 (52001 – 53000)
dissipating 1.829 m2
area 1.829 m2 (53001 and up)
After cooler (Fuel cooler)

• Core type: CF40-1
• Total heat dissipating area: 6.45 m2
After cooler
10-6-2 WA600-3
(16)
RADIATOR, HYDRAULIC OIL COOLER (with suction fan)

1. After cooler SPECIFICATIONS

2. Coolant level sensor Radiator
3. Upper tank • Core model: PF2-7
4. Radiator core • Total heat dissipating area: 135.22 m2
5. Fuel cooler • Cross-sectional area of water flow:
6. Sub tank 217.01 cm2
7. Lower tank (hydraulic oil cooler 7A, 7B) Hydraulic oil cooler
A: After cooler outlet port Oil cooler 7A Oil cooler 7B

B: After cooler inlet port Core type PTO-OL PTO-OL
C: Coolant inlet port
Heat
D: Hydraulic oil cooler inlet port dissipating 1.396 m2 1.829 m2
E: Hydraulic oil cooler outlet port area
F: Coolant outlet port After cooler (Fuel cooler)
• Core type: CF40-1
After cooler
10-6-4 WA600-3
(16)
WA600-3 10-6-5
(15)
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
Serial No.: 50001 – 52018
1. Axle shaft
2. Sun gear (Teeth: 19)
3. Ring gear (Teeth: 71)
4. Planetary carrier
5. Planetary gear (Teeth: 25)
6. Wheel
WA600-3 10-55
(16)
Serial No.: 52019 and up
1. Axle shaft
2. Sun gear (Teeth: 19)
3. Ring gear (Teeth: 71)
4. Planetary carrier
5. Planetary gear (Teeth: 25)
6. Wheel
10-56 WA600-3
(16)
OUTLINE
• To gain a large drive force, the final drive
uses a planetary gear system to reduce the
speed and send drive force to the tires.
OPERATION
• The motive force transmitted from the
differential through axle shaft (1) to sun gear
(2) is transmitted to planetary gear (5). The
planetary gear rotates around the inside of a
fixed ring gear (3) and in this way transmits
rotation at a reduced speed to the planetary
carrier (4). This motive force is then sent to
the wheels (6) which are installed to the
planetary carriers (4).
WA600-3 10-57
(16)
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (RIGHT)
Serial No.: 50001 – 52018
1. Brake pedal (left, right brake) A: Pilot port (right brake)

2. Rod (right brake) B: To rear brake (right brake)
3. Pilot piston (right brake) C: To front brake (right brake)
4. Spool (right brake) D: Drain (left, right brake)
5. Upper cylinder (right brake) E: To pilot port (left brake)
6. Spool (right brake) F: From accumulator (left, right brake)
7. Lower cylinder (right brake)
8. Rod (left brake)
9. Spool (left brake)
10. Cylinder (left brake)
10-88 WA600-3
(16)
BRAKE VALVE (LEFT)

Serial No.: 50001 – 52018
OUTLINE
• There are two brake valves installed in paral- In addition, the left brake pedal operates the
lel under the front of the operator’s cab, and transmission cut-off switch to actuate the
these are actuated by depressing the pedal. transmission solenoid valve electrically and
• When the right pedal is depressed, oil is sent set the transmission to neutral.
to the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent
to the right pedal to apply the brakes in the
same way as when the right pedal is de-
pressed.
WA600-3 10-88-1
(16)
BRAKE VALVE (RIGHT)

1. Brake pedal (left, right brake) A: Pilot port (right brake)

2. Rod (right brake) B: To rear brake (right brake)
3. Pilot piston (right brake) C: To front brake (right brake)
4. Spool (right brake) D: Drain (left, right brake)
5. Upper cylinder (right brake) E: To pilot port (left brake)
6. Spool (right brake) F: From accumulator (left, right brake)
7. Lower cylinder (right brake)
8. Rod (left brake)
9. Spool (left brake)
10. Cylinder (left brake)
10-88-2 WA600-3
(16)
BRAKE VALVE (LEFT)

OUTLINE
• There are two brake valves installed in paral- In addition, the left brake pedal operates the
lel under the front of the operator’s cab, and transmission cut-off switch to actuate the
these are actuated by depressing the pedal. transmission solenoid valve electrically and
• When the right pedal is depressed, oil is sent set the transmission to neutral.
to the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent
to the right pedal to apply the brakes in the
same way as when the right pedal is de-
pressed.
WA600-3 10-89
(16)
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
Serial No.: 50001 – 52018
1 2 3
5 4 B A SEW00121
1. Bleeder FUNCTION
2. Cylinder • The slack adjuster is installed in the brake oil
3. Check valve line from the brake valve to the brake piston.
4. Piston It acts to provide a fixed time lag when the
5. Spring brake is applied.
A: Inlet port
B: Outlet port
SPECIFICATIONS
Piston actuation pressure:
0.01 + 0.01
0 MPa {0.1 + 0.1 2
0 kg/cm }
Check valve cracking pressure:
0.93 ± 0.05 MPa {9.5 ± 0.5 kg/cm2}
Check valve closing pressure:
0.6 ± 0.05 MPa {6.0 ± 0.5 kg/cm2}
10-98 WA600-3
(16)
STRUCTURE AND FUNCTION SLACK ADJUSTER
1. Cylinder FUNCTION
2. Check valve • The slack adjuster is installed in the brake oil
3. Piston line from the brake valve to the brake piston.
4. Spring It acts to provide a fixed time lag when the
5. Bleeder brake is applied.
A: Inlet port
B: Outlet port
WA600-3 10-98-1
(16)
STRUCTURE AND FUNCTION BRAKE
BRAKE
Serial No.: 50001 – 52018
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear (No. of teeth: 164)
6. Hub gear (No. of teeth: 112)
7. Plate
8. Disc
WA600-3 10-101
(16)
STRUCTURE AND FUNCTION BRAKE
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear (No. of teeth: 164)
6. Hub gear (No. of teeth: 112)
7. Plate
8. Disc
10-101-1 WA600-3
(16)
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
1. Kick-down switch 5. Solenoid valve for bucket lever

2. Boom lever 6. Solenoid valve for boom lever
3. Bucket lever 7. PPC valve
4. Work equipment lock lever
10-112 WA600-3
(16)
STRUCTURE AND FUNCTION CUT-OFF VALVE
CUT-OFF VALVE
1. Unload valve FUNCTION

2. Check valve • The cut-off valve is installed between the
3. Cut-off relief valve switch pump and the main control valve. De-
4. Screen pending on the operating condition, it
switches the oil from the switch pump to the
C: Port C (from hydraulic pump) main control valve or to the drain circuit.
P: Port P (from steering valve)
T: Port T (to tank)
T1: Port T1(to tank)
WA600-3 10-121
(16)
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
3-SPOOL (If equipped)
A1: To attachment cylinder D1: Drain port PA2: From PPC valve P4
A2: To bucket cylinder bottom D2: Drain port PA3: From PPC valve P2
A3: To boom cylinder bottom P: From pump PB1: From option PPC valve
B1: To attachment cylinder P1: From PPC valve P2 PB2: From PPC valve P1
B2: To bucket cylinder head P2: From PPC valve P3 PB3: From PPC valve P3
B3: To boom cylinder head PA1: From option PPC valve T: Drain port
10-126 WA600-3
(16)
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR DISPLAY FUNCTION

Display
category Symbol Display item Display range Display method
When there is Display flashes (for details, see

Check Check abnormality display on MAINTENANCE MONITOR
maintenance monitor DISPLAY FUNCTION)
Emergency steering
actuated When actuated Display flashes
Parking brake actuated,

transmission not at Display flashes and buzzer
Caution sounds
neutral
Caution Display flashes (buzzer may
When there is also sound) for details, see
abnormality display on MAINTENANCE MONITOR
maintenance monitor DISPLAY FUNCTION)
Hi beam When operated Display lights up
Turn signal
(left, right) When operated Display lights up
Display lights up
Parking brake When operated Buzzer sounds when parking
brake is applied and shift lever
is not at N
Pilot Emergency steering When normal (oil is

normal flowing in hydraulic Display lights up
circuit)
Lights up
Lighting up time changes
according to engine water
Preheating When preheating temperature when starting
switch is turned ON (for details,
see PREHEATING OUTPUT
FUNCTION)
Shift hold
(Machine equipped When shift is held Display lights up
with auto shift)
Digital display (display switches
Speedo- Travel speed 0 – 99 km/h between tachometer and
meter speedometer)
Shift
indicator Shift indicator 1–4N Digital display
When controller detects

failure and action by Digital display
Failure operator is needed, Buzzer sounds
action Failure action code CALL is displayed, (For details of the travel data
code or CALL AND E B B display mode, see TROUBLE
(action code) are DATA DISPLAY MODE)
displayed in turn
Shift F, R, display (when

indicator equipped with F. R Digital display
joystick steering)
10-160 WA600-3
(16)
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR DISPLAY FUNCTION
Display
Symbol Display item Display range Display method
category
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Check Display when normal: OFF
Engine oil level Below low level Display when abnormal: Flashes
CHECK lamp flashes
Engine water level Below low level Displays when engine is running
Display when normal: OFF
Display when abnormal: Flashes
Engine oil pressure Below specified CAUTION lamp flashes
pressure Buzzer sounds
Brake oil pressure Below specified

pressure
––––––––––––––––––––-
Engine water temperature Above 102°C Buzzer sounds if above 105°C
––––––––––––––––––––-
Torque converter oil Above 120°C Buzzer sounds if above 130°C
Caution temperature
Fuel level Below low level Displays when engine is running

Display when normal: OFF
CAUTION lamp flashes
Battery charge When charge is Displays when engine is running

defective Display when normal: OFF
Air cleaner Above specified CHECK lamp flashes
negative pressure
Service meter 0 – 9999.9h Actuated when charge is normal

Advances 1 for every hour
Service
meter Service meter indicator Lights up when service meter is
running
Fuel level All lamps light up below applicable

level
Flashes when level is 1
Engine water temperature One place lights up to show

Gauges applicable level
Flashes when level is 6 or 7
Torque converter oil One place lights up to show

temperature applicable level
Flashes when level is 6 or 7
WA600-3 10-165
(16)
STRUCTURE AND FUNCTION MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL
Table 1 Automatic shift change points table
Gear-shift inhibition
Item Gear speed Travel speed (km/ h) time (sec)
1. Basic shift change 1→2 Min. 5.6 (5.8) 2
2→3 Min. 9.3 (9.8) 2
3→4 Min. 17.6 1
4→3 Max. 15.6 1
3→2 Max. 9.8 (9.3) 2
2. Engine speed 4→2 Max. 1.0 0
(Below 1,450rpm)
3→2 Max. 1.0 0
3. Engine speed 4→2 Max. 8.0 2
(Below 1,450rpm → 1,450rpm or
higher) 3→2 Max. 8.0 2
4. Shift-up operation while hold 1→2 5.6 0
function is ON
2→3 9.3 0
3→4 17.6 0
5. Shift-down operation while 2→1 No limit 5
kickdown function is ON
3→1 Max. 12.7 5
4→1 Max. 12.7 5
6. Changeover of F and R to each other 4→2 Note 1)
(Range I in Fig. 1)
(F→)N→R 3→2 2
(R→)N→F 1→2
7. Changeover of F and R to each other Note 2)
(Range II in Fig. 1)
(F→)N→R →4 Min. 17.6 2
(R→)N→F →3 Max. 9.3 – 17.6
8. Changeover of F and R to each other →4 Min. 17.6
F→N→F →3 Max. 9.3 – 17.6 0
R→N→R →2 Max. 9.3
Note 1)The engine speed is below 1,800rpm and travel speed is below 16km/h, or travel speed is below 13km/h.
Note 2)When the engine speed is 1,800rpm or higher and travel speed is 13km/h or higher, or travel speed is
16km/h or higher, the gear is not shifted immediately, but shifted down to the 2nd position as the travel
speed drops.
10-165-5 WA600-3
(16)
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
APS completely
APS started
stopped
Passage of time
Glow plug Starting Engine starts,
preheats motor turns intake air
heated
Starting switch ON START ON

Heater switch OFF ON AUTO OFF
APS water temperature
ON (Max. 20°C) OFF
sensor
Glow plug OFF ON OFF
Monitor pilot lamp
display OFF ON OFF Flashes OFF
Fuel injection nozzle. No injection Intermittent injection No injection
STARTING WITH APS (actuated when engine

water temperature is below 20°C)
1. Open the APS fuel valve in the center of the 6. Depress the accelerator pedal half way.
left side of the engine. 7. The preheating stops after approx. 12 seconds
fl Leave the fuel valve open during the cold and the monitor pilot lamp goes out. Turn
season when the temperature goes down the starting switch key to the START position
and the APS is used. to start the engine.
2. Turn the starting switch ON. fl If the starting switch is turned to the
3. Turn the fuel cut-off switch OFF, then turn the START position while the monitor pilot
starting switch to the START position and lamp is still lighted up, the glow plug will
crank the starting motor for approx. 10 sec- become wet and it will be impossible to
onds. carry out ignition.
fl Do this to lubricate the whole engine with 8. When the engine starts, return the starting
oil. switch to the ON position.
fl When the fuel cut-off switch is turned OFF, 9. After the engine starts, when the engine rota-
the fuel cut solenoid is turned OFF and tion becomes smooth and the exhaust gas
the fuel injection pump is set to the NO color becomes normal, turn the heater switch
INJECTION position. OFF.
4. Turn the fuel cut-off switch ON. fl After the engine is started and the engine
fl Release the switch and it will automati- water temperature reaches approx. 20°C,
cally return to the ON position. the monitor pilot lamp flashes to inform
5. If the heater switch is set to the ON position, the operator that the afterheating has
the monitor pilot lamp will light up and the been completed. At the same time, the
glow lamp will preheat. afterheating is automatically canceled.
fl When the monitor pilot lamp lights up, set
the heater switch to AUTO.
WA600-3 10-167
(16)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
Engine SAA6D170E-3
Cat- Standard value Service limit
egory Item Measurement conditions Unit for new machine value
Low idle 750 ± 25 750 ± 25
Engine speed High idle rpm 2,175 ± 50 2,175 ± 100
Rated speed 2,000 —
Whole speed range

Exhaust temperature (ambient temperature: 20°C) ˚C 680 700
Air supply pressure

(boost pressure) At rated output kPa {mmHg} Min. 113 {850} 100 {750}
At sudden acceleration Max. 5.0 7.0

Exhaust gas color Bosch index
At rated output Max. 2.0 3.0
Valve clearance Intake valve 0.32 —

(normal temperature) mm
Exhaust valve 0.62 —
Compression pressure Oil temperature: 40 – 60°C 2

(SAE30 oil) (Engine speed: 210 – 250 rpm) MPa {kg/cm } Min. 2.9 {30} 2.1 {21}
Engine related
(Coolant temperature:
Blow-by pressure Green range) kPa {mmH2O}
(SAE30 oil) Max. 3.9 {400} 7.9 {800}
At high idle
Green range) MPa {kg/cm2} 0.39–0.54 {4.0–5.5} 0.21 {2.1}
At high idle (SAE30)
Green range) MPa {kg/cm2} 0.34–0.49 {3.5–4.0} 0.18 {1.8}
At high idle (SAE10W)
Oil pressure
At low idle (SAE30) MPa {kg/cm2} Min. 0.12 {1.2} Max. 0.07 {0.7}
At low idle (SAE10W) MPa {kg/cm2} Min. 0.1 {1.0} Max. 0.05 {0.5}
Whole speed range

Oil temperature (inside oil pan) °C 90 –␣ 110 120
Deflection of one belt when

Alternator belt tension pressed with finger force of
approx. mm 10 – 15 10 – 15
58.8 N {approx. 6 kg.}
Air conditioner compres- Deflection when pressed

sor belt tension with finger force of approx. mm 10 – 15 10 – 15
58.8 N {approx. 6 kg.}
WA600-3 20-2-1
(16)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Serial No. : 50001 – 52000

Operating • Engine stopped

N – FORWARD, • Measure at center of lever
Directional
effort REVERSE N {kg} 5.88 +4.9 +0.5

– 2.94 {0.6 – 0.3 } 16.7 {1.7}
knob
lever
N – FORWARD,
Travel
REVERSE mm 35 ±␣ 10 35 ±␣ 10
1st – 2nd • Engine stopped 5.88 +4.9 +0.5

– 2.94 {0.6 – 0.3 } 16.7 {1.7}
Speed control lever
• Measure at center of lever

Operating 2nd – 3rd knob N {kg} 5.88 +4.9 +0.5
effort – 2.94 {0.6 – 0.3 } 16.7 {1.7}
3rd – 4th 5.88 +4.9 +0.5
– 2.94 {0.6 – 0.3 } 16.7 {1.7}
1st – 2nd 35 ±␣ 10 35 ±␣ 20
Travel 2nd – 3rd mm 35 ±␣ 10 35 ±␣ 20

3rd – 4th 35 ±␣ 10 35 ±␣ 20
HOLD→RAISE • Engine speed: Low idle Max. 23.5 {2.4} 35.3 {3.6}
• Hydraulic oil temperature:
RAISE→HOLD 45 – 55°C Max.15.7 {1.6} 23.5 {2.4}
HOLD→LOWER Max. 24.5 {2.5} 37.3 {3.8}
Operating effort
Lift arm
LOWER→HOLD — —
Work equipment control lever
LOWER→FLOAT N {kg} Max. 34.3 {3.5} 52.0 {5.3}

FLOAT→HOLD Max. 14.7 {1.5} 22.6 {2.3}
HOLD→DUMP Max. 23.5 {2.4} 35.3 {3.6}
Bucket HOLD→TILT Max. 23.5 {2.4} 35.3 {3.6}
TILT→HOLD Max. 14.7 {1.5} 22.6 {2.3}
HOLD→RAISE
• Engine speed: Low idle 67 ±␣ 15 67 ±␣ 30
Lift arm HOLD→LOWER 45 – 55°C 53 ±␣ 15 53 ±␣ 30
Travel
HOLD→FLOAT mm 67 ±␣ 15 67 ±␣ 30
HOLD→DUMP 60 ±␣ 15 60 ±␣ 30
Bucket
HOLD→TILT 60 ±␣ 15 60 ±␣ 30
• Engine stopped
Play • Machine facing straight to mm Max. 40 50 –␣ 100
front
• Flat, horizontal, straight, dry 10.0 ±␣ 3.0

Steering wheel
Operating effort paved road surface N {kg} {1.0 ±␣ 0.3} 19.6 {2.0}
• Engine speed: High idle

Turns • Left lock - right lock Turns 3.9 ±␣ 0.4 4.5
• Engine running
Low idle • Hydraulic oil temperature: Max. 5.8 6.5
Operating
time 45 – 55°C sec.
• Left lock - right lock
High idle Max. 4.1 5.0
WA600-3 20-3
(16)

Operating effort • Engine speed: Low idle
(Measure at 150 mm point • Hydraulic oil temperature: 68.6 ± 3.0
N {kg} {7.0 ± 0.3} 78 {88}
from pedal fulcrum) 45 – 55°C
Accelerator pedal
Operating angle
Neutral (α 1) 51 —
STD model
deg.
Max. (α 2) 34 —
Stopper height (L) mm 56 —

• If high idle speed exceeds
specified value, adjust L longer.

• Hydraulic oil temperature: 294 ± 29.4
(Measure at 150 mm point N {kg} {30 ± 3} 421.4 {43}
Operating angle
Brake pedal
deg.
+1
Max. (α 2) 15 0 —
Play mm 5 ±␣ 0.5 —
• Tire inflation pressure:

A Specified pressure Max. 2.5 —
Fitting of wheel lock

ring
Tire
B Max. 4.0 —
mm
Clearance of wheel lock C 2 – 15 —

ring
• Engine coolant temperature:

Torque converter stall Green range 2,070 ± 100 2,070 ± 200
• Torque converter oil tempera-
ture: 60 – 80°C
Engine speed

45 – 55°C
Hydraulic stall • Gearshift lever: F4 or R4 2,080 ± 100 2,080 ± 200
rpm
Torque converter stall

+ 1,670 ± 100 1,670 ± 300
hydraulic stall
20-4 WA600-3
(16)

• Torque converter oil
Low idle temperature: 60 – 80°C 2.94 ± 0.2 2.94 ± 0.2
{30 ±␣ 2.0} {30 ±␣ 2.0}
Main relief
pressure
High idle 3.19 ± 0.2 3.19 ± 0.2
{32.5 ±␣ 2.0} {32.5 ±␣ 2.0}
Transmission, torque converter

F2, R2 cluch pressure temperature: 60 – 80°C 1.76 ± 0.10 1.76 ± 0.10
• Engine speed: High idle {18 ±␣ 1} {18 ±␣ 1}
Pilot pressure MPa 1.05 ± 0.10 1.05 ± 0.10

{kg/cm2} {10.8 ±␣ 1.0} {10.8 ±␣ 1.0}
Torque converter relief 0.78 ± 0.1 0.78 ± 0.1

pressure (inlet port) {8 ±␣ 1} {8 ±␣ 1}
Torque converter outlet 0.34 ± 0.05 0.34 ± 0.05

port pressure {3.5 ±␣ 0.5} {3.5 ±␣ 0.5}
Lubrication pressure 0.2 ± 0.1 0.2 ± 0.1

(oil cooler outlet port) {2 ±␣ 1} {2 ±␣ 1}

Steering relief pressure 45 – 55°C 20.6 +0.98 +10
– 0.29 {210 – 3 } 20.6 +0.98 +10
– 1.27 {210 – 3 }
Steering

MPa
{kg/cm2}
Orbit-roll output pressure 3.72 +0.19
0 {38 +20 } 3.72 +0.39 +4
– 0.19 {38 – 2 }
• Point when brake

• Engine oil pressure
Accumulator
Charge cut-in pressure speed: warning lamp 5.88 +0.49

0 {60 +50 } 5.88 +0.98 +10
– 0.49 {60– 5 }
Low idle goes out
MPa
• Hydraulic {kg/cm2}
oil tem- • Point when oil
pressure is going
Charge cut-out pressure perature: up and then 9.8 +0.98
0 {100+10
0 } 9.8 +1.47 +15
– 0.49 {100– 5 }
45 – 55°C starts to go down
1st 7.4 ± 0.3 7.4 ± 0.3
2nd 12 ± 0.6 12 ± 0.6

FORWARD
3rd 21.0 ± 1.0 21.0 ± 1.0
Power train
4th 33.5 ± 1.7 33.5 ± 1.7

Travel speed km/h
1st 8.2 ± 0.4 8.2 ± 0.4
2nd 13.9 ± 0.7 13.9 ± 0.7

REVERSE
3rd 23.0 ± 1.1 23.0 ± 1.1
4th 35.2 ± 1.8 35.2 ± 1.8
WA600-3 20-5
(16)

• Hydraulic oil temperature: 4.9 ± 0.49 4.9 ± 0.69
Brake oil pressure 45 – 55°C {50 ± 5} {50 ± 7}
MPa
• Engine stopped {kg/cm2}
Drop in brake pressure • Keep brake pedal depressed at Max. 0.49 {5} 0.49 {5}
4.9 MPa {50 kg/cm2} and measure
drop in oil pressure after 5 min.
Wheel brake

Specified pressure
• Flat, horizontal, straight, dry
paved road surface
Performance • Speed when applying brake: m Max. 5 5
20 km/h, braking delay: 0.1 sec
• Brake pedal operating effort:
Specified operating effort
(294±29.4 N {30±3 kg})
• Measure stopping distance
• Measure piston stroke
Disc wear mm 7.5 ±␣ 0.6 13.4
• Torque converter oil 5.9 – 9.8 5.9 – 9.8

Parking Brake released temperature: 60 – 80°C {60 – 100} {60 – 100}
brake inlet • Engine at high idle MPa
port {kg/cm2}
pressure Max. 0.14 0.14
Brake operated {Max. 1.4} {1.4}

Specified pressure
• Flat dry paved road with
1/5 (11°20') grade
• Machine at operating condition
Parking brake
Performance — Stopped Stopped
Pad thickness Including pack metal 31.7 ±␣ 0.3 12.7

mm
Clearance Total of each end 1.06 ±␣ 0.18 2.1

PPC valve source pressure
(Orbit-roll source pressure)
45 – 55°C 3.72 +0.2 +2
0 {38 0 } 3.72 +0.2 +2
– 0.2 {38 – 2 }
Lift arm RAISE, • Hydraulic oil temperature:
PPC
MPa
FLOAT; bucket 45 – 55°C {kg/cm2} 3.72 +0.2 +2
0 {38 0 } 3.72 +0.2 +2
– 0.2 {38 – 2 }
PPC valve DUMP, TILT
output • Engine speed: High idle
pressure • Work equipment control lever: 2.54 ± 0.05 2.54 ± 0.05
Lift arm Operated fully
LOWER {26 ± 0.5} {26 ± 0.5}
20-6 WA600-3
(16)

• Hydraulic oil temperature: MPa 20.6 +0.49 20.6 +0.49
Work equipment relief 45 – 55°C – 0.29 – 1.27
pressure {kg/cm2} {210+5
–3 } {210 +5
–13 }

45 – 55°C
• No load
Lift arm RAISE 7.9 ± 0.5 9.0
Work equipment speed
Lift arm LOWER 4.8 ±␣ 0.5 6.0
sec.
45 – 55°C
Work equipment
• No load
When fully operated 3.0 ±␣ 0.3 4.0
Bucket tiltback
Bucket horizontal 2.1 ±␣ 0.3 3.0

(above ground)

45 – 55°C
• Leave for 5 minutes after
Retraction of lift stopping engine then
measure for next 15 minutes Max. 40 40
cylinder rod
• Bucket empty, lift arm,
Hydraulic drift
bucket horizontal
mm
Retraction of bucket Max. 20 0

cylinder rod
Clearance of bucket
Proximity
3 –␣ 5 —
switch
positioner proximity switch

mm
Clearance of boom kick out 3 –␣ 5 —
proximity switch
WA600-3 20-7
(16)

Operating • Engine stopped

N – FORWARD, • Measure at center of lever
Directional
+4.9 +0.5
effort REVERSE N {kg} 5.88 – 2.94 {0.6 – 0.3 } 16.7 {1.7}
knob
lever
N – FORWARD,
Travel
REVERSE mm 35 ±␣ 10 35 ±␣ 10
+4.9 +0.5
1st – 2nd • Engine stopped 5.88 – 2.94 {0.6 – 0.3 } 16.7 {1.7}
Speed control lever
• Measure at center of lever

Operating 2nd – 3rd knob +4.9 +0.5
effort N {kg} 5.88 – 2.94 {0.6 – 0.3 } 16.7 {1.7}
+4.9 +0.5
3rd – 4th 5.88 – 2.94 {0.6 – 0.3 } 16.7 {1.7}
1st – 2nd 35 ±␣ 10 35 ±␣ 20
Travel 2nd – 3rd mm 35 ±␣ 10 35 ±␣ 20
3rd – 4th 35 ±␣ 10 35 ±␣ 20
HOLD→RAISE • Engine speed: Low idle Max. 23.5 {2.4} 35.3 {3.6}
RAISE→HOLD 45 – 55°C Max.15.7 {1.6} 23.5 {2.4}
HOLD→LOWER Max. 24.5 {2.5} 37.3 {3.8}
Operating effort
Lift arm
LOWER→HOLD — —
Work equipment control lever
LOWER→FLOAT N {kg} Max. 34.3 {3.5} 52.0 {5.3}

FLOAT→HOLD Max. 14.7 {1.5} 22.6 {2.3}
HOLD→DUMP Max. 23.5 {2.4} 35.3 {3.6}
Bucket HOLD→TILT Max. 23.5 {2.4} 35.3 {3.6}
TILT→HOLD Max. 14.7 {1.5} 22.6 {2.3}
• Engine speed: Low idle
HOLD→RAISE 67 ±␣ 15 67 ±␣ 30
Lift arm HOLD→LOWER 45 – 55°C 53 ±␣ 15 53 ±␣ 30
Travel
HOLD→FLOAT mm 67 ±␣ 15 67 ±␣ 30
HOLD→DUMP 60 ±␣ 15 60 ±␣ 30
Bucket
HOLD→TILT 60 ±␣ 15 60 ±␣ 30
• Engine stopped
Play • Machine facing straight to mm Max. 40 50 –␣ 100
front

10.0 ±␣ 3.0
Steering wheel
Operating effort paved road surface N {kg} 19.6 {2.0}

{1.0 ±␣ 0.3}

Turns • Left lock - right lock Turns 3.9 ±␣ 0.4 4.5
• Engine running
Low idle • Hydraulic oil temperature: Max. 5.8 6.5
Operating
time 45 – 55°C sec.
• Left lock - right lock
High idle Max. 4.1 5.0
20-7-1 WA600-3
(16)

(Measure at 150 mm point • Hydraulic oil temperature: 58.8 ± 2.45
N {kg} {6.0 ± 0.25} 88.2 {9.0}
Accelerator pedal
Operating angle
STD model
deg.
Max. (α 2) 35 —
Stopper height (L) mm 56 ± 5 —

• If high idle speed exceeds
specified value, adjust L longer.

• Hydraulic oil temperature: 294 ± 29.4
(Measure at 150 mm point N {kg} {30 ± 3} 421.4 {43}
Operating angle
Brake pedal
deg.
+1
Max. (α 2) 15 0 —
Play mm 5 ±␣ 0.5 —

A Specified pressure Max. 2.5 —
Fitting of wheel lock

ring
Tire
B Max. 4.0 —
mm
Clearance of wheel lock C 2 – 15 —

ring
• Engine coolant temperature:

Torque converter stall Green range 2,100 ± 100 2,100 ± 200
• Torque converter oil tempera-
ture: 60 – 80°C
Engine speed

45 – 55°C
Hydraulic stall • Gearshift lever: F4 or R4 2,130 ± 100 2,130 ± 200
rpm
Torque converter stall

+ 1,740 ± 100 1,740 ± 300
hydraulic stall
WA600-3 20-7-2
(16)

Low idle temperature: 60 – 80°C 2.94 ± 0.2 2.94 ± 0.2
{30 ±␣ 2.0} {30 ±␣ 2.0}
Main relief
pressure
High idle 3.19 ± 0.2 3.19 ± 0.2
{32.5 ±␣ 2.0} {32.5 ±␣ 2.0}
Transmission, torque converter

F2, R2 cluch pressure temperature: 60 – 80°C 1.76 ± 0.10 1.76 ± 0.10
• Engine speed: High idle {18 ±␣ 1} {18 ±␣ 1}
Pilot pressure MPa 1.05 ± 0.10 1.05 ± 0.10

{kg/cm2} {10.8 ±␣ 1.0} {10.8 ±␣ 1.0}
Torque converter relief 0.78 ± 0.1 0.78 ± 0.1

pressure (inlet port) {8 ±␣ 1} {8 ±␣ 1}
Torque converter outlet 0.34 ± 0.05 0.34 ± 0.05

port pressure {3.5 ±␣ 0.5} {3.5 ±␣ 0.5}
Lubrication pressure 0.2 ± 0.1 0.2 ± 0.1

(oil cooler outlet port) {2 ±␣ 1} {2 ±␣ 1}

Steering relief pressure 45 – 55°C 22.1 +1.27 {225 +13
0 } 22.1 +1.27 +13
– 0.98 {225 – 10 }
Steering
0
• Engine speed: High idle MPa
{kg/cm2}
Orbit-roll output pressure 3.72 +0.19
0 {38 +20 } 3.72 +0.39 +4
– 0.19 {38 – 2 }
• Point when brake

• Engine oil pressure
Accumulator
Charge cut-in pressure speed: warning lamp 5.88 +0.49

0 {60 +50 } 5.88 +0.98 +10
– 0.49 {60– 5 }
Low idle goes out
MPa
• Hydraulic {kg/cm2}
oil tem- • Point when oil
pressure is going
Charge cut-out pressure perature: up and then 9.8 +0.98
0 {100+10
0 } 9.8 +1.47 +15
– 0.49 {100– 5 }
45 – 55°C starts to go down
1st 6.4 ± 0.3 6.4 ± 0.3
2nd 11.1 ± 0.6 11.1 ± 0.6

FORWARD
3rd 18.8 ± 1.0 18.8 ± 1.0
Power train
4th 30.3 ± 1.6 30.3 ± 1.6

Travel speed km/h
1st 7.1 ± 0.4 7.1 ± 0.4
2nd 12.9 ± 0.7 12.9 ± 0.7

REVERSE
3rd 20.5 ± 1.1 20.5 ± 1.1
4th 32.7 ± 1.7 32.7 ± 1.7
20-7-3 WA600-3
(16)

• Hydraulic oil temperature: 4.9 ± 0.49 4.9 ± 0.69
Brake oil pressure 45 – 55°C {50 ± 5} {50 ± 7}
MPa
• Engine stopped {kg/cm2}
Drop in brake pressure • Keep brake pedal depressed at Max. 0.49 {5} 0.49 {5}
4.9 MPa {50 kg/cm2} and measure
drop in oil pressure after 5 min.
Wheel brake

Specified pressure
paved road surface
Performance • Speed when applying brake: m Max. 5 5
20 km/h, braking delay: 0.1 sec
• Brake pedal operating effort:
Specified operating effort
(294±29.4 N {30±3 kg})
• Measure stopping distance
• Measure piston stroke
Disc wear mm 7.5 ±␣ 0.6 13.4
• Torque converter oil 5.9 – 9.8 5.9 – 9.8

Parking Brake released temperature: 60 – 80°C {60 – 100} {60 – 100}
brake inlet • Engine at high idle MPa
port {kg/cm2}
pressure Max. 0.14 0.14
Brake operated {Max. 1.4} {1.4}

Specified pressure
• Flat dry paved road with
1/5 (11°20') grade
• Machine at operating condition
Parking brake
Performance — Stopped Stopped
Pad thickness Including pack metal 31.7 ±␣ 0.3 12.7

mm
Clearance Total of each end 1.06 ±␣ 0.18 2.1
PPC valve source pressure • Hydraulic oil temperature:

(Orbit-roll source pressure) 45 – 55°C 3.72 +0.2 +2
0 {38 0 } 3.72 +0.2 +2
– 0.2 {38 – 2 }
Lift arm RAISE, • Hydraulic oil temperature:
PPC
MPa
FLOAT; bucket 45 – 55°C {kg/cm2} 3.72 +0.2 +2
0 {38 0 } 3.72 +0.2 +2
– 0.2 {38 – 2 }
PPC valve DUMP, TILT
output • Engine speed: High idle
pressure • Work equipment control lever: 2.54 ± 0.05 2.54 ± 0.05
Lift arm Operated fully
LOWER {26 ± 0.5} {26 ± 0.5}
WA600-3 20-7-4
(16)

• Hydraulic oil temperature: MPa 20.6 +0.49 20.6 +0.49
Work equipment relief 45 – 55°C – 0.29 – 1.27
pressure {kg/cm2} {210+5
–3 } {210 +5
–13 }

45 – 55°C
• No load
Lift arm RAISE 7.9 ± 0.5 9.0
Work equipment speed
Lift arm LOWER 4.8 ±␣ 0.5 6.0
sec.
45 – 55°C
Work equipment
• No load
When fully operated 3.0 ±␣ 0.3 4.0
Bucket tiltback
Bucket horizontal 2.1 ±␣ 0.3 3.0

(above ground)

45 – 55°C
• Leave for 5 minutes after
Retraction of lift stopping engine then
measure for next 15 minutes Max. 40 40
cylinder rod
• Bucket empty, lift arm,
Hydraulic drift
bucket horizontal
mm
Retraction of bucket Max. 20 0

cylinder rod
Clearance of bucket
Proximity
3 –␣ 5 —
switch
positioner proximity switch

mm
Clearance of boom kick out 3 –␣ 5 —
proximity switch
20-7-5 WA600-3
(16)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Sys- Connector Inpsec- Measurement

Name of component tion Judgement table
tem No. method conditions
If the condition is as shown in the table 1) Turn starting
below, it is normal
Measure
switch OFF.
voltage
2) Insert T-
Power supply L05 Between (1), (2) –␣ chassis adapter.
20 – 30 V 3) Turn starting
Between (1), (2) – (3)
switch ON.

below, it is normal switch OFF.
Measure voltage
2) Insert T-
Engine running adapter.
(at above 1/2 throttle) Between 28 ±␣ 2 V
Battery charge L05
(alternator) Starting switch ON (5) – (3)
(Engine stopped) Max. 1 V
ª If the battery is old, or after starting in

cold areas, the voltage may not rise for
some time.

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

Measure
voltage
2) Insert T-
Main monitor
Starting switch Srarting switch at START 20 –␣ 30 V adapter.

terminal C L05
Between
Srarting switch at (4) – (3) Max. 1 V
OFF or ON

Measure
APS preheating signal

voltage
2) Insert T-
(★) Preheating stopped Between Max. 1 V adapter.
Preheating ON signal L05
3) Turn starting
(★★) Preheating operated (19) – (3) 20 –␣ 30 V switch ON.

Measure
voltage
2) Insert T-
Starting switch terminal Starting switch ON
BR L07 Between 20 –␣ 30 V adapter.
Starting switch OFF (10) – (12) Max. 1 V

Measure
voltage
2) Insert T-
Directional switch (F) Directional lever at F Between 20 –␣ 30V adapter.
(7) – 3) Turn starting
Directional lever switch ON.
not at F chassis Max. 1 V
L08
Measure
voltage
2) Insert T-
Directional switch (R) Directional lever at R Between 20 –␣ 30V adapter.
Directional lever switch ON.
not at R chassis Max. 1 V
(★) Serial No.: 50001 – 52000

(★★) Serial No.: 52001 and up
WA600-3 20-9
(15)

below, it is normal
Measure
switch OFF.
voltage
2) Insert T-
Power supply L18 Between (1), (2) –␣ chassis adapter.
20 – 30 V 3) Turn starting
Between (1), (2) – (3)
switch ON.

Measure voltage below, it is normal switch OFF.
2) Insert T-
Engine running adapter.
(at above 1/2 throttle) Between 28 ±␣ 2 V 3) Engine
Battery charge (12) – started.
L18 Starting switch ON (3), (14)
(alternator) Max. 1 V
(Engine stopped)
ª If the battery is old, or after starting in
cold areas, the voltage may not rise for
some time.

2) Disconnect
Measure resistance
Float connector.
raised to 3) Drain fuel.
stopper Approx. 4 Ω 4) Remove fuel
level sensor.
Fuel level sensor 5) Connect
R07 T-adapter.
Maintenance monitor
(male) Float
lowered
to Approx. 85 Ω
stopper

resistance
Measure
2) Disconnect
Radiator coolant level G01 Coolant level normal Between Max. 1 Ω connector.
switch (male) (1) – (2) Min. 1 MΩ 3) Connect
Coolant level low
T-adapter.

Measure resistance

2) Disconnect
Min. 0.07 MPa Between Min. 1MΩ connector.
{0.7 kg/cm2} sensor 3) Connect
E11 terminal T-adapter.
(★) Max. 0.03 MPa – Max. 1Ω 4) Engine
{0.3 kg/cm2} Chassis started.
Engine oil pressure

switch
If the condition is as shown in the table
Measure voltage
below, it is normal
Min. 0.05 MPa Between
R17 {0,5 kg/cm2} sensor 20 – 30 V
(★★) R17(A)
Max. 0.05 MPa –
{0,05 kg/cm2} Max. 1V
Chassis
(★) Serial No.: 50001 – 52000

20-10 WA600-3
(16)

2) Disconnect
Measure resistance
Accumlator pressure: connector.
Min 5.39 ± 0.49 MPa Max. 1 Ω 3) Connect
Brake accumulator {5.39 ± 0.49 kg/cm2} T-adapter.
C03 (male) Between
low pressure switch C04 (male) Depress brake pedal (1) – (2)
and lower accumlator
pressure to below Min. 1 MΩ
4.41 ± 0.49 MPa
{45 ± 5 kg/cm2}

Measure resistance
2) Disconnect
Normal temperature Approx. connector.
(25˚C) Between 40 kΩ 3) Connect
Engine coolant (1) – (2) Approx. T-adapter.
E04 (male) 100 ˚C
temperature sensor 3.7 kΩ
Maintenance monitor

Measure resistance

2) Disconnect
Normal temperature Approx. connector.
E07 (male) (25˚C) Between 40 kΩ 3) Connect
Torque converter oil
temperature sensor (1) – (2) T-adapter.
100 ˚C Approx.
3.7 kΩ

switch OFF.
Measure resistance
below, it is normal
2) Disconnect
Oil level normal Between Max. 1 Ω terminal.
Oil level abnormal (1) – (2) Min. 1 MΩ
Engine oil lever switch E10

Measure continuity
2) Disconnect
connector.
Air cleaner normal Between Continuity 3) Start engine.
E13 (1) 4) Measure
E13 (male) No
Dust indicator
E14 (male) Air cleaner clogged – E14 (1) Continuity continuity.
WA600-3 20-11
(16)
Sys- Measurement
Name of component Judgement table
tem conditions
If the condition is as shown in Table 1, the monitor panel is 1) Turn starting
normal switch OFF.
2) Insert T-
Table 1 adapter.
Connec- Monitor item Measurement Display Sensor
tor No. (input connector) conditions signal
Engine coolant Engine stopped, Flashing 15 – 20 V
level starting switch ON
((8)–(3),(14)) OFF Max. 1 V
Engine oil Engine stopped, Flashing 15 – 20 V
level starting switch ON
CHECK items ((13)–(3),(14)) OFF Max. 1 V
CAUTION items Engine oil Flashing 15 – 20 V
pressure Engine running
L18 ((10)–(3),(14)) OFF Max. 1 V
(male) Brake oil Flashing 15 – 20 V
pressure Engine running
((11)–(3),(14)) OFF Max. 1 V
Battery charge Engine running Flashing Max. 10 V
((12)–(3),(14)) OFF Min. 12 V
Air cleaner Flashing 15 – 20 V
((15)–(3),(14))
Engine running
OFF Max. 1 V
Table 2 1) Turn starting

switch OFF,
Display level according then insert
Gauge display to sensor resistance dummy
resistance or
Maintenance monitor
(Starting switch ON) (Starting switch OFF) measure

resistance of
Min. Green 6 0 – 15.7 sensor.
Green 1
Green 2
Green 3
Green 4
Green 5
Green 6
Fuel level Green 5 12.6 – 24.0 2) Turn starting

Red
gauge Green 4 20.5 – 30.6 switch ON and

L18 (male)  check display.
Measure Green 3 26.7 – 39.6
resistance E F Green 2 35.2 – 51.6
between (6)
– (3), (14) Red Green 1 46.5 – 80.6
Green
Flash-  ON  Max. Red 73.8 –
ing ←→  ← (Ω)
67 102130°C
  
Engine Min. Red 2 0.24 – 3.47
Green 1
Green 2
Green 3
Green 4
coolant Red 1 3.13 – 3.75

White
Red 1
Red 2
Gauge tempera-
ture gauge Green 4 3.39 – 4.26
L18 (male) 
Green 3 3.85 – 5.14
Measure
resistance E F Green 2 4.65 – 6.94
between (4) Green 1 6.27 –10.26
– (3), (14) White Green
→ ON  Red
←→
Max. White 9.29 –
 (1 place)
Flashing
 (1 place) (kΩ)
50 120130°C
   Min. Red 2 0.24 – 1.90
Torque
Red 1 1.68 – 2.40
Green 1
Green 2
Green 3
Green 4
Green 5
converter
Red 1
Red 2
oil Green 5 2.15 – 3.05

tempera- 
ture gauge Green 4 2.74 – 5.14
L18 (male) Green 3 4.65 – 9.39
Measure E F
resistance Green 2 8.43 –18.18
between (5)  Green Max. Geeen 1 15.88 –
 Red
– (3), (14) → ON ←→
 Flashing
(kΩ)
(1 place) (1 place)
20-12 WA600-3
(16)

Measure continuity
2) Disconnect
Between (1) – (2) Continuity connectors.
ON 3) Connect
Between (3) – (4) Continuity
T-adapter.
APS switch L74 Between (1) – (2) No continuity
AUTO
Between (3) – (4) Continuity
Between (1) – (2) No continuity
OFF
Between (3) – (4) No continuity

resistance
Measure
APS coolant 2) Disconnect

temperature sensor
Between Up tp 20˚C Max. 0.5 Ω connector.
E05 (male) terminal
– chassis 20˚C and up Min. 1 MΩ

resistance
Measure
Glow plug 2) Disconnect

No.1 Between connector.
E02 (male) glow plug (1) –␣ chassis
APS contoller system (★)
0.8 –␣ 1.3 Ω
No.2 Between
glow plug (4) –␣ chassis

resistance
Measure
2) Disconnect
APS nozzle Between nozzle terminals 1.5 – 2.5 Ω terminals.
—

below, it is normal switch ON.
Measure
2) Insert
voltage
L71 Between L72 (1) – L71 (1) 20 – 30 V T-adapter.

Power source L72

APS contoller

Measure
2) Insert
voltage
APS coolant Up tp 20˚C Max. 1 V T-adapter.

temperature L71 Between
sensor (1) – (2) 20˚C and up 7 – 10 V

Measure
2) Insert
voltage
L72 Between ASP stopped Max. 1 V T-adapter.

Glow plug 1 L71 L72 (2)
– L71 (1) ASP operating 4 – 12 V
(★) Serial No.: 50001 – 52000
20-14 WA600-3
(16)

Measure
voltage
2) Insert
Glow plug 2 L72 (3)
L71
– L71 (1) ASP operating 4 – 12 V

Measure below, it is normal switch ON.
voltage
2) Insert
APS nozzle
APS contoller system (★)
L71 L72 (4)

– L71 (1) ASP operating 0.4 – 5 V
APS contoller

Measure
voltage
Engine starting 2) Insert

Between (3) – (1) 10 – 24 V T-adapter.
signal of starting L71
switch

Measure voltage

2) Insert
Between ASP stopped Max. 1 V T-adapter.
Monitor lamp
signal of L71 (4) – (1) ASP operating 12 – 20 V ª
preheating
ª Voltage is kept 12 –␣ 20 V for 12 seconds
after starting switch ON, then goes
down to below 1V.
Pre-heat system (★★)

2) Connect
Measure
Between (2) –␣ chassis 20 – 30 V T-adapter.

voltage
3) Turn starting
Pre-heat power HEAT ª When coolant temperature is main- switch ON.
tained at lower than 0ºC for more than
30 seconds.
(★) Serial No.: 50001 – 52000

WA600-3 20-15
(16)
FOR MACHINE WITH JOYSTICK AND AUTMATIC SHIFT CONTROL
Only specific items are described for machine with joystick and automatic shift control.
Name of Connector Inspection Measurement
System Judgement table
component No. method conditions
Measure voltage
below, it is normal. switch OFF.
Between C1(7), (13) – chassis 2) Insert T-
adapter.
Power supply C1 3) Turn starting
Between C2(1), (12) – chassis
C2 switch ON.
20 – 30 V
Between C1(7), (13) – (6), (12)
Between C2(1), (12) – (11), (21)
Measure voltage

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

Transmission & Joystick steering control
Measure
voltage
Turn parking brake 2) Insert T-

Parking L01 20 – 30 V adapter.
brake switch switch ON Between
3) Turn starting
Turn parking brake (1) – (3) Max. 1 V switch ON.
switch OFF

resistance
Measure

Solenoid T01 2) Disconnect
(1st) (male) Between (H) – (B) 50 – 70 Ω connectors.
Between (H), (B) – chassis Min. 1 MΩ 3) Connect T-
adapter.

resistance
Measure

(2nd) (male) Between (G) – (B) 50 – 70 Ω connectors.
Between (G), (B) – chassis Min. 1 MΩ 3) Connect T-
adapter.

resistance
Measure

(3rd) (male) Between (F) – (B) 50 – 70 Ω connectors.
Between (F), (B) – chassis Min. 1 MΩ 3) Connect T-
adapter.
resistance
Measure

(4th) (male) Between (E) – (B) 50 – 70 Ω connectors.
Between (E), (B) – chassis Min. 1 MΩ 3) Connect T-
adapter.

resistance
Measure

Between (D) – (A) 50 – 70 Ω connectors.
(F) (male)
Between (D), (A) – chassis Min. 1 MΩ 3) Connect T-
adapter.
20-16 WA600-3
(15)
Name of Connector Inspection Measurement

System Judgement table
component No. method conditions
resistance
Measure
(R) (male) Between (C) – (A) 50 – 70 Ω connectors.
Between (C), (A) – chassis Min. 1 MΩ 3) Connect T-
adapter.
resistance
Measure
Engine speed E06 2) Disconnect
sensor (male) Between (1) – (2) 500 – 1000 Ω connectors.
Between (1), (2) – chassis Min. 1 MΩ 3) Connect T-
adapter.
Measure in AC range 1) Turn starting

Controller
Measure
switch OFF.
voltage
Engine Between (2) – (9) Min. 0.5 V 2) Insert T-

C4 adapter.
speed
3) Start engine.
Adjust
1) Screw in until the tip of sensor contacts

Engine speed — gear, then turn back 1 turn. —
2) It works normally by adjustment above.
Transmission & Joystick steering control

resistance
Measure

T05 2) Disconnect
Speed Between (1) – (2) 500 – 1000 Ω connectors.
(male)
Between (1), (2) – chassis Min. 1 MΩ 3) Connect T-
adapter.
1) Screw in until the tip of sensor contact

Adjust
Speed — gear, then turn back 3/4 –1 turn.

—
2) Sensor should work normally when
adjusted as above.
Measure
Speed
voltage
control Speed control lever 2) Insert T-

at 1st Between 20 – 30 V adapter.
lever (7) – 3) Turn starting
(1st) Speed control lever chassis switch ON.
Max. 1 V
not at 1st

Measure
Speed
voltage
control Speed control lever Between 2) Insert T-

at 2nd 20 – 30 V adapter.
(2nd) Speed control lever chassis switch ON.
Controller
Max. 1 V
not at 2nd

Measure
Speed
voltage

C3B Between 20 – 30 V adapter.
lever at 3rd
(3rd) Speed control lever chassis switch ON.
Max. 1 V
not at 3rd

Measure
Speed
voltage

at 4th Between 20 – 30 V adapter.
(4th) Speed control lever chassis switch ON.
Max. 1 V
not at 4th
WA600-3 20-17
(15)
TESTING AND ADJUSTING
Table of tools for testing, adjusting, and troubleshooting ................................................................... 20-102

Measuring engine speed ..................................................................................................................... 20-103-2
Measuring exhaust gas color .............................................................................................................. 20-105-1
Adjusting valve clearance .................................................................................................................... 20-105-2
Testing and adjusting injector lift (Serial No. : 52001 and up) .......................................................... 20-106-1
Measuring compression pressure ......................................................................................................... 20-107
Measuring blow-by pressure ................................................................................................................. 20-108
Measuring engine oil pressure .............................................................................................................. 20-109
Testing and adjusting fuel injection timing (Serial No. : 50001 – 52000) ............................................ 20-110
Replacing fan belt adjusting auto-tensioner ......................................................................................... 20-112
Testing and adjusting alternator belt tension ....................................................................................... 20-113
Testing and adjusting belt tension for air conditioner compressor ................................................. 20-113-1
Handling eqipment in fuel circuit (Serial No. : 52001 and up) .......................................................... 20-113-2
Measuring fuel pump output port pressure (Serial No. : 52001 and up) ......................................... 20-113-2
Bleeding air from fuel circuit (Serial No. : 52001 and up) ................................................................. 20-113-3
Measuring exhaust temperature ............................................................................................................ 20-114
Measuring air supply pressure (boost pressure) .................................................................................. 20-115
Adjusting speed sensor .......................................................................................................................... 20-116
Adjusting fuel control cable (Serial No. : 50001 – 52000) .................................................................... 20-117
Method for adjusting engine stop motor cable (Serial No. : 50001 – 52000) ..................................... 20-118
Testing and adjusting torque converter, transmission oil pressure .................................................... 20-120
Procedure for flushing torque converter, transmission hydraulic circuit ........................................... 20-125
Procedure for moving machine when transmission valve fails .......................................................... 20-126
Testing and adjusting steering oil pressure .......................................................................................... 20-128
Testing and adjusting steering stop valve ............................................................................................. 20-130
Testing brake oil pressure ....................................................................................................................... 20-131
Measuring wear of brake disc ................................................................................................................ 20-132
Measuring brake performance ............................................................................................................... 20-133
Testing and adjusting parking brake ...................................................................................................... 20-134
Testing and adjusting accumulator charge cut-in and cut-out pressure ............................................ 20-136
Testing and adjusting PPC oil pressure ................................................................................................. 20-137
Measuring work equipment hydraulicpressure .................................................................................... 20-139
Adjusting work equipment lever linkage .............................................................................................. 20-141
Testing and adjusting of bucket positioner ........................................................................................... 20-143
Testing and adjusting of boom kick-out ................................................................................................ 20-144
Testing proximity switch actuation pilot lamp ...................................................................................... 20-145
Adjusting main monitor (speedometer module) .................................................................................. 20-146
Bleeding air .............................................................................................................................................. 20-147
Releasing remaining pressure in hydraulic circuit ............................................................................... 20-148
Pm clinic inspection table ....................................................................................................................... 20-149
WA600-3 20-101
(11)
TABLE OF TOOLS FOR TESTING, ADJUSTING,
TESTING AND ADJUSTING AND TROUBLESHOOTING
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND

TROUBLESHOOTING
Serial No. : 50001 – 52000
Test, measurement item Symbol Part No. Part Name Remarks
Engine speed A 799-205-1100 Tachometer kit Digital display: 6.0 – 99,999.9 rpm
Coolant, oil, exhaust Digital temperature
temperatures B 799-101-1502 –99.9 to + 1,299°C
gauge
2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Analog hydraulic tester Pressure gauge:
{25, 60, 400, 600 kg/cm2}
1
790-261-1204 Digital hydraulic tester
Oil pressure C 2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}

Both male and female 14 × 1.5
790-261-1311 (female PT 1/8)
3 Adapter
790-261-1321 (female PT 1/8)
1 795-502-1590 Compression gauge
Compression pressure D 0 – 6.9 MPa {0 – 70 kg/cm2}
2 795-502-1350 Adapter Kit part No. : 795-502-1205
1 799-201-1504 Blow-by checker —

Blow-by pressure E
2 799-201-1590 Gauge 0 – 98 kPa {0 – 1,000 mmH2O}
Valve clearance Commercially

F available Feeler gauge
1 799-201-9001 Handy smoke checker Bosch index: 0 – 9

Exhaust color G
Commercially
2 available Smoke meter
Air supply pressure –101.3 to + 199.9 kPa
(boost pressure) H 799-201-2202 Pressure gauge {–760 to + 1,500 mmHg}
1 793-520-1805 Brake test kit —
Brake oil pressure I 2 • 793-520-1851 Nipple —
3 790-301-1230 Elbow Kit part No. : 799-101-5002
1 79A-264-0020 0 – 294.2N {0 – 30 kg}

Operating effort J Push-pull scale
2 79A-264-0090 0 – 490.3N {0 – 50 kg}
Commercially
Stroke, hydraulic drift K available Scale
Commercially
Work equipment speed L available Stopwatch —
Measuring brake disc Commercially
M available Caliper gauge —
wear
Measuring voltage, N 79A-264-0211 Tester —
resistance value
Adjusting fuel injection P 795-471-1200 Gauge assembly  Dial gauge is commercially 
timing  available 
1 799-601-7400 T-adapter assembly —
2 799-601-3460 MS 10P
Troubleshooting of Q
wiring harness, sensors
3 799-601-7360 Adapter Relay 5P
4 799-601-7370 Relay 6P
20-102 WA600-3
(16)

Engine speed A 799-205-1100 Tachometer kit Digital display: 6.0 – 99,999.9 rpm
Digital temperature
1 799-101-1502 gauge –99.9 to + 1,299°C
Coolant, oil, exhaust
temperatures B
2 — Heat gun
(surface temperature gauge)
2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Analog hydraulic tester Pressure gauge:
{25, 60, 400, 600 kg/cm2}
1
790-261-1204 Digital hydraulic tester
Oil pressure C 2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}

790-261-1311 (female PT 1/8)
3 Adapter
790-261-1321 (female PT 1/8)
1 795-502-1590 Compression gauge
Compression pressure 0 – 6.9 MPa {0 – 70 kg/cm2}
D
Kit part No. : 795-502-1205
2 795-502-1350 Adapter
799-201-1504 Blow-by checker

Blow-by pressure E
799-201-1590 Gauge 0 – 98 kPa {0 – 1,000 mmH2O}
1 6162-23-4500 Barring device

Valve clearance F
2 Commercially Feeler gauge
available
1 799-201-9001 Handy smoke checker Bosch index: 0 – 9
Exhaust color G
Commercially Smoke meter
2 available
Air supply pressure (boost Pressure gauge –101.3 to + 199.9 kPa
H 799-201-2202 {–760 to + 1,500 mmHg}
pressure)
1 793-520-1805 Brake test kit —
Brake oil pressure I 2 • 793-520-1851 Nipple —
3 790-301-1230 Elbow Kit part No. : 799-101-5002
1 79A-264-0020 0 – 294.2N {0 – 30 kg}

Operating effort J Push-pull scale
2 79A-264-0090 0 – 490.3N {0 – 50 kg}
Commercially Scale
Stroke, hydraulic drift K available
Commercially Stopwatch —
Work equipment speed L available
Measuring brake disc Commercially Caliper gauge —
wear M available
Measuring voltage, 79A-264-0211 Tester —
resistance value N
Adjusting fuel injection
P 795-471-1200 Gauge assembly  Dial gauge is commercially 
timing  available 
WA600-3 20-103
(16)
1 799-601-7400 T-adapter assembly —
2 799-601-3460 MS 10P
3 799-601-7360 Adapter Relay 5P
4 799-601-7370 Relay 6P
Cable Atmospheric pressure

5 795-799-5460 (cummins No.: 3824774) Fuel rail pressure sensor
Timing rail pressure actuator
Cable Fuel pump actuator
6 795-799-5470 (cummins No.: 3824775) Fuel rail actuator
Timing rail actuator
Cable Engine oil pressure sensor
7 795-799-5480 (cummins No.: 3824776) Boost pressure sensor
Fuel pump pressure sensor
Troubleshooting of
wiring harness, Q 8 795-799-5520 Socket (S) For speed sensor 1 and 2
sensors
9 Socket (C) For fuel temperature sensor
795-799-5530 For coolant temperature sensor
10 795-799-5540 Socket (A) For intake air temperature sensor
12 799-601-9020 DT 2P
13 799-601-9050 DT 6P
14 799-601-9270 HD30 – 24 – 21P

Adapter
15 799-601-9290 HD30 – 24 – 31P
16 799-601-9350 DRC26 – 40P
17 799-601-9360 DRC26 – 24P
20-103-1 WA600-3
(14)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

Serial No. : 50001 – 52000
¤ Put blocks securely under the tires.
¤ When removing or installing the measuring
equipment, be careful not to touch any high tem-
perature parts.
¤ Before starting measurement, check that there
is no one in the surrounding area.
fl Measure the engine speed under the following
conditions.
• Coolant temperature: Within green range
• Hydraulic temperature: 45°C – 55°C
• Power train oil temperature: 70°C – 90°C
1. Measuring engine speed (low idle and high

idle)
1) Remove plug (1) from the engine speed pick-
up port.
2) Install nut of tachometer kit A, then connect
bracket [1], probe and tachometer.
3) Start the engine and measure the engine
speed at high idle and low idle.
2. Measuring torque converter stall speed

1) Install the tool same as procedure 1.
2) Start the engine.
3) Turn the transmission cut-off selector switch
(2) OFF and depress the left brake securely.
(Check that the transmission cut-off selector
pilot lamp is OFF.)
4) Place the gearshift lever at F4 or R4.
• For machines equipped with automatic
transmission, turn the main monitor
manual switch ON and place the speed
lever at F4 or R4.
5) Release the parking brake.
6) Depress the accelerator pedal gradually to
raise the engine speed to high idle, then mea-
sure the engine speed when the torque conver
ter stalls.
fl Avoid stalling more than 20 seconds and prevent
the torque converter oil temperature from going
above 120˚C.
WA600-3 20-103-2
(16)
3. Measuring hydraulic stall speed

2) Start the engine and run at high idle.
3) Extend the lift cylinder or bucket cylinder and
measure the engine speed when the circuit is
relieved.
4. Measuring torque converter stall + hydraulic

stall (full stall) speed
OFF and depress the left brake securely.
pilot lamp is OFF.)
lever at F4 or R4.
6) Run the engine at high idle and stall the torque
converter, and at the same time, extend the
lift cylinder or bucket cylinder and measure
the engine speed when the circuit is relieved.
20-103-3 WA600-3
(16)

¤ Put blocks securely under the tires.
¤ When removing or installing the measuring
equipment, be careful not to touch any high tem-
perature parts.
¤ Before starting measurement, check that there
is no one in the surrounding area.
fl Measure the engine speed under the following
conditions.
• Coolant temperature: Within green range
• Hydraulic temperature: 45°C – 55°C
• Power train oil temperature: 70°C – 90°C
1. Measuring engine speed (low idle and high

idle)
1) Stick the reflective tape of tachometer kit A to
crankshaft pully.
2) Set the probe of tachometer kit A by stand to
the front of reflective tape, then connect to
tachometer.
3) Start the engine and measure the engine
speed at high idle and low idle.
2. Measuring torque converter stall speed

1) Set the tool same as procedure 1.
(2) OFF and depress the left brake securely.
pilot lamp is OFF.)
lever at F4 or R4.
6) Depress the accelerator pedal gradually to
raise the engine speed to high idle, then mea-
sure the engine speed when the torque conver
ter stalls.
fl Avoid stalling more than 20 seconds and prevent
the torque converter oil temperature from going
above 120˚C.
20-104 WA600-3
(16)
3. Measuring hydraulic stall speed

2) Start the engine and run at high idle.
3) Extend the lift cylinder or bucket cylinder and
measure the engine speed when the circuit is
relieved.
4. Measuring torque converter stall + hydraulic

stall (full stall) speed
OFF and depress the left brake securely.
pilot lamp is OFF.)
lever at F4 or R4.
6) Run the engine at high idle and stall the torque
converter, and at the same time, extend the
lift cylinder or bucket cylinder and measure
the engine speed when the circuit is relieved.
WA600-3 20-105
(16)
TESTING AND ADJUSTING ADJUSTING MAIN MONITOR
ADJUSTING MAIN MONITOR

(SPEEDOMETER MODULE)
• The speedometer on the main monitor is a com-
mon part for all machines, and the input signal
for the travel speed differs according to the ma-
chine, so it is necessary to adjust the monitor for
use with the particular model.
• In addition, the tire diameter also differs accord-
ing to the type of tire fitted, so it is necessary to
adjust to give the correct travel speed.
• It is also necessary to change the switches if the
optional E.C.S.S. (Electronically Controlled Sus-
pension System) is installed.
Adjustment procedure
• Turn off the power, then remove the machine
monitor and adjust the switches at the back of
the speedometer.
1. Setting machine model
1) Remove the rubber caps from dipswitches (1),
(2) and (3) at the back of the speedometer.
2) When the rubber cap is removed, a rotary
switch can be seen inside. Using a flat-headed
screwdriver, turn this switch to adjust it to the
settings in the table below.
DIP SW 1 DIP SW 2 DIP SW 3

(model (speed- (tachom-
Tire size ometer cor- eter input
selection)
rection) selection)
35-65-33-24PR
6 7 0
(STD)
29.5-29-28PR
(OPT) 6 A 0
3) When the cap is removed from dipswitch (4)

at the back of the speedometer, an ON/OFF
switch can be seen.
Adjust the setting if the E.C.S.S. (Electronically
Controlled Suspension System) is installed.
DIP SW 4
Switch
No. Without With
E.C.S.S. E.C.S.S.
Reference
1 ON ON
Amount of correction for switch (2)
2 ON ON
3 ON OFF Switch position 0 1 2 3 4 5 6 7
4 ON ON Amount of
correction (%) +14 +12 +10 +8 +6 +4 +2 +0
4) After completing the adjustment, fit the rub-
ber caps securely and install the main moni-
Switch position 8 9 A B C D E F
tor.
fl Before installing the main monitor, check Amount of
correction (%) 0 –2 –4 –6 –8 –10 –12 –14
again that its setting is matched to the speci-
fication of the machine.
20-146 WA600-3
(11)
Pm CLINIC INSPECTION TABLE WA600-3 # 52001 and up
Machine Serial No. #
HOUR INSPECTION Mounted Engine SAA6D170E-3
Work instruction No. Date of execution Service meter Inspector

Year: Month: Day:
hours
INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK
Is there abnormality before starting inspection? Ambient temperature
.............................................................................................................................................................................................................................................
Max.: ˚C
............................................................................................................................................................................................................................................. Min.: ˚C
.............................................................................................................................................................................................................................................
Height: m
What is maximum level of coolant temperature? What is maximum level of torque converter and
(During work) transmission oil temperature? (During work)
White Green Green Green Green Red Red Green Green Green Green Green Red Red
1 2 3 4 5 6 7 1 2 3 4 5 6 7
fl AFTER STARTING ENGINE

Standard value Service Measurement
Item Condition Unit for new machine limit value result Good Bad
Low idle 675 – 725 —
High idle 2,125 – 2,225 2,075 – 2,275
Engine speed Torque converter stall rpm 2,000 – 2,200 1,900 – 2,300
Hydraulic stall 2,030 – 2,230 1,930 – 2,330
Full stall 1,640 – 1,840 1,440 – 2,040
kPa Max. 3.9 Max. 7.9
Blow-by pressure Torque converter stall {mmAq} {Max. 400} {Max. 800}
Engine
0.39 – 0.54 Min. 0.21

Engine: Full throttle {4.0 – 5.5} {Min. 2.1}
SAE30
MPa Min. 0.12 Min. 0.07
Engine pressure Engine: Low idle {Min. 1.2} {Min. 0.7}
{kg/cm2}
Min. 0.1 Min. 0.07
SAE10W Engine: Low idle {Min. 1.0} {Min. 0.7}
Torque converter stall with engine at full kPa Min. 113 Min. 100
Boost pressure throttle {mmHg} {Min. 850} {Min. 750}
Ambient temperature -–- -–-
Exhaust ˚C
temperature Torque converter stall with engine at full Max. 680 Max. 700
throttle
Inlet pressure 1 Engine: Full throttle 0.68 – 0.88 0.68 – 0.88

T/C
MPa {7.0 – 9.0} {7.0 – 9.0}

Torque converter oil temperature: 60 – 80˚C
{kg/cm2} 0.29 – 0.39 0.29 – 0.39
Outlet pressure 2 Transmission: Neutral
{3.0 – 4.0} {3.0 – 4.0}
fl WHEN THE TRANSMISSION IS IN THE SPEED RANGE, APPLY THE BRAKE FULLY
2.74 – 3.14 2.74 – 3.14
Main relief pressure P6 Transmission: Neutral
{28.0 – 32.0} {28.0 – 32.0}
Modulating pressure in Directional lever: Neutral 2.74 – 3.14 2.74 – 3.14

Gearshift lever:
N and 1st P1 2nd → 1st {28.0 – 32.0} {28.0 – 32.0}
Directional lever: Neutral 1.66 – 1.86 1.66 – 1.86
Transmission
Modulating pressure P3 Gearshift lever: Engine:

1st → 2nd {17.0 – 19.0} {17.0 – 19.0}
Low idle
Modulating pressure in Directional lever: Neutral Oil MPa 2.74 – 3.14 2.74 – 3.14
Gearshift lever: {kg/cm2}
N & 3rd P1 2nd → 3rd temperature: {28.0 – 32.0} {28.0 – 32.0}
(SAE30)
Modulating pressure in Directional lever: Neutral 70 – 90˚C 2.74 – 3.14 2.74 – 3.14
Gearshift lever:
N & 4th P1 3rd → 4th {28.0 – 32.0} {28.0 – 32.0}
Modulating pressure in Directional lever: 2.74 – 3.14 2.74 – 3.14

Neutral → F
F & 4th P1 Gearshift lever: 4th {28.0 – 32.0} {28.0 – 32.0}
Modulating pressure in Directional lever: 2.74 – 3.14 2.74 – 3.14

Neutral → R
R & 4th P1 Gearshift lever: 4th {28.0 – 32.0} {28.0 – 32.0}
WA600-3 20-149
(16)
WA600-3 # 52001 and up
Standard value Service Measurement
Item Condition Unit for new machine limit value result Good Bad
Operating Right lock Engine: Low idle Oil Max. 5.8 Max. 6.5
time of (Left lock) - temperature: sec
Steering
steering Left lock

45 – 55˚C
wheel (Right lock) Engine: Full throttle Max. 4.1 Max. 5.0
APPLY THE WORK EQUIPMENT LOCK LEVER TO THE FRAME

Engine: Full throttle MPa 20.3 – 21.6 19.3 – 21.6
Relief pressure Oil temperature: 45 - 55˚C {kg/cm2} {207 – 220} {197 – 220}
Pad thickness (including backing) 31.4 – 32.0 12.7

Parking brake sec
Clearance between pad and disc 0.88 – 1.24 2.1
Front right
Brake
Wear of brake disc Front left

Wheel brake (Measured by piston mm 6.9 – 8.1 Max. 13.4
stroke) Rear right
Rear left
5.9 – 6.4 5.4 – 6.9
Charge cut-in pressure
Accumulator charge Engine: MPa {60 – 65} {55 – 70}
pressure Low idle {kg/cm2} 9.8 – 10.8 9.3 – 11.3
Charge cut-out pressure
{100 – 110} {95 – 115}
Hydraulic oil temperature ˚C — —

Hydraulic equipment
Work equipment valve Engine: Full throttle MPa 20.3 – 21.1 19.3 – 21.1
relief pressure Oil temperature: 45 – 55˚C {kg/cm2} {207 – 215} {197 – 215}
Raising with engine at full throttle 7.4 – 8.4 Max. 9.0
Lift arm speed
Lowering with engine at full throttle 4.3 – 5.3 Max. 6.0
sec
Full stroke 2.7 – 3.3 Max. 4.0
Tilting back with engine
Bucket speed and full throttle Bucket:
Horizontal 1.8 – 2.4 Max. 3.0
SET THE LIFT ARM AND BUCKET IN THE MEASURING POSITION AND STOP THE ENGINE
Hydraulic drift of work Lift arm and bucket: Bucket cylinder mm/15 Max. 20 Max. 20
equipment Horizontal Lift cylinder minutes Max. 40 Max. 40
REPLACE PLUG WITH SPARE

Front axle
Axle
Visual check of Must be free from

Engine: Stopped fully extremely much metal dust
differential drain plug Rear axle
MEMO: Write a phenomenon, information, etc. detected by the check of today.
......................................................................................................................................................................................................................................................................................
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............................................................................................................................... ............................................................................................................................... .......................
............................................................................................................................... ............................................................................................................................... .......................
............................................................................................................................... ............................................................................................................................... .......................
............................................................................................................................... ............................................................................................................................... .......................
............................................................................................................................... ............................................................................................................................... .......................
............................................................................................................................... ............................................................................................................................... .......................
............................................................................................................................... ............................................................................................................................... .......................
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20-150 WA600-3
(16)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item standard Remedy
1. Check fuel level, type of fuel — Add fuel

Lubricating oil, engine coolant
2. Check for impurities in fuel — Clean, drain

3. Check hydraulic oil level — Add oil
4. Check hydraulic filter
. (Torque converte, Transmission hydraulic oil) — Clean, drain
5. Check brake oil level — Add oil

6. Check engine oil level — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

equipments
Electrical
10. Check for looseness, corrosion of alternater terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, —
wiring Tighten or replace
12. Check operation of instruments — Repair or replace

Hydtaulic, mechani-
cal equipments
13. Check for abnormal noise,smell — Repair
14. Check for oil leakage — Repair
15. Carry out air bleeding — Bleed air
16. Check effect of parking brake, wheel brake — Repair or replace
17. Check battery voltage (engine stopped) 24 – 26 V Replace
18. Check battery electrolyte level — Add or replace

Electrics, eiectrical equipment
19. Check for discolored, burnt, exposed wiring — Replace
20. Check for missing wiring clamps, hanging wiring — Repair
21. Check for water leaking on wiring (be particularly careful Disconnect
attention to water leaking on connectors or terminals) — connector and dry
22. Check for blown, corroded fuses — Replace
23. Check alternator voltage

(engine runing at 1/2 throttle or above)
(If the battery charge is low, the voltage may be approx. 28.5 – 29.5 V Replace
25V immediately after starting.)
24. Sound of actuation of battery relay

(when starting switch is turned ON, OFF) — —
20-212 WA600-3
(16)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

Serial No. : 50001 – 52000
fl The Address column in the table below shows the address in the connector arrangement drawing
(3-dimensional drawing).
Con- No. Con- No.
nector Type of Place of use Add- nector Type of Place of use Add-
No. pins ress No. pins ress
A02 Connector 1 Battery relay (BR) L3 B08 KES 1 2 Window washer (rear) H9
A03 Terminal 1 Battery relay (E) L3 BR1 SWP 6 Intermediate connector (bulk head) J2
A04 Connector 1 Battery relay (BR) L4 C01 X 2 Low pressure switch (emergency) H1
A4 X 2 Air conditioner air servo motor P6 C01 SWP 6 Front wiper motor B7
A05 Terminal 1 Battery relay (E) L4 C02 X 2 Lift arm proximity switch H1
A5 M 2 Air conditioner thermistor R5 C02 Yazaki 9 Cassette stereo B7
A6 SWP 6 Air conditioner air mixing motor R5 C03 X 2 Low pressure switch (brake) G1
A7 M 6 Air conditioner blower motor R5 C03 M 2 Front working lamp (R.H.) C8
A8A S 10 Intermediate connector (air conditioner) R4 C04 X 2 Low pressure switch (brake) G1
A8B S 8 Intermediate connector (air conditioner) R4 C04 M 2 Front working lamp (L.H.) D8
A9 Yazaki 4 Air conditioner blower relay (M) R2 C05 — 4 Beacon lamp switch D8
A10 Yazaki 4 Air conditioner blower relay (Hi) Q1 C06 KES 1 2 Room lamp E9
A11 Yazaki 4 Air conditioner blower relay (M2) R2 C07 M 4 Rear wiper motor H9
A12 Yazaki 4 Air conditioner condenser relay Q2 C08 Connector 1 Cigar lighter B7
A13 Yazaki 4 Air conditioner blower relay (M1) R2 C09 Connector 1 Cigar lighter C7
A14 X 2 Air conditioner switch R5 C11 Connector 1 Door switch (R.H.) E8
A14 Yazaki 4 Air conditioner condenser relay Q2 C12 Connector 1 Door switch (L.H.) G9
A15 Yazaki 2 Air conditioner switch R5 C13 KES 0 2 Speaker switch (L.H.) G9
A15 Yazaki 4 Air conditioner condenser relay R2 C14 KES 0 2 Speaker switch (R.H.) F9
A16 Yazaki 4 Air conditioner compressor relay Q2 C15 Connector 1 Beacon lamp D8
A16 AMP 12 Air conditioner controller P1 C16 M 2 Side working lamp (L.H.) G9
A17 AMP 16 Air conditioner controller P1 C17 M 2 Side working lamp (R.H.) E8
A18 SWP 8 Air conditioner air servo motor (L.H.) P1 CL1 S (blue) 12 Intermediate connector (cab harness) M3
A19 SWP 8 Air conditioner air servo motor (R.H.) M4 CL2 S 10 Intermediate connector (air conditioner) M3
AL1 MiC 21 ECSS (controller) M5 CL3 M 6 Intermediate connector (air conditioner) M3
AL2 AMP040 20 ECSS (controller) M5 CL4 M 6 Intermediate connector (power window) M3
AL3 AMP040 16 ECSS (controller) R6 CL18 Connector 1 Power window motor (L.H.) E1
AL4 M 6 ECSS (machine selection) P1 CL19 Connector 1 Power window motor (L.H.) E1
ASS X 2 Air suspension R5 CL20 Connector 1 Power window motor (R.H.) C7
B01 X 1 Air conditioner condenser I2 CL21 Connector 1 Power window motor (R.H.) C7
B02 X 2 Air conditioner condenser J2 CR1 X 4 Low pressure switch (brake) I1
B03 X 1 Air conditioner condenser L6 E01 Terminal 1 Slow blow fuse (80A) W3
B04 X 2 Air conditioner condenser L5 E02 X 4 Intermediate connector (glow plug) S6
B05 KES 1 2 Diode (window washer) I9 E03 SWP 8 Engine stop motor T2
B06 KES 1 2 Diode (window washer) I9 E04 X 2 Coolant temperature sensor T7
B07 KES 1 2 Window washer (front) H9 E05 Connector 2 APS coolant temperature sensor S5
ECSS : Electronically controlled suspension system
WA600-3 20-213
(16)
Con- No. Con- No.

E06 X 2 Engine speed sensor S4 FS1 L 2 Fuse I R6
E07 X 2 Torque converter temperature sensor S3 FS2 S (blue) 12 Fuse I Q6
E08 X 2 Starting motor U2 FS3 M 6 Fuse I Q6
E09 X 2 Starting motor T2 FS4 L 2 Fuse II Q6
E10 X 1 Engine oil level switch S2 FS5 M 6 Fuse II Q6
E11 Terminal 1 Engine oil pressure switch S5 FS6 M 4 Fuse II P6
E12 X 1 Air conditioner compressor switch V7 G01 X 2 Coolant level switch K9
E13 Connector 1 Dust indicator U7 G02 M 2 Working lamp (R.H.) J9
E14 Connector 1 Dust indicator U7 G03 M 2 Working lamp (L.H.) L8
E15 Terminal 1 Alternator (B) X5 G04 M 6 Rear combination lamp L8
E16 Terminal 1 Alternator (R) X7 G05 M 6 Rear combination lamp L6
E17 Terminal 1 Alternator (E) X6 GR1 SWP 6 Intermediate connector L7

(radiator harness)
E18 Terminal 1 GND L3 GRE SWP 6 Auto-grease (OP) R3
E19 KES 1 2 Diode (starting motor) X4 L01 SWP 6 Parking brake switch N2
E20 KES 1 2 Diode (starting motor) V3 L02 SWP 6 Light & dimmer switch N2
E21 KES 1 2 Diode (starting motor) V3 L03 SWP 6 Turn signal switch N2
E22 KES 1 2 Diode (starting motor) V2 L04 SWP 14 Transmission switch N1
E23 KES 1 2 Diode (Air conditioner compressor) V7 L05 AMP040 20 Main monitor M4
ECSS SWP 14 Intermediate connector (ECSS) R4 L06 AMP040 16 Main monitor M3
ER1 SWP 14 Intermediate connector (engine harness) U2 L07 AMP040 12 Main monitor M4
ER2 SWP 12 Intermediate connector (engine harness) V2 L08 AMP040 8 Main monitor M2
F01 M 3 Intermediate connector (head lamp R.H.) A6 L09 M 6 Starting switch M2

Intermediate connector
F02 M 3 (combination lamp R.H.) A6 L10 S 10 Wiper switch O1
F03 M 3 (combination lamp L.H.) E1 L12 X 2 Transmission cut off switch O1
F04 M 3 Intermediate connector (head lamp L.H.) D1 L15 M 4 Kick-down switch M5
F05 X 3 Bucket positioner proximity switch A2 L15 KES 1 2 Boom kick-out solenoid M5
F06 X 3 Boom kick-out proximity switch A1 L17 KES 1 2 Bucket positioner solenoid M4
F07 Connector 1 Horn (L.H.) A1 L18 AMP040 16 Maintenance monitor N6
F08 Connector 1 Horn (R.H.) A5 L19 AMP040 8 Maintenance monitor N6
F09 Connector 1 Horn (R.H.) A4 L21 KES 1 2 Maintenance monitor N6
F10 Connector 1 Horn (L.H.) B1 L22 KES 1 2 Maintenance monitor O6
F13 Terminal 1 GND (front frame) C1 L40 Yazaki 7 Power window switch (R.H.) N6
F14 X 2 Parking brake solenoid D1 L41 Yazaki 7 Power window switch (L.H.) M5
F15 X 2 Parking caution (monitor) C1 L42 Connector 1 Caution buzzer O6
FR1 S 10 Intermediate connector (front lamp) D8 L43 Connector 1 Caution buzzer O6
FR2 SWP 6 Intermediate connector F1 L44 KES 0 6 Wiper relay O6

(boom• bucket switch)
20-214 WA600-3
(16)
Con- No. Con- No.

L46 KES 1 4 Flasher unit O7 LR5 X 4 Intermediate connector (GND) R3
L48 — 5 Bucket relay N7 LR6 L 2 Intermediate connector (power supply) R3
L49 — 5 Lift arm relay N7 R01 X 2 Emergency steering switch H1
L51 — 6 Side working lamp relay O8 R03 KES 1 2 Diode (battery relay) K2
L52 — 5 Hazzard relay M7 R04 KES 1 2 Diode (battery relay) K3
L53 — 5 Stop lamp relay M8 R05 KES 1 2 Fuel level sensor J2
L55 — 5 Horn relay O8 R06 Terminal 1 Slow blow fuse (30A) X4
L56 — 5 ECSS relay M9 R07 Terminal 1 Slow blow fuse (30A) W3
L57 — 5 Neutral relay M8 R08 Terminal 1 Slow blow fuse (80A) W3
L58 — 5 Neutralizer relay M8 R09 Terminal 1 Slow blow fuse (80A) W3
L59 — 5 Parking brake safety relay M9 R10 Terminal 1 GND K3
L60 — 6 Front working lamp relay N9 R11 Terminal 1 Battery relay (M) L4
L61 — 6 Rear working lamp relay O9 R12 Terminal 1 Battery relay (B) L5
L62 — 5 Engine stop relay N9 R13 Terminal 1 Back buzzer L6
L63 Connector 8 Horn switch O1 R14 Terminal 1 Back buzzer L6
L64 — 5 Engine oil pressure switch M8 RA1 X 2 Intermediate connector (battery relay) L5
L65 — 5 Transmission cut off relay N9 T01 MS 10 Transmission control valve E9
L66 — 6 Traveling FORWARD relay O7 T02 KES 1 2 Diode (transmission control valve) F9
L67 — 6 Traveling REVERSE relay O8 T03 KES 1 2 Diode (transmission control valve) F1
L68 — 6 Kick down relay O8 T04 KES 1 2 Diode (transmission control valve) F9
L71 SWP 6 APS controller M5 T05 X 2 Speed sensor A2
L72 X 2 APS controller M4 TL1 SWP 2 Intermediate connector R3
L73 KES 1 2 Engine stop switch N1
L74 KES 1 4 Preheating switch M2
L75 KES 1 2 ECSS (Switch) P6
L76 — 5 2nd – 1st selector relay N7
L80 — 5 Dust indicator relay M8
L81 X 2 Stop lamp switch O1
L91 — 5 Power window relay (left rise) O9
L92 — 5 Power window relay (left lower) O8
L93 — 5 Power window relay (right rise) N9
L94 — 5 Power window relay (right lower) O9
LR1 S (blue) 12 Intermediate connector (lamp, horn) R4

LR2 SWP 14 (air conditioner, washer) R4
LR3 SWP 12 Intermediate connector (engine) R3
LR4 SWP 14 Intermediate connector (engine) R4
ECSS : Electronically controlled suspension system
WA600-3 20-215
(16)
Con- No. Con- No.

CL20 Connector 1 Power window regulator (R.H.) C7 ER3 X 3 Intermediate connector V1
CL21 Connector 1 Power window regulator (R.H.) C7 F01 M 3 Intermediate connector (head lamp R.H.) A6
CLTP Connector 2 Engine coolant temperature sensor T8 F02 M 3 (combination lamp R.H.) A6
CR1 X 4 Low pressure switch (brake) I1 F03 M 3 (combination lamp L.H.) E1
E01 Terminal 1 Slow blow fuse (80A) W2 F04 M 3 Intermediate connector D1

(head lamp L.H.)
E04 X 2 Water temperature sensor X4 F05 X 3 Bucket positioner proximity switch A2
E06 X 2 Engine speed sensor T2 F06 X 3 Boom kick-out proximity switch A1
E07 X 2 Torque converter temperature T2 F07 Connector 1 Horn (L.H.) A1

sensor(monitor)
E08 X 2 Starting motor U1 F08 Connector 1 Horn (R.H.) A5
E09 X 2 Starting motor T1 F09 Connector 1 Horn (R.H.) A4
E10 X 1 Engine oil level switch T5 F10 Connector 1 Horn (L.H.) B1
E12 X 1 Air conditioner compressor switch U9 F13 Terminal 1 GND (front frame) C1
E13 Connector 1 Dust indicator T3 F14 X 2 Parking brake solenoid D1
E14 Connector 1 Dust indicator T2 F15 X 2 Parking caution (monitor) C1
E15 Terminal 1 Alternator (B) S7 FLTP Connector 2 Fuel temperature sensor U9
E16 Terminal 1 Alternator (R) S6 FR1 S 10 Intermediate connector (front lamp) D8
E17 Terminal 1 Alternator (E) S7 FR2 SWP 6 F1
E18 Terminal 1 GND L3 FSO- Terminal 1 Fuel shutoff valve (-) S7
E19 KES 1 2 Diode (starting motor) X3 FSO+ Terminal 1 Fuel shutoff valve (+) S8
E20 KES 1 2 Diode (starting motor) X3 FS1 L 2 Fuse I Q6
E21 KES 1 2 Diode (starting motor) T1 FS2 S (blue) 12 Fuse I Q6
E22 KES 1 2 Diode (starting motor) T1 FS3 M 6 Fuse I Q6

E23 Connector 2 Diode (air conditioner compressor) U9 FS4 L 2 (lift arm, bucket switch) Q6
E24 Terminal 1 Heater relay V9 FS5 M 6 Fuse II P6
E25 Terminal 1 Heater relay W9 FS6 M 4 Fuse II P6
E26 Terminal 1 Heater relay U9 G01 X 2 Radiator water level sensor K9
E27 Terminal 1 Heater relay W9 G02 M 2 Working lamp (R.H.) J9
E31 Terminal 1 Slow blow fuse W2 G03 M 2 Working lamp (L.H.) L8
E32 Terminal 1 Slow blow fuse V1 G04 M 6 Rear combination lamp L8
E33 Terminal 1 Heater relay W9 G05 M 6 Rear combination lamp L6
ECMA DRC26 40 Engine controller T5 GR1 SWP 6 Intermediate connector L7

(radiator harness)
ECMB DRC26 40 Engine controller V9 GRE SWP 6 Auto-grease (OP) R3
ECB2 DT 2 — S6 GND Terminal 1 GND (OP) M2
ECSS SWP 6 Intermediate connector (ECSS) (OP) R4 GND Terminal 1 Engine block GND M2
ER1 SWP 14 Intermediate connector (engine harness) V1 GND Terminal 1 GND S6
ER2 SWP 14 Intermediate connector (engine harness) V1 GND Terminal 1 GND S7
WA600-3 20-219-2
(16)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
(Pin No. is printed on connector (wire insertion side), too.)

Type HD30 series connector
(Shell
size Part No. of
code) Body (Plug) Body (Receptacle)
T-adapter
Pin (male terminal) Pin (female terminal)
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
(7) Pin (female terminal) Pin (male terminal)
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102

08191-72205, 08191-72206 08191-73105, 08191-73106
Pin (male terminal) Pin (female terminal)
799-601-9280
Part No.:08191-81201,08191-81202,08191-81203, Part No.: 08191-84101,08191-84102,08191-84103,

24-23 08191-81204,08191-81205,08191-80206 08191-84104,08191-84105,08191-84106
(8) Pin (female terminal) Pin (male terminal)
799-601-9280
Part No.:08191-82201,08191-82202,08191-82203, Part No.:08191-83101,08191-83102,08191-83103,

08191-82204,08191-82205,08191-82206 08191-83104,08191-83105,08191-83106
20-228-4 WA600-3
(11)
DT series connector
c
Body (Plug) Body (Receptacle) Part No. of T-adapter
8GR :799-601-9060
8B :799-601-9070
8
8G :799-601-9080
8BR :799-601-9090
Part No.: 08192-18200 (Normal type) Part No.: 08192-18100 (Normal type)
08192-28200 (Fine wire type) 08192-28100 (Fine wire type)
12GR :799-601-9110
12B :799-601-9120
12 12G :799-601-9130
12BR :799-601-9140
Part No.: 08192-19200 (Normal type) Part No.: 08192-19100 (Normal type)
08192-29200 (Fine wire type) 08192-29100 (Fine wire type)
WA600-3 20-228-7
(11)

Type
(Shell DTM series connector
size
code) Body (Plug) Body (Receptacle) Part No. of T-adapter
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100

Type
(Shell DTHD series connector
size
code) Body (Plug) Body (Receptacle) Part No. of T-adapter
2 —
Part No.: 08192-31200 (Contact size #12) Part No.: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-228-8 WA600-3
(14)
AMP070 type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
10 799-601-7510
— Part No.: 7821-92-7330
12 799-601-7520
— Part No.: 7821-92-7340
14 799-601-7530
— Part No.: 7821-92-7350
18 799-601-7540
— Part No.: 7821-92-7360
20 799-601-7550
— Part No.: 7821-92-7370
WA600-3 20-228-9
(14)
[The pin No. is also marked on the connector (electric wire insertion end)]
DRC26 Series connector

No.of
pins T-adapter Part
Body (plug) Body (receptacle)
No.
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
20-228-10 WA600-3
(14)
T-BRANCH BOX AND T-BRANCH TABLE
a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker assembly.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
—
Part No. No. of pins
part name
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
799-601-7140 S 8P
WA600-3 20-228-11
(14)
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
—
Part No. No. of pins
part name
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD30 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DRC26 40P
799-601-9360 DRC26 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 press. 3P
799-601-9430 PVC socket 2P
20-228-12 WA600-3
(14)
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts ............................................................................................... 20-302

S- 1 Starting performance is poor (starting always takes time) ....................................................... 20-306
S- 2 Engine does not start
(1) Engine does not turn ............................................................................................................. 20-308
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ..................... 20-309
(3) Exhaust gas smoke comes out but engine does not start (fuel is being injected) ........... 20-310
S- 3 Engine does not pick-up smoothly (follow-up is poor) ............................................................. 20-311
S- 4 Engine stops during operations .................................................................................................. 20-312
S- 5 Engine does not rotate smoothly (hunting) ............................................................................... 20-313
S- 6 Engine lacks output (no power) .................................................................................................. 20-314
S- 7 Exhaust smoke is black (Incomplete combustion) .................................................................... 20-315
S- 8 Oil comsumption is excessive (or exhaust smoke is blue) ....................................................... 20-316
S- 9 Oil becomes contaminated quickly ............................................................................................. 20-317
S-10 Fuel consumption is excessive .................................................................................................... 20-318
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down ..................................... 20-319
S-12 Oil pressure lamp lights up (drop in oil pressure) ..................................................................... 20-320
S-13 Oil level rises ................................................................................................................................. 20-321
S-14 Coolant temperature becomes too high (overheating) ............................................................. 20-322
S-15 Abnormal noise is made .............................................................................................................. 20-323
S-16 Vibration is excessive ................................................................................................................... 20-324
WA600-3 20-301
(16)
TROUBLESHOOTING S-1
S-1 Starting performance is poor

(starting always takes time)
Causes
General causes why exhaust gas comes out but engine does
not start.
• Defective electrical system
uc k )
• Insufficient dupply of fuel
er st
• Insufficient intake of air
• Improper selection of fuel (At ambient temperature of –
at
lung
elem alve se
10°C or below, use ASTEM D975 No. 1)
nozz attery
ck, p
fl Battery charging rate
ent
e, v
devi trainer
Charging rate
p (ra
Ambient 100 % 90 % 80 % 75 % 70 %
ctive d pump iner
db
er
temperature
e
v
injec n timing
cont , cylind
l
rate
f val
20°C 1.28 1.26 1.24 1.23 1.22
ra
pum
s
ce
r, st
0°C 1.29 1.27 1.25 1.24 1.23
ctive ernator
ctive deterio
ner
act o
tion
lato
–10°C 1.30 1.28 1.26 1.25 1.24
tion
filte
ng
o
e
i
injec
• The specific gravity should exceed the value for the charging rate of 70%
Defe ve regu
Defe iston ri
t
APS
l
injec
air c
fuel
in the above table.
alt
fee
or
• In cold weather the specific gravity must be for the charging rate of at
ctive
ctive
least75% in the above table.
ged
ged
ged
tive
tive
np
cti
Clog
Clog
Clog
Defe
Defe
Defe
Defe
Defe
Defe
Wor
Confirm recent repair history
Degree of use Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Indicator lamp does not light up

Engine oil must be added more frequently
Replacement of filters has not been carried out according to operation manual
Dust indicator is red
Non-specified fuel has been used
Type of oil is not used according to operation manual
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Check items
Blow-by gas is excessive

Match marks on fuel injection pump are out of alignment
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When compression pressure is measured, it is found to be low

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Troubleshooting
APS combustion portion does not become warm

Voltage is 26–30V between alternator terminal B and terminal E Yes
with engine at low idle No
Either specific gravity of electrolyte or voltage of battery is low
Some cylinders does not change engine speed when operating on reduced cylinders
When check is made using delivery method, injection timing is found to be incorrect
When control rack is pushed, it is found to be heavy or does not return
(when blind plug at rear of pump is removed, it can be seen that plunger
control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged
When overflow valve is inspected, it is found to be stiff, or always stays open
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
: Possible cause (jugding from Questions and Check items)

Clean
Clean
Clean
: Most probable causes (judging from Questions and Check items) Remedy
: Possible causes due to length of use (used for a long period)
: Items confirm the cause
20-306 WA600-3
(16)
TROUBLESHOOTING S-2
S-2 Engine does not start

(1) Engine does not turn
General causes why engine does not turn

Causes
• Internal parts of engine seized
wire
fl If internal parts of the engine are seized, carry out
otor
troubleshooting for "Engine stops during opera-
op m
tions".
itch
n
ctio
• Failure in power train
ty s w
it
op m gine st
ttery
nne
circu
• Defective electrical system
al c o
s afe
otor
d ba
rting
f en
ch
or
rmin
Defe ve batte elay or
rate
nt o
f sta
lay
mot
swit
o
ctive ttery te
ry re
e
ctive gine st
ctive r deteri
ng o
stm
ting
ting
ty r
r
gea
adju
Defe ive safe
wiri
star
star
ba
en
ing
o
ctive
ctive
ctive
ctive
en r
cti
ct
Defe
Defe
Defe
Brok
Defe
Defe
Defe
Defe
Questions

Condition of horn when start- Horn does not sound
ing switch is turned ON Horn sound level is low
Rotating speed is slow
When starting switch is Makes grating noise
turned to START, pinion
moves out, but Soon disengages again
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not move out
Check items
wiring of starting circuit
When starting switch is turned to ON, there is no clicking

shooting for defective
sound
Carry out trouble-
Battery terminal is loose
When starting switch is turned to ON, linkage does not move
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) – 5), turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are
defective wiring of starting circuit
Carry out troubleshooting for
connected, engine starts

Troubleshooting
2) When terminal B and terminal C of starting motor are

3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
5) There is no 24V voltage between terminal B and terminal
E of battery relay
When ring gear is inspected directly, tooth surface is found to
be chipped
Does not move even when engine stop mtoro linkage is
disconnected
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
: Possible cause (jugding from Questions and

—
Remedy
Check items)
: Most probable causes (judging from Questions and
Check items)
20-308 WA600-3
(16)
TROUBLESHOOTING S-3
S-3 Engine does not pick-up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly Causes
r
leve
• Insufficient supply of fuel
stop
r
sato
y
spra
• Improper condition of fuel injection
mp
pen
seat
• Use of improper fuel
hole
n pu
tive
r pu ost com
e
enc
• Defective fuel injection pump
lve
ef ec
ectio
her
, va
rfer
mp
ent
ng
iner
r
ed p ozzle, d
reat
r
aine
j
p bo
alve
pipi
ce
inte
e
of in
lem
d
stra
aran
cylin
air b
, str
v
er e
pum
fuel
n ai
,
ump
ent
r
t of
ump
e
n
e cle
harg
r
ank
lean
,
n
stm
roke
filte
ring
king
ntac
ctio
hrag ction
ed p
valv
Clog d fuel t
adju
c
air c
m, b
fuel
urbo
inje
, lea
ston
e co
e fe
diap en inje
f e
r
rope
ged
ged
rope
ged
ged
ged
ctiv
ctiv
ed t
n pi
ge
Clog
Clog
Clog
Defe
Defe
Clog
Clog
k
Seiz
Wor
Imp
Imp
Bro
Replacement of filters has not been carried out according to
operation manual
Questions

Rust and water are found when fuel is drained
Noise of interference is heard from around turbocharger
Engine pick-up suddenly became poor
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Check items
There is leakage from fuel piping

High idle speed under no load is normal, but speed suddenly
drops when load is applied
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low

When fuel filter, strainer are inspected directly, they are found to be clogged
Some cylinders does not change engine speed when operating
on reduced cylinders
Troubleshooting
Inspect feed pump

When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When feed pump is operated, operation is too light or too heavy
When starting switch is turned ON, there is a clearance
between stop lever and stopper bolt
When boost compensator diaphragm is inspected it is found
to be broken, or pipe is crushed
Legend
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust
Clean
Clean
Clean
Clean
: Possible cause (jugding from Questions and Remedy

Check items)
Check items)
WA600-3 20-311
(16)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations Causes
• Internal parts of engine seized
)
)
tuck
etc.
er s
ver,
• Overheating
rod
lung
er le
fl If there is overheating and the engine stops, carry
ent
g
ting
ey
pum er hole
on
out troubleshooting for overheating.
ck, p
rock
arin
ft, k
ipm
pist
nec
in
• Failure in power train
ft be
er
p (r a
g
lve,
sha
r tra
equ
ipin
iner
con
rain
ath
p
fl If the engine stops because of a failure in the
train
pum
a
ksha
ive
owe
r bre
v
el p
y
stra
p st
on,
power train, carry out troubleshooting for the
r
xilia
em
p dr
cran
ear
feed
g fu
sis p
pist
i
pum
chassis.
ion
ter,
a
syst
p au
pum
tank
ed g
ject
l
zed
zed
has
zed
i
i
f
feed
k
e
fuel
, lea
pum
z
fuel
valv
e in
el
fuel
, sei
, sei
, sei
in c
, sei
of fu
ged
ged
ged
ctiv
ged
ken
ken
ken
ken
ken
ken
ken
ure
Clog
Lack
Clog
Defe
Clog
Clog
Bro
Bro
Fail
Bro
Bro
Bro
Bro
Bro
Abnormal noise was heard and engine
stopped suddenly
Condition when Engine overheated and stopped
engine stopped
Questions
Engine stopped slowly

There was hunting and engine stopped
Fuel gauge lamp lights up
Fuel tank is found to be empty
operation manual
When feed pump is operated, there is no response or it is heavy
Engine turns, but stops when transmission control lever is operated
Does not turn at all
Carry out troubleshooting
Check items
Try to turn by hand using Turns in opposite direction

in chassis volume
barring tool
Moves amount of backlash
Shaft does not turn

Rust and water are found when fuel is drained
Metal particles are found when oil is drained
Remove oil pan and inspect directly

Carry out troubleshooting in
Remove head cover and inspect directly

When gear train is inspected, it does not turn
Troubleshooting
Turns when pump auxiliary equipment is removed

When fuel filter, strainer are inspected directly, they are
chassis volume
found to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
Inspect feed pump directly
When control rack is pushed, it is found to be heavy or does
not return
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair

Clean
Clean
Clean
Remedy
Add
Check items)
Check items)
20-312 WA600-3
(16)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly Causes
p
le
pum
nozz
• Air in fuel system
eed
• Defective governor mechanism
and
nd f
um
nk a
ed p
hole
ck
rnor
el ta
ol ra
rnor
n fe
her
n fu
ove
er
ove
ontr
twee
reat
iner
rain
wee
of g
ump
of g
of c
t be
air b
stra
t bet
p st
ent
ed p
ino
rcui
o lo
ion
pum
lter,
ircui
stm
tank
erat
erat
in ci
el fe
s to
i
c
adju
f
feed
uel
air in
e op
fuel
e op
ed i
e fu
, air
el
f
of fu
e
ged
ged
spe
ctiv
ged
ctiv
ctiv
ged,
ged
ctiv
Clog
Clog
Defe
Defe
Clog
Defe
Lack
Defe
Clog
Low
Clog
Occurs at fixed speed range
Condition of hunting Occurs at low idle
Questions
Occurs even when speed is raised

Occurs on slopes
Fuel tank is found to be empty
operation manual
Rust is found when fuel is drained
When feed pump is operated,
1) No response, light, return is quick
Check items
2) No response, light, return is normal

Engine speed sometimes changes greatly
Sometimes difficult to stop engine
Seal on injection pump has come off
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
improperly adjusted
Troubleshooting
When control rack is pushed, it is found to be heavy or

does not return
When fuel cap is inpsected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
When fuel filter, strainer are inspected directly, they are found
to be clogged
Check fuel feed pump
Legend
Replace
Repair
Repair
Adjust
Adjust
Adjust
Adjust

Clean
Clean
Clean
Remedy
Add
Check items)
Check items)
WA600-3 20-313
(16)
TROUBLESHOOTING S-6
S-6 Engine lacks output

Carry out troubleshooting to decide if the cause is in the Causes
enginer or in the machine. (Measure engine stall speed).
phr ag m
t
men
General causes why engine lacks output
r dia
e ad at
ray
just
e se
high f stop le pensato

e sp
valv
hole
nce
ctiv
ctiv
ver
ger
om
fere
and
defe
ther
ent
er
ir br g
defe
ost c
plun
pum ainer
n
der
nter
rain
a
alve
lem
pipi
nce
zle,
• Use of Improper fuel
e
p bo
cylin
ge,
p st
er, i
mp
r
er e
a
of v
noz
(If non-specified fuel is used, output drops)
l
r
e
s
nka
clea
no
g fu
nk a
pum
n pu
,
harg
r
lean
ing,
• Lack of output due to overheating
tion
filte
tact
er li
sitio
akin
el ta
lve
Inco njection
o
fl If there is overheating and lack of output,
on r
boc
air c
con
c
eed
i
fuel
inje
l lev
r va
l too
t po
njec
e
u
carry out troubleshooting for overheating
l
t
f
u
e
s
,
ged
ged
ged
t fue
rope
ged
ged
ged
n pi
ctiv
ed t
rrec
ed i
eve
en i
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Wor
Seiz
Brok
Seiz
Oil l
Ben
Imp
Suddenly
Power was lost
Gradually
Questions

operation manual
Black
Noise of interference is heard from around turbocharger
Engine pickup is poor and combustion is irregular
High idle speed under no load is normal, but speed suddenly
drops when load is applied
Check items

Clanging sound is heard from around cylinder head
High idle speed of engine is low
When injection pipe is held between fingers, there is no pulse,
or there are cylinders with a weak pulse

When turbocharger is rotated by hand, it is found to be heavy
Go to S-3 Engine does not pick up smoothly

Troubleshooting
When fuel filter, strainer are inspected directly, they are found
to be clogged
When control rack is pushed, it is found to be heavy or does not return
When valve clearance is checked directly, it is found to be
outside standard value
When lever is placed at FULL position, it does not contact stopper
When feed pump is operated, operation is too light or too heavy
Legend
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust

Clean
Clean
Clean
Clean
Remedy
Check items)
Check items)
20-314 WA600-3
(16)
TROUBLESHOOTING S-8
S-8 Oil comsumption is excessive (or exhaust smoke is blue)

fl To prevent the oil from leaking up or down, do
not run the engine at idling for more than 20
minutes continuously. (Both low and high idling) Causes
m
General causes why oil consumption is excessive
hrag
r
arge
diap
tc.
• Abnormal combustion of oil
och
ator
d, e
seal
• External leakage of oil
ace
Turb
pens
stem
hea
ose
ken
• Wear of lubrication system
surf
r
oole
r
er h
t c om
line
der
, bro
e sy
eal
plug
oil c
ylin
eath
der
boos
ide)
s
d
nd
a
g
,
n
t
n, c
l
ylin
m in
r
n
n
ter,
cked ear sea

e
er e
or b
, gu
i
i
a
p
ump
bine
il pa
il dr
il pi
g, c
il fil
g
blow
n fro
tem
high
ther
n rin
on p
oole
t tur
n
mo
mo
mo
mo
nr
i
e (s
r
i
brea
l at
isto
roke
jecti
ston
l too
al a
oil c
e fro
e fro
e fro
e fro
v
a
l
en p
en in
n va
n se
n se
ged
n, b
n pi
eve
t su
kag
kag
ken
kag
kag
Brok
Clog
Wor
Wor
Wor
Wor
Wor
Brok
Oil l
Dus
Lea
Lea
Bro
Lea
Lea
Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust gas is blue under light load
Abnormally excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine coolant
When exhaust pipe is removed, inside is found to be dirty with oil
Check items
Inside of turbocharger intake pipe is dirty with oil

Oil level in clutch or TORQFLOW transmission damper case rises
When oil level is checked with dipstick, it is found to be above
H mark
Clamps for intake system are loose
If engine is run at low idle, oil leaks from joint of turbocharger
and exhaust manifold
Inside of joint bolt of injection pump and boost compensator

pipe is wet with oil
Troubleshooting
When breather element is inspected, it is found to be clogged

with dirty oil
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Check rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty with oil
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Adjust

Clean
Remedy
Check items)
Check items)
20-316 WA600-3
(16)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Intake of exhaust gas due to internal wear Causes

• Clogging of lubrication passage
• Improper combustion
• Use of improper oil
d
• Operation under excessive load
e en
• Interval between oil change too long
rbin
pipe
er tu
e
r tub
g
ain
r
athe
r
a
inde
och
r dr
ide
lve
, bre
e gu
arge
turb
, cyl
k
blac
y va
r
ther
oole
high
ring
valv
och
l at
ilter
t
s is
e
brea
a
oil c
turb
f
oil f
ston
e sa
e se
lve,
l too
t ga
n va
ged
ged
ged
ctiv
ctiv
ged
n pi
eve
aus
Defe
Defe
Clog
Clog
Clog
Clog
Wor
Wor
Oil l
Exh
Questions

Black
Carry out troubleshooting also

Abnormally excessive
Amount of blow-by gas
None
for "Exhaust gas is black".
Oil filter caution lamp stays on even when oil pressure rises
Check items
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be
dirty with oil
Engine oil temperature rises quickly
When oil level is checked with dipstic, it is found to be above
H mark
Carry out troubleshooting also

for "Exhaust gas is black".
When breather element is inspected directly, it is found to be

Troubleshooting
clogged with dirty oil, or hose is broken

When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is inspected directly, spring is found to be
catching or broken
Legend
Replace
Replace
Replace
Replace
Replace
Adjust

Clean
Clean
Clean
Remedy
—
Check items)
Check items)
WA600-3 20-317
(16)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
• Leakage of fuel Causes

• Excessive injection of fuel
)
n)
cap
ctio
r
)
filte
ing
e
o
kag
inje
t
(pis
tain
fuel
r lin
sive
e re
ng,
pum
r
eve
nge
xces
ray
loos
pipi
ng
l
u
feed
e sp
fuel
p (e
timi
l
zle (
p
fuel
ump
ozzl
t of
pum
ide
ion
noz
from
men
l ins
on n
p
ject
ion
ion
ion
age
l sea
n
just
i
ject
ject
ject
ject
l i
r fue
leak
e ad
e in
e in
e in
e oi
e in
rope
ctiv
rnal
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Imp
Questions
More than for other machines of same model

Condition of fuel
Gradually increased
consumption
Suddenly increased
Black
Exhaust gas color
White
There is irregular combustion
Check items

Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idle speed is high
Injection pump test shows that injectin amount is too high

Troubleshooting
When control rack is pushed, it is found to be heavy or does

not return
When check is made using delivery method, injection timing is
found to be incorrect
Remove nozzle holder and inspect directly
Remove feed pump and inspect direclty
When engine speed is measured, low idle speed is found to be high
Legend
Replace
Replace
Repair
Repair
Repair
Adjust
Adjust
Adjust

Check items)
Check items)
20-318 WA600-3
(16)
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down
General causes why oil is in coolant
• Internal leakage in lubrication system Causes

• Internal leakage in cooling system
ed)
ittin
ogg
by p
t
le cl
aske
used
r ho
r
ad g
ne
s ca
i
athe
l
r he
r
train
e
k
hole
lind
(bre
bloc
inde
-ring
r
f cy
ng,
e
ump
der
w
, cyl
re, O
on o
o
O-ri
p
ylin
ter p
d
r for
r co
hea
rusi
line
c
n wa
ks in
oole
oole
der
prot
der
eal o
cylin
crac
ylin
oil c
oil c
ent
en c
en s
ffici
rnal
ken
ken
ken
Brok
Brok
Insu
Inte
Bro
Bro
Bro
Questions

Suddenly increased
Increase in oil level
Gradually increased
Hard water is being used as coolant (corrosion resistor valve
is closed)
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, water spurts back

Hydraulic oil, torque converter, transmission oil is cloudy white
When hydraulic oil, torque converter, transmission oil is
drained, water comes out
Troubleshooting

Pressure-tightness test of cylinder head shows there is leakage
Remove cylinder head and inspect directly
Inspect water pump
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Check items)
Check items)
WA600-3 20-319
(16)
S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp
lights up.
• Leakage, clogging, wear of lubricating

system Causes
• Defective oil pressure control
• Used of improper oil (improper viscosity)
• Deterioration of oil due to overheating
ng p il pan
★ Standards for engine oil selection
rtion
g
eo
ipin
KIND AMBIENT TEMPRATURE
o
n
nsid
OF FLUID -20 –10 0 10 20 30 40 50°C
n
il pa
r
ic p
l pa
nso
pe i
razi
raul
de o
r
lve
n oi
SAE 30CD
e
nso
s
il pi
r va
b
nal
sure
hyd
alve
i
insi
el se
pipe
vel
mp
SAE 10WCD
jour
r
en o
lato
oole
pres
hed
ef v
ilter
il le
iner
Engine oil
il
l lev
l pu
in o
ion
regu
brok
ring
i
crus
oil c
nt o
SAE 10W-30CD
oil f
l
stra
l
e re
suct
e oi
e oi
e oi
uel
a
e
e
,
n be
ged
ged
,
ctiv
ged
ged
ctiv
ctiv
ffici
ctiv
ctiv
king
SAE 15W-40CD
er, f
ken
Defe
Clog
Clog
Defe
Defe
Clog
Clog
Defe
Defe
Wor
Insu
Wat
Lea
Bro
Questions

operation manual
Caution lamp lights up
Lights up at low idle
Condition when oil pres- Lights up at low, high idle
sure lamp lights up
Lights up on slopes
Sometimes lights up
Crushed piping, leakage from hydraulic piping (external)
Check items
Oil level sensor lamp lights up

When oil level in oil pan is checked, it is found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
When oil filter is inspected directly, it is found to be

clogged
Carry out troubleshooting

Troubleshooting
Oil pump rotation is heavy, there is play

for "Oil level rises".
There is catching of relief valve, regulator valve, or spring,

valve guide is broken
When oil level sensor is replaced, oil pressure sensor lamp
goes out
When oil pressure is measured, it is found to be within
standard value
Check oil cooler
Legend
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust

Clean
Clean
Clean
Clean
Remedy
—
Add
Check items)
Check items)
20-320 WA600-3
(16)
S-13 Oil level rises

fl If there is oil in the coolant, carry out trouble-
shooting for "Oil is in coolant".
Causes
General causes why oil level rises
g
seal
ap
ittin
t
ng c
m en
ing
tive
by p
• Water in oil (cloudy white)
clud
aini
quip
efec
• Fuel in oil (diluted, and smells of diesel fuel)
ade
r ret
t (in
le, d
ry e
• Entry of oil from other component
les m
aske
olde
ace
xilia
ho
g, ho
e
surf
her
g
-ring
zle h
leev
mp
k
ham ead
O-rin
bloc
reat
at
er)
eal
u
s
noz
o
re, O
core
p
on c d, h
t se
der
mp
b
b
ar s
der
liner
ctio
ump
from
osta
usti er hea
l
r co
f pu
o
oler
e
cylin
h
inje
der
er p
ged
zzle
oole
erm
al o
r-co
uel
d
cylin
side
side
cylin
e no
ama
wat
f
e se
e th
oil c
afte
e of
ks in
omb
aged
ct in
ged
ctiv
ctiv
ctiv
n, d
ken
kag
ken
ken
Defe
Defe
Clog
Defe
Defe
Crac
prec
Dam
Wor
Bro
Lea
Bro
Bro

Questions

There is oil in radiator coolant
Exhaust gas is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idle, an
abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud
Check items
When water pump breather hole is cleaned, water comes out

Oil level does down in TORQFLOW transmission, or damper case
Oil level does down in hydraulic tank
Engine oil smells of diesel fuel
Fuel is added more frequently

Remove water pump and inspect directly
Troubleshooting
Inspect rear seal directly

When pump auxiliary equipment is removed, seal is found to be
broken
Remove nozzle holder and inspect directly
Remove injection pump and inspect directly
There is improper contact of thermostat seat valve
Pressure-tightness test of after-cooler core shows there is leakage
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair

Check items)
Check items)
WA600-3 20-321
(16)
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too high
Causes
• Lack of cooling air (deformation, damage of fan)
g
• Drop in heat dissipation efficiency
ittin
• Defective cooling circulation system
by p
• Rise in oil temperature of power train
ure
ade
fl Carry out troubleshooting for chassis
en)
)
erat
5A-1
les m
e
t
aug
t op
aske
y
em p
ulle
(D47
g, ho
e
g
s no
ad g
kag
in
an p
ure
oil t
tor f
O-rin
otor
doe
, lea
oole
erat
, he
e
e
f
t
rter
valv
adia
a
n
pum k
pm
tat (
ng w
wor
core
ead
p
oil c
liner
bloc
tem
e
ump
ed r
v
sure
mos
er h
con
ing,
ooli
ator
ken
der
der
ater
Clog water p
Clog d, crush
Bro ve pres
lind
ther
lipp
rque
cylin
nt c
, bro
fan
ylin
radi
ew
y
s
e
c
e
ctive
c
in to
aged
ged
ffici
ged
ctiv
ctiv
belt
k in
ken
ken
cti
ge
Defe
Clog
Defe
Insu
Defe
Defe
Crac
Dam
Rise
Fan
Bro

Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Carry out troubleshooting for chassis

Radiator coolant level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on coolant
Coolant flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Check items
Engine oil level has risen, oil is cloudy white

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
Belt tension is found to be slack
Power train oil temperature enters red range before engine
coolant temperature
Temperature difference between top and bottom radiator tanks

is excessive
Temperature difference between top and bottom radiator tanks

is too small
When radiator is inspected through water filler port, the core
is found to be clogged
When a function test is carried out on the thermostat, it does
Troubleshooting
not open at the cranking temperature

When coolant temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair

—
—
Add
Check items)
Check items)
20-322 WA600-3
(16)
S-16 Vibration is excessive

fl If there is abnormal noise together with the vibra-
tion, carry out troubleshooting for "Abnormal noise
is made" Causes
d)
seize
in
General causes why vibration is excessive
ion
r tra
k
nger
ring
stuc
ush
owe
per)
, plu
• Defective parts (abnormal wear, breakage)
bea
en c
tc.)
nd p
dam
ction
• Improper alignment
er, e
ain
utpu ts, brok
a
• Abnormal combustion
aft (
n da ssive inje
d, m
v
e
er le
ngin
lash
t sh
l
g ro
r
g bo
mpe
rock
en e
(exce
k
zzle
bac
ctin
ntin
twe
ve,
n no
de o
p
nne
m
ng
t
mou
i
pilo
atio
r tra
(val
n pu
t be
i
d co
ctio
ush
insi
vibr
Defe injectio
t
a
n
tem
e
r
r ge
inje
ppo
mb
ngin
nme
eize
part
e
s
rope
e sy
ctiv
n su
n ca
ged
n, s
se e
alig
ctive
ken
Valv
Wor
Clog
Wor
Wor
Mis
Imp
Defe
Loo
Bro
Questions
Condition of vibration Suddenly increased

Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idle
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust gas is black

Remove side cover and inspect directly
Troubleshooting
Check directly for worn support pilot, play

Inspect directly for loose engine mounting bolts, broken
cushion
Check inside of output shaft (damper) directly
When radial runout, face runout are measured, they are found
to be outside standard
Remove front cover, and inspect directly
Remove head cover and inspect directly
Injection pump test shows that injection amount is incorrect
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust

Check items)
Check items)
20-324 WA600-3
(16)
TROUBLESHOOTING OF ENGINE
CONTROLLER SYSTEM
(EA MODE)
Serial 52001 and up

Method of error code display ...................................................................................................................... 20-353
Action taken by controller and condition of machine when error code is displayed .................................... 20-356
Schematic diagram for engine control system ............................................................................................ 20-364
EA-1 Error code [111] (Abnormality in controller memory)....................................................................... 20-366
EA-2 Error code [112] (Abnormality in timing rail actuator ....................................................................... 20-366
EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system) ......................... 20-367
EA-4 Error code [115] (Abnormality in engine speed sensor 2 system) .................................................. 20-368
EA-5 Error code [116] (Abnormality in timing rail pressure sensor system high level) ............................ 20-370
EA-6 Error code [117] (abnormality in timing rail pressure sensor system low level) .............................. 20-371
EA-7 Error code [118] (Abnormality in fuel pump pressure sensor system high level) ............................ 20-372
EA-8 Error code [119] (Abnormality in fuel pump pressure sensor system low level) ............................. 20-373
EA-9 Error code [121] (Abnormality in engine speed sensor 1 system) .................................................. 20-374
EA-10 Error code [122] (Abnormality in boost pressure sensor system high level)................................... 20-375
EA-11 Error code [123] (Abnormality in boost pressure sensor system low level) .................................... 20-376
EA-12 Error code [131] (Abnormality in accelerator sensor system high level)......................................... 20-377
EA-13 Error code [132] (Abnormality in accelerator sensor system low level) .......................................... 20-378
EA-14 Error code [135] (Abnormality in oil pressure sensor system high level) ........................................ 20-379
EA-15 Error code [141] (Abnormality in oil pressure sensor system low level) ......................................... 20-380
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1)) .............................................................. 20-381
EA-17 Error code [144] (Abnormality in coolant temperature sensor system high level) .......................... 20-382
EA-18 Error code [145] (Abnormality in coolant temperature sensor system low level) ............................ 20-383
EA-19 Error code [151] (Abnormal rise in coolant temperature)................................................................ 20-383
EA-20 Error code [153] (Abnormality in intake air temperature sensor system high level)........................ 20-384
EA-21 Error code [154] (Abnormality in intake air temperature sensor system low level) ......................... 20-384
EA-22 Error code [221] (Abnormality in atmospheric pressure sensor system high level) ........................ 20-385
EA-23 Error code [222] (Abnormality in atmospheric pressure sensor system low )................................. 20-386
EA-24 Error code [234] (Overspeed) ......................................................................................................... 20-388
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage).............................................. 20-389
EA-26 Error code [259] (Abnormality in fuel shut-off valve)....................................................................... 20-390
EA-27 Error code [261] (Abnormal rise in fuel temperature) ..................................................................... 20-390
EA-28 Error code [263] (Abnormality in fuel temperature sensor system high level) ................................ 20-391
EA-29 Error code [265] (Abnormality in fuel temperature sensor system low level).................................. 20-391
EA-30 Error code [316] (Abnormality in fuel pump actuator system current) ............................................ 20-392
EA-31 Error code [318] (Abnormality in fuel pump actuator) ..................................................................... 20-393
EA-32 Error code [343] (Abnormality in controller internal communication) .............................................. 20-393
EA-33 Error code [346] (Abnormality in controller power down)................................................................ 20-394
EA-34 Error code [384] (Abnormality in preheating heater control system) .............................................. 20-395
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2)) .............................................................. 20-396
EA-36 Error code [423] (Abnormality in timing rail pressure sensor system in range) .............................. 20-397
WA600-3 20-351
(16)
EA-37 Error code [431] (Abnormality 1 in idling validation switch system) ................................................ 20-399
EA-38 Error code [432] (Idle validation process error)............................................................................ 20-399-2
EA-39 Error code [441] (Abnormality in battery voltage low level).......................................................... 20-399-4
EA-40 Error code [442] (Abnormality in battery voltage high level) ........................................................ 20-399-4
EA-41 Error code [451] (Abnormality in fuel rail pressure sensor system high level) ............................. 20-399-5
EA-42 Error code [452] (Abnormality in fuel rail pressure sensor system low level) .............................. 20-399-6
EA-43 Error code [455] (Abnormality in fuel rail actuator system current) .............................................. 20-399-7
EA-44 Error code [467] (Abnormality in timing rail actuator control)....................................................... 20-399-8
EA-46 Error code [514] (Abnormality in fuel rail actuator) ...................................................................... 20-399-8
EA-47 Error code [527] (Abnormality in dual output solenoid A system) ................................................ 20-399-9
EA-48 Error code [551] (Abnormality 2 in idle validation switch system) ................................................ 20-399-9
EA-49 Error code [554] (Abnormality in fuel rail pressure sensor in range).......................................... 20-399-10
20-352 WA600-3
(16)
ACTION TAKEN BY CONTROLLER AND CONDITION OF
TROUBLESHOOTING MACHINE WHEN ERROR CODE IS DISPLAYED
Action by controller Problem that appears on machine Probable cause
• Red lamp lights up • Engine cannot be started • Defective engine controller
• Red lamp lights up • Engine speed goes down • Excessive negative pressure at inlet port
• Limits engine speed to 1,500 rpm of fuel pump
• Defective timing rail actuator or clogged
screen
• Broken injector O-ring
• Defective engine controller
• Yellow lamp lights up • Engine output goes down • Defective timing rail actuator
• Engine emits white smoke • Defective wiring harness and connector
of timing rail actuator circuit
• Red lamp lights up • Engine stops • Defective engine speed sensor

• Outputs speed signal 0 rpm • Defective wiring harness and connector
of engine speed sensor circuit
• Red lamp lights up • Engine makes abnormal explosion • Defective timing rail pressure sensor
• Carries out open control of timing rail sound or emits white smoke, then • Defective wiring harness and connector
• Limits engine speed to 1,500 rpm engine speed becomes 1,500 rpm of timing rail pressure sensor circuit
• Red lamp lights up • Engine makes abnormal explosion • Defective timing rail pressure sensor
• Carries out open control of timing rail sound or emits white smoke, then • Defective wiring harness and connector
• Limits engine speed to 1,500 rpm engine speed becomes 1,500 rpm of timing rail pressure sensor circuit
• Yellow lamp lights up • Defective fuel pump pressure sensor

• Carries out open control of fuel pump • Defective wiring harness and connector
— of fuel pump pressure sensor circuit
• Yellow lamp lights up • Defective fuel pump pressure sensor

• Carries out open control of fuel pump • Defective wiring harness and connector
of fuel pump pressure sensor circuit
— • Defective engine controller
• Yellow lamp lights up • Defective engine speed sensor

• Defective wiring harness and connector
—
of engine speed sensor circuit
• No lamps light up • Exhaust gas color is poor when • Defective boost pressure sensor
accelerating • Defective wiring harness and connector
• Engine output increases of boost pressure sensor circuit
• No lamps light up • Engine output goes down • Defective boost pressure sensor
of boost pressure sensor circuit
WA600-3 20-357
(16)
User System with abnormality Nature of abnormality Condition when normal

code
• Abnormality has occurred in throttle sen- • Resistance of throttle sensor

131 Abnormality in throttle sor circuit Between L13(3) – (2) (power source):
sensor system high level ECMB (29): 4.80 V or more detected 2,000 – 3,000 z
Between L13(1) – (2) (signal): 200 – 3,000 z
• Abnormality has occurred in throttle sen- • Resistance of throttle sensor

Abnormality in throttle sor circuit Between L13 (3) and (2) (power source):
132
sensor system low level ECMB (29): 0.30 V or less detected 2,000 – 3,000 z
Between L13 (1) and (2) (signal):
200 – 3,000 z
• Abnormality has occurred in oil pressure • Voltage of oil pressure sensor

Abnormality in oil sensor circuit Between ECMA (6) and (17) (power source):
ECMB (24): 4.88 V or more detected 4.75 – 5.25 V
135 pressure sensor system
Between ECMA (24) and (17) (signal):
high level 0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in oil pressure • 14. Voltage of oil pressure sensor
Abnormality in oil sensor circuit Between ECMA (6) and (17) (power source):
141 pressure sensor system ECMA (24): 0.31 V or less detected 4.75 – 5.25 V
low level
0.42 – 0.58 V
(engine stopped)
• Oil pressure sensor detected pressure

lower than set oil pressure (level 1)
Level 1 judgment value (reference)
143 Abnormal drop in oil At 600 rpm Max. 0.05 MPa { 0.5 kg/cm2} —
pressure (level 1) At 1,000 rpm Max. 0.09 MPa { 0.9 kg/cm2}
At 1,500 rpm Max. 0.15 MPa { 1.5 kg/cm2}
At 1,800 rpm Max. 0.18 MPa {1.85 kg/cm2}
At 2,000 rpm Max. 0.21 MPa { 21 kg/cm2}
• Abnormality has occurred in coolant tem- • Resistance of coolant temperature sensor

Abnormality in coolant Between CLTP (A) and (B): 600 – 36k z
144 temperature sensor perature sensor circuit
ECMA (22): 4.95 V or more detected
system high level
• Abnormality has occurred in coolant tem- • Resistance of coolant temperature sensor

Abnormality in coolant perature sensor circuit Between CLTP (A) and (B): 600 – 36k z
145 temperature sensor
ECMA (22): 0.21 V or less detected
system low level
• Coolant temperature sensor has detected

151 Abnormal rise in coolant
temperature temperature higher than set temperature
Judgment value (reference): Min. 105°C
Abnormality in intake air • Abnormality has occurred in intake air • Resistance of intake air temperature sensor
temperature sensor temperature sensor circuit Between IMTP (A) and (B): 36 – 600 z
153
system high level ECMA (23): 4.88 V or more detected
Abnormality in intake air • Abnormality has occurred in intake air • Resistance of intake air temperature sensor
temperature sensor temperature sensor circuit Between IMTS (A) and (B): 36 – 600 z
154 system low level ECMA (23): 0.08 V or less detected
• Abnormality has occurred in atmospheric • Voltage of atmospheric temperature sensor

pressure sensor circuit Between ECMA (6) and (17) (power source):
Abnormality in
221 atmospheric pressure ECMA (34): 4.78 V or more detected 4.75 – 5.25 V
sensor system high level Between ECMA (34) and (17) (signal):
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in atmospheric • Voltage of atmospheric pressure sensor

pressure sensor circuit Between ECMA (6) and (17) (power source):
Abnormality in atmo- ECMA (34): 0.20 V or less detected 4.75 – 5.25 V
222 spheric pressure sensor Between ECMA (34) and (17) (signal):
system low level 0.42 – 0.58 V
(engine stopped)
• Engine speed sensor has detected speed

higher than set speed
Judgment value (reference):
234 Overspeed D375A :2,400 rpm or more —
WA600 :2,500 rpm or more
PC1100 :2,400 rpm or more
Morita :2,550 rpm or more
20-358 WA600-3
(16)
• Red lamp lights up • Engine output and speed suddenly • Defective throttle sensor
• Holds engine at constant speed go down • Defective wiring harness and connector
of throttle sensor circuit
• Red lamp lights up • Engine output and speed suddenly • Defective throttle sensor
• Holds engine at constant speed go up • Defective wiring harness and connector
of throttle sensor circuit
• Yellow lamp lights up • Defective oil pressure sensor

of oil pressure sensor circuit
—
• Yellow lamp lights up • Defective oil pressure sensor

— of oil pressure sensor circuit
• Orange lamp lights up • Defective engine

• After 10 seconds limits injection amount to • Defective oil pressure sensor
50%
—
• Yellow lamp lights up • Defective coolant temperature sensor

—
of coolant temperature sensor circuit
• Yellow lamp lights up • Defective coolant temperature sensor

—
of coolant temperature sensor circuit

• After 10 seconds limits injection amount to — • Defective coolant temperature sensor
50%
• Yellow lamp lights up • Defective intake air temperature sensor

—
of intake air temperature sensor circuit
• Yellow lamp lights up • Defective intake air temperature sensor

— of intake air temperature sensor circuit
• Yellow lamp lights up • Defective atmospheric pressure sensor

of atmospheric pressure sensor circuit
—
• Yellow lamp lights up • Defective atmospheric pressure sensor

of atmospheric pressure sensor circuit
—
• Red lamp lights up • Defective engine

• Shut off common rail actuator (fuel cut-off). • Defective engine speed sensor
• Defect on machine
—
WA600-3 20-359
(16)

code
• Abnormality has occurred in fuel shut-off • Resistance of fuel shut-off valve

Abnormality in fuel shut- valve circuit Between FSO (+) and (-): 23 – 40 z
254 Between ECMA (30) and (8):
off valve system voltage
Voltage of 6.0 V or less or resistance of
20 z or less detected
• Fuel shut-off valve remains open and

259 Abnormality in fuel shut- does not close (even when electric power —
off valve
is turned off, engine does not stop)
Abnormal rise in fuel • Fuel temperature sensor has detected

261 temperature higher than set temperature —
temperature Judgment value (reference): 76°C or more
• Abnormality has occurred in fuel tempera- • Resistance of fuel temperature sensor

Abnormality in fuel
263 temperature sensor ture sensor circuit Between FLTP (A) and (B): 600 – 36k z
system high level ECMA (26): 4.95 V or more detected
• Abnormality has occurred in fuel tempera- • Resistance of fuel temperature sensor

Abnormality in fuel
265 temperature sensor ture sensor circuit Between FLTP (A) and (B): 600 – 36k z
system low level ECMA (26): 0.21 V or less detected
• Abnormality has occurred in fuel pump • Resistance of fuel pump actuator

actuator circuit Between PUMP (A) and (C): 7 – 9 z
316 Abnormality in fuel pump Between ECMA (11) and (40) (reference
actuator system current value):
Detected value outside range of
0.40±0.35A (engine stopped)
• Excessive difference between fuel pump

command pressure value and actual pres-
sure
318 Abnormality in fuel pump Judgment value (reference): —
actuator Difference more than ±2.11 MPa {2.1 kg/
cm2}
(when coolant temperature is 38°C or
above)
Abnormality in controller • Microprocessor error inside controller

343 internal communication —
• Error in data recorded in power-down

Abnormality in controller internal memory of controller
346 —
power down
• Abnormality has occurred in preheating • Resistance of heater relay

heater control circuit Between relay coils: 200 – 400 z
Abnormality in preheating
384 ECMB (2):
heater control system
Circuit open or short circuit in circuit
detected
• Oil pressure sensor detected pressure

lower than set oil pressure (level 2)
Level 1 judgment value (reference)
Abnormal drop in oil At 600 rpm Max. 0.04 MPa {0.4 kg/cm2}
415 At 1,000 rpm Max. 0.08 MPa {0.8 kg/cm2}
—
pressure (level 2)
• Timing rail pressure sensor detected

Abnormality in timing rail abnormal pressure
423 pressure sensor system Judgment value (reference) —
in range when starting switch is ON:
2.42 MPa {24.65 kg/cm2} or more
• Simultaneous detection of voltage from • Resistance of idle switch

Abnormality 1 in idle both ON signal and OFF signal of idle val- Between L14(1) – (2):
431 idation switch Max. 125 z (pedal released)
validation switch system
ECMB (12): Idle OFF signal Between L14(1) – (3):
ECMB (13): Idle ON signal Max. 125 z (pedal depressed)
20-360 WA600-3
(16)
• No lamps light up • Engine stops • Defective fuel shut-off valve

• Shuts off power supply to fuel shut-off valve • Defective wiring harness and connector
of fuel shut-off valve circuit
• Red lamp lights up • Engine cannot stop • Defective fuel shut-off valve
• Shuts off power supply to fuel shut-off valve • Defective injector

• After 30 seconds limits engine speed to 800 — • Defective fuel temperature sensor
rpm • Defect on machine
• Yellow lamp lights up • Defective fuel temperature sensor

—
of fuel temperature sensor circuit
• Yellow lamp lights up • Defective fuel temperature sensor

— • Defective wiring harness and connector
of fuel temperature sensor circuit
• Yellow lamp lights up • Defective fuel pump actuator

— of fuel pump actuator circuit
• Yellow lamp lights up • Engine speed becomes unstable • Defective fuel pump actuator
• Excessive negative pressure at inlet port
of fuel pump
• Defective fuel temperature sensor
• Defective injector
• Yellow lamp lights up • Defective controller

—
• Yellow lamp lights up • Loss of power-down data • Defective battery

(maintenance data, present controller • Blown fuse
data, engine operating time, etc.) • Defective wiring harness and connector
of controller power source circuit
• Yellow lamp lights up • Defective heater relay

— of heater relay circuit

• After 10 seconds limits injection amount to • Defective oil pressure sensor
50%
—
• Yellow lamp lights up • Defective timing rail pressure sensor

• Limits high idle speed to 1,500 rpm • Defective wiring harness and connector
— of timing rail pressure sensor circuit
• Excessive suction resistance of fuel filter
• Red lamp lights up • Defective idle validation switch

— of idling validation switch
WA600-3 20-361
(16)

code
• Throttle sensor signal and idle validation • Resistance of idle switch

Idle validation process ON signal, OFF signal do not match Between L14(1) – (2):
432 Max. 125 z (pedal released)
error ECMB (12): Idle OFF signal
ECMB (13): Idle ON signal Between L14(1) – (3):
Max. 125 z (pedal depressed)
• Abnormality has occurred in controller • Voltage of controller power source

power source circuit Between ECMB (3)(4)(5) and ECMA (7)(8):
Abnormality in battery
441 ECMB (3)(4)(5): 12 V or less detected 17.3 – 34.7 V
voltage low level
(When starting switch is OFF)
• Abnormality has occurred in controller • Voltage of controller power source

Abnormality in battery power source circuit Between ECMB (3)(4)(5) and ECMA (7)(8):
442 ECMB (3)(4)(5): 38 V or less detected 17.3 – 34.7 V
voltage high level
(When starting switch is OFF)
• Abnormality has occurred in fuel rail pres- • Voltage of fuel rail pressure sensor
Abnormality in fuel rail sure sensor circuit Between ECMA (5) and (18) (power source):
ECMA (31): 4.78 V or more detected 4.75 – 5.25 V
451 pressure sensor system
high level Between ECMA (31) and (18) (signal):
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel rail pres- • Voltage of fuel rail pressure sensor
Abnormality in fuel rail sure sensor circuit Between ECMA (5) and (18) (power source):
452 pressure sensor system ECMA (31): 0.15 V or less detected 4.75 – 5.25 V
low level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel rail actu- • Resistance of fuel rail actuator
Abnormality in fuel rail ator circuit Between RAIL (A) and (C): 7 – 9 z
455
actuator system current Between ECMA (1) and (20) (reference
value): 0.40 ± 0.35 A (engine stopped)
• Excessive difference between timing rail

command fuel value and actual timing
467 Abnormality in timing rail fuel, does not reach target value —
actuator control
• Excessive difference between fuel rail

command injection amount value and
Abnormality in fuel rail actual injection amount, does not reach
468 actuator control target value —
• Excessive difference between fuel rail

command injection amount value and
actual injection amount
514 Abnormality in fuel rail Fuel rail judgment value (reference): —
actuator Difference ±600 mm3/st or more for
±50 msec or difference ±250 mm3/st
or more for ± 200 msec
• Abnormality has occurred in dual output • Resistance of dual output solenoid A

Abnormality in dual output solenoid A circuit Between R17(female)(A) – chassis: 28 – 32
527
solenoid A system ECMB (1): z
Circuit open or short circuit detected
• Abnormality has occurred in dual output • Resistance of dual output solenoid B

529
Abnormality in dual output solenoid B circuit Between solenoid pins: 28 – 32 z
solenoid B system ECMB (9):
Circuit open or short circuit detected
• Simultaneous detection of no voltage from • Resistance of idle switch

Abnormality 2 in idle both ON signal and OFF signal of idle val- Between IVS (A) and (B):
551 validation switch system idation switch Max. 125 z (pedal released)
ECMB (12): Idle OFF signal Between IVS (A) and (C):
ECMB (13): Idle ON signal Max. 125 z (pedal depressed)
• Fuel rail pressure sensor detected abnor-

mal pressure
Abnormality in fuel rail
554 pressure sensor in range
Judgment value (reference): —
When starting switch is ON:
0.17 MPa {1.76 kg/cm2} or more
20-362 WA600-3
(16)

• Recognizes throttle signal as 0% • Defective wiring harness and connector
— of idling validation switch
• Defective battery
• Blown fuse
— — • Defective wiring harness and connector
• Defective battery
• Blown fuse
— — • Defective wiring harness and connector
• Red lamp lights up • Defective fuel rail pressure sensor

• Carries out open control of fuel rail • Defective wiring harness and connector
of fuel rail pressure sensor circuit
—
• Red lamp lights up • Defective fuel rail pressure sensor

• Carries out open control of fuel rail • Defective wiring harness and connector
— of fuel rail pressure sensor circuit
• Red lamp lights up • Defective fuel rail actuator

• Sets current to fuel rail actuator to 0 A • Defective wiring harness and connector
— of fuel rail actuator circuit
• Yellow lamp lights up • Excessive negative pressure at inlet port

• Limits engine speed to 1500 rpm of fuel pump
• Defective timing rail actuator or clogged
—
screen

• Limits maximum injection amount to 217 of fuel pump
mm3/st • Defective fuel rail actuator or clogged
— screen

• Limits maximum injection amount to 217 of fuel pump
mm3/st • Defective fuel rail actuator or clogged
— screen
• Yellow lamp lights up • Defective dual output solenoid A

—
of dual output solenoid A circuit
• Yellow lamp lights up • Defective dual output solenoid B

— • Defective wiring harness and connector
of dual output solenoid B circuit

• Recognizes throttle signal as 0% • Defective wiring harness and connector
— of idling validation switch circuit
• Yellow lamp lights up • Defective fuel rail pressure sensor

• Limits maximum injection amount to 270 • Defective wiring harness and connector
mm3/st — of fuel rail pressure sensor circuit
• Excessive suction resistance of fuel filter
WA600-3 20-363
(16)
TROUBLESHOOTING EA-1, EA-2
EA-1 Error code [111] (Abnormality in controller memory)
Cause Remedy
1
• Turn starting switch OFF
and wait for 5 minutes. Is error code [111] re-enacted?
NO
• Run engine at low idle.
YES
Defective engine controller Replace
2
It has probably been reset, so operate
Has error code [111] already been NO
for a short time and watch for any —
generated 3 or more times?
change in symptoms
YES
EA-2 Error code [112] (Abnormality in timing rail actuator

& #'
%
) (

!
! "

*%(
!
! !

#$! $ % %
%!
! ! #$!
$ % % %!
"
%

#
%
*%( %'
(

+$ , '
20-366 WA600-3
(16)
TROUBLESHOOTING EA-17
EA-17 Error code [144] (Abnormality in coolant temperature sensor sys-

tem high level)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between CLTP NO Defective coolant temperature sensor Replace
• Disconnect CLTP. (male) (A) and (B) 600 – 36kΩ?
YES
2
Is resistance between ECMA (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (22) and CLTP (female)
(A), and between ECMA (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and
(22) and surrounding wiring har- ECMA (female) (22) and CLTP (fe- replace
CLTP.
nesses as shown in Table 1? male) (A)
YES
3
Is resistance between ECMA (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (17) and CLTP (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and (B), and between ECMA (female) ECMA (female) (17) and CLTP (fe- replace
CLTP. (17) and surrounding wiring har-
nesses as shown in Table 2? male) (B)
YES
Table 1 Table 2
ECMA (female), CLTP (female) Resistance value ECMA (female), CLTP (female) Resistance value
Between ECMA (22) and CLTP (A) Max. 10 Ω Between ECMA (17) and CLTP (B) Max. 10 Ω
Between ECMA (22) and Between ECMA (17) and surround-
surrounding wiring harnesses Min. 1 MΩ ing wiring harnesses Min. 1 MΩ
EA-17 Related electrical circuit diagram
20-382 WA600-3
(16)
TROUBLESHOOTING EA-18, EA-19
EA-18 Error code [145] (Abnormality in coolant temperature sensor sys-

tem low level)
a Carry out troubleshooting for error code [144].
EA-19 Error code [151] (Abnormal rise in coolant temperature)

- '

(
+ ,

*
'

-*
!"##$ !"#%$ ) * ,
&
' '

(
) *
', '
'
WA600-3 20-383
(16)
EA-38 Error code [432] (Idle validation process error)
Cause Remedy
1
Is resistance between L14
• Turn starting switch OFF. NO Replace
(female) (1) and (3), and between Defective idle validation switch
• Disconnect L14. (2) and (3) as shown in Table 1?
YES
2
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (21) and L14 (male) (1), NO
and between ECMB (female) (21) short circuit in wiring harness between Repair or
• Disconnect ECMB and L14. and surrounding wiring harnesses ECMB (female) (21) and L14 (male) replace
as shown in Table 2? (1)
YES
3
• Turn starting switch OFF. (female) (13) and L14 (male) (2), NO short circuit in wiring harness between Repair or
and between ECMB (female) (13) ECMB (female) (13) and L14 (male) replace
• Disconnect ECMB and L14. and surrounding wiring harnesses
as shown in Table 3? (2)
YES
4
(female) (12) and L14 (male) (3), short circuit in wiring harness between
• Turn starting switch OFF. and between ECMB (female) (12) NO Repair or
• Disconnect ECMB and L14. and surrounding wiring ECMB (female) (12) and L14 (male) replace
harnesses as shown in Table 4? (3)
YES
Table 1 Table 2
L14 (male) Pedal Resistance value ECMB (female), L14 (male) Resistance value
Between (1) and (3) Released or depressed 2,000 – 3,000 Ω Between ECMA (21) and L14 (1) Max. 10 Ω
Released (idling ON) 1,500 – 3,000 Ω Between ECMB (21) and
Min. 1 MΩ
Between (2) and (3) surrounding wiring harnesses
Depressed (idling OFF) 200 – 1,500 Ω
Table 3 Table 4
ECMB (female), L14 (male) Resistance value ECMB (female), L14 (male) Resistance value
Between ECMB (13) and L14 (2) Max. 10 Ω Between ECMB (12) and L14 (3) Max. 10 Ω
Between ECMB (13) and Between ECMB (12) and
surrounding wiring harnesses Min. 1 MΩ surrounding wiring harnesses Min. 1 MΩ
WA600-3 20-399-2
(16)
20-399-3 WA600-3
(16)
TROUBLESHOOTING EA-47, EA48
EA-47 Error code [527] (Abnormality in dual output solenoid A system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance of relay L64 (male) NO Defective engine oil pressure relay Replace
• Disconnect L64. (1) and (2) 200 – 400 Ω?
YES
2
Is resistance between ECMB Defective contact or disconnection in
• Turn starting switch OFF. NO wiring harness between ECMB Repair or
• Disconnect ECMB and L64. (female) (1) and L64 (female) (1) replace
less than 1 Ω? (female) (1) and L64 (female) (1)
YES
3
Is the resistance value between There is a disconnection or connection
• Turn starting switch OFF. NO fault in the wiring harness between L64 Repair or
L64(frmale) (2) and the chassis
• Disconnect L64. replace
less than 1 Ω? (female) (2) and the chassis.
YES
4
Is resistance between ECMB
Short circuit in wiring harness between
(female) (1) and surrounding NO Repair or
• Turn starting switch OFF. ECMB (female) (1) and L64 (female)
wiring harnesses more than 100 replace
• Disconnect ECMB and L64. (1)
kΩ?
YES
EA-48 Error code [551] (Abnormality 2 in idle validation switch system)

a Carry out troubleshooting for error code [431].
20-399-9 WA600-3
(16)
M-13 Abnormality in parking brake dragging warning ...................................................................... 20-424
a) When parking brake is applied, buzzer sounds intermittently and caution lamp
flashes even when directional lever is at N ......................................................................... 20-424
b) When parking brake is applied, buzzer does not sound and caution lamp does not
light up even when directional lever is at position other than N ....................................... 20-424
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated
continuously, or they are not actuated ....................................................................................... 20-425
a) Actuated continuously ........................................................................................................... 20-425
b) Not actuated ........................................................................................................................... 20-425
M-15 Abnormality in buzzer .................................................................................................................. 20-426
a) Buzzer does not sound for 3 seconds during self-check when starting switch is
turned ON ............................................................................................................................... 20-426
b) Buzzer always sounds ........................................................................................................... 20-426
M-16 Condition of monitor switches is not stored in memory .......................................................... 20-427
M-17 Abnormality in failure display mode .......................................................................................... 20-428
a) Failure display mode does not work .................................................................................... 20-428
b) Count for time elapsed since failure in failure display mode does not advance ............. 20-428
M-18 Abnormality in emergency steering display .............................................................................. 20-429
a) Emergency steering display does not flash ......................................................................... 20-429
b) Emergency steering display stays flashed .......................................................................... 20-429
M-19 Abnormality in auto-greasing system ........................................................................................ 20-430
a) Forced greasing cannot be carried out ................................................................................ 20-430
b) Monitor display flashes rapidly (2 times/sec) ...................................................................... 20-430
c) When no more grease remains, monitor display flashes rapidly (2 times/sec) ............... 20-430
d) Monitor display flashes slowly (1 time/sec) ........................................................................ 20-431
e) Monitor display goes out ...................................................................................................... 20-431
M-20 Abnormality in ECSS system [*] ................................................................................................. 20-432
a) Display does not change when switch is pressed .............................................................. 20-432
b) Monitor display lights up but ECSS function does not work ............................................. 20-432
c) Monitor lamp does not light up ............................................................................................ 20-432
M-21 Failure code is not sent to main monitor (abnormality in network) ........................................ 20-434
* : Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check
that DIP switch 4 on the back side of the main monitor is set correctly.
Note:
• Hot short circuit
Harness which is not connected to power source (24V) circuit is in contact with power source
(24V) circuit.
• Short circuit
Independent harnesses are in contact with each other abnormally.
20-402 WA600-3
(16)
TROUBLESHOOTING M-2
M-2 When starting switch is turned ON and engine is started immedi-

ately, all lamps stay lighted up
fl Before disconnecting or connecting connectors, always turn starting switch OFF.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
L05 (4) and chassis
ground normal? Defective contact or discon-
nection in wiring harness Repair or
• 20 – 30 V NO between L05 (female) (4) replace
• Turn starting switch and L57 (female) (3)
to START.
M-2 Related electrical circuit diagram
20-408 WA600-3
(16)
TROUBLESHOOTING M-4
M-4 Abnormality in shift indicator

fl Check that the transmission shifts normally.
a) Displays N even when directional lever is at F
Cause Remedy
1 YES
Is voltage between
L08 (7) and chassis
ON.
• Directional lever: F
b) Displays N even when directional lever is at R

Cause Remedy
1 YES
Is voltage between
L08 (8) and chassis
ON.
• Directional lever: R
c) Does not display N even when directional lever is at N
Cause Remedy
1 YES
Is voltage between
L05 áG and chassis Defective contact or
ground normal? disconnection in wiring
harness between L05 Repair or
• 20 – 30V NO (female) (8) and L04 replace
• Turn starting switch (female) (3)
ON.
• Directional lever: N
20-410 WA600-3
(16)
TROUBLESHOOTING M-5
M-5 High beam display does not light up

fl Before starting troubleshooting, check that the lamp bulbs of night lighting are not blown.
Cause Remedy
2 YES
Is resistance bet-
YES ween L06 (female)
1 (13) and chassis
Defective contact or discon-
Is voltage between ground normal? Repair or
nection in wiring harness
L06 (12) and • Max. 1 Ω NO between L06 (female) (13) replace
chassis ground • Turn starting switch OFF. and L02 (female) (3)
normal? • Disconnect L06.
• 20 – 30 V • Dimmer switch: Hi beam nection in wiring harness Repair or
• Turn starting NO between L06 (female) (12) replace
switch ON. and FS2 (female) (2)
WA600-3 20-413
(16)
TROUBLESHOOTING M-6
M-6 Turn signal display does not light up

fl Check the bulb of the turn signal display for breakage.
a) L.H. turn signal display does not light up Cause Remedy
1 YES
Is voltage between
L06 (14) and
chassis ground
normal? Repair or
• Repeats 0V and NO between L06 (female) (14) replace
20 – 30V. and L03 (female) (4)
• Turn starting switch ON.
• Turn L.H. turn signal ON.
b) R.H. turn signal display does not light up

Cause Remedy
1 YES
Is voltage between
L06 (15) and
chassis ground
normal? Repair or
• Repeats 0V and NO between L06 (female) (15) replace
20 – 30V. and L03 (female) (3)
• Turn starting switch ON.
• Turn R.H. turn signal ON.
20-414 WA600-3
(16)
TROUBLESHOOTING M-8
M-8 Abnormality in preheating display

Serial No. : 50001 – 52000

fl If there is abnormality in APS system, carry out troubleshooting according to E-4, then carry out
troubleshooting according to M-8.
Cause Remedy
a) Preheating display does not light up
YES Defective main monitor

Replace
1 (monitor module)
Is voltage between
L05 (19) and Defective contact or
chassis ground 2 YES disconnection in wiring Repair or
normal? harness between L71
replace
Is voltage (female) (4) and L05
• 20 – 30V (female) (19)
between L71 (4)
• Turn starting NO and (1) normal?
switch ON.
• Turn APS switch Defective APS controller Replace
• 20 – 30V NO
to AUTO. • Turn starting switch ON.
• Water temperature • Turn APS switch to AUTO.
is below 20°C. • Water temperature is below 20°C.
b) Preheating display stays lighted up

Short circuit with power
2 YES source in wiring harness Repair or
between L71 (female) (4) replace
Is voltage and L05 (female) (19)
YES
between L71 (4)
1
and (1) normal?
Does preheating Defective APS controller Replace
stop when L05 is • 20 – 30V NO
disconnected? • Turn starting switch ON.
• Turn APS switch to AUTO.
• Disconnect L05. • Water temperature is below 20°C. Defective main monitor
Replace
• Turn starting NO (monitor module)
switch ON.
• Turn APS switch to AUTO.
• Water temperature is below 20°C.
20-416 WA600-3
(16)
TROUBLESHOOTING M-9
M-9 Night lighting of monitor does not light up

fl Before starting troubleshooting, check that the lamp bulbs of night lighting are not blown.
Cause Remedy
1 YES
Is voltage between
L05 (16) and
chassis ground
Defective contact or
normal? Repair or
disconnection in wiring
• 20 - 30 V NO harness between L05 replace
• Turn starting switch (female) (16) and FS2 (5)
ON.
• Turn small lamp switch
ON.
WA600-3 20-417
(16)
TROUBLESHOOTING M-10
M-10 Abnormality in front working lamp

fl Before starting troubleshooting, check that the monitor lighting is lighted up.
a) Neither monitor display nor front working lamp light up
Cause Remedy
Defective contact or
disconnection in wiring
YES Repair or
harness between L60
(female) (1), L05 (female) replace
(17) and CL1 (female) (7)
1
Is voltage 3 YES Defective front working Replace
between L60 (1) Is voltage lamp relay
and chassis YES between L60 (1)
ground normal? and chassis Defective main monitor or
2
ground normal? defective contact or discon
•0–3V Is voltage between Repair or
-nection in wiring harness
• Turn starting L60 (2), (5) and •0–3V NO between L60 (female) (6) replace
switch ON. NO chassis ground • Turn starting switch ON. and L06 (female) (1)
normal? • Turn working lamp switch ON.
Defective contact or discon
• 20 – 30 V -nection in wiring harness Repair or
• Turn starting NO between L60 (female) (2), replace
switch ON. (5) and FS5 (female) (1)
b) Working lamp lights up but monitor display does not light up
Cause Remedy
1 YES
Is voltage between
L05 (17) and
chassis ground
normal? Repair or
ON.
c) Monitor display lights up but working lamp does not light up
Cause Remedy

between L60 (1) – CL1 (7) – Repair or
C03 (female) (1), C04 replace
(female) (1), or blown
working lamp bulb
20-418 WA600-3
(16)
M-11 Abnormality in rear working lamp

fl Before starting troubleshooting, check that night lighting of monitor is lighted up.
a) Neither monitor display nor rear working lamp light up
Cause Remedy

-nection in wiring harness
YES Repair or
between L61 (female) (1)
and L05 (female) (18), CR1 replace
(female) (12)
1
Is voltage 3 YES Defective front working Replace
between L61 (1) Is voltage lamp relay
and chassis YES between L06 (2)
ground normal? and chassis Defective main monitor or
2
ground normal? defective contact or discon
•0–3V Is voltage between -nection in wiring harness Repair or
• Turn starting L61 (2), (5) and •0–3V NO between L61 (female) (6) replace
switch ON. NO chassis ground • Turn starting switch ON. and L06 (female) (2)
normal? • Turn working lamp switch ON. Defective contact or discon
• 20 – 30 V -nection in wiring harness Repair or
• Turn starting NO between L61 (female) (2), replace
switch ON. (5) and FS5 (female) (2)
b) Working lamp lights up but monitor display does not light up
Cause Remedy
1 YES
Is voltage between
L05 (18) and
chassis ground
normal? Repair or
ON.
c) Monitor display lights up but working lamp does not light up
Cause Remedy

between L61 (1) – LR1 (12) Repair or
– G02 (female) (1), G03 replace
(female) (1), or blown
working lamp bulb
20-420 WA600-3
(16)
WA600-3 20-421
1
M-12 Abnormality in transmission cut-off

a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not
change
Cause Remedy
b) When transmission cut-off switch is turned OFF, cut-off function is always actuated
Cause Remedy
YES

4 YES -nection in wiring harness Repair or
1 between L65 (female) (5)
Is voltage replace
and L66 (female) (1)
Is voltage between YES between L65 (5)
L06 (3) and chassis and chassis
3
ground normal? ground normal? Defective transmission
Is voltage Replace
YES between L65 (1) • 20 – 30 V NO cut-off relay
• 20 – 30 V • Turn starting switch ON.
• Turn cut-off 2 and chassis Defective contact or discon
ground normal? • Turn packing switch
switch ON. Is resistance bet- OFF -nection in wiring harness
Repair or
ween L06 (female) • 20 – 30 V between L65 (female) (1),
FS2 (female) (8) and fuse I replace
NO (3) and L65 (female) • Turn starting
(2) normal? switch ON. NO (9)
• Disconnect L65 Defective contact or discon
• Max. 1 Ω
-nection in wiring harness Repair or
• Turn starting
NO between L06 (female) (3) replace
switch OFF.
and L65 (female) (2)
• Disconnect L06 and L65.
20-422 WA600-3
(16)
M-16 Condition of monitor switches is not stored in memory

Cause Remedy
1 YES
Is voltage between
L07 (10) and
chassis ground
normal? Repair or
ON.
WA600-3 20-427
(16)
M-17 Abnormality in failure display mode

a) Failure display mode does not work

Cause Remedy
1 YES
Is voltage between
L05 (5) and chassis Short circuit with power
ground normal? source in wiring harness
between L05 (female) (5) – Repair or
•0–5V NO LR4 (6) – ER1 (9) – replace
• Turn starting switch alternator terminal R, or
defective alternator
ON.
b) Count for time elapsed since failure in failure display mode does
not advance
Cause Remedy
1 YES
Is voltage between
L05 (5) and chassis Defective contact or discon-
ground normal? nection in wiring harness
between L05 (female) (5) – Repair or
• 20 – 30 V NO LR4 (6) – ER1 (9) – replace
• Start engine. alternator terminal R, or
defective alternato
20-428 WA600-3
(16)
d) Monitor display flashes slowly (1 time/sec)

Confirm that grease is not empty.
Cause Remedy
See “Handling auto-greasing

system” in Operation and —
Maintenance Manual
e) Monitor display goes out Cause Remedy
YES
1
Is voltage between
L07 (11) and
chassis ground 2 YES Hot short in wiring harness
Repair or
normal? between L07 (female) (11)
Is voltage between and GRE (female) (2) replace
• Max. 3 V GRE (female) (2)
• Turn starting NO and chassis
switch ON. ground normal? See “Handling auto-greasing
system” in Operation and —
•2–3V NO Maintenance Manual
• Turn starting switch
ON.
• Disconnect GRE.
Table 1 (Relationship between input signal

and display)
L07(11) L08(5) Display
L L Rapid flashing (2 times/sec)
H L Slow flashing (1 time/sec)
H H OFF
L H ON
WA600-3 20-431
(16)
M-20 Abnormality in ECSS system

Serial No. : 50001 – 52000
fl ECSS : Electronic Controlled Suspension System.
fl Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that
DIP switch 4 on the back side of the main monitor is set correctly.
a) Display does not change when switch is pressed

Cause Remedy
b) Monitor display lights up but ECSS function does not work
Cause Remedy
2 YES Go to Troubleshooting
for ECSS controller —
Is voltage between system (D MODE)
YES
AL2 (15) and chassis
1 Defective contact or
ground normal?
Is voltage between disconnection in wiring Repair or
• Max. 3 V NO harness between L06 (7) replace
L06 (7) and chassis
• Turn starting switch and AL2 (15)
ground normal?
ON.
• Max. 3 V
• Turn starting switch NO
ON.
c) Monitor lamp does not light up

Cause Remedy
20-432 WA600-3
(11)
WA600-3 20-432-1
(11)
fl ECSS : Electronic Controlled Suspension System.
a) Display does not change when switch is pressed Cause Remedy
b) Monitor display lights up but ECSS function does not work

Cause Remedy
2 YES Go to Troubleshooting
for ECSS controller —
Is voltage between system (D MODE)
YES
AL2 (15) and chassis
1 Defective contact or
ground normal?
Is voltage between disconnection in wiring Repair or
• Max. 3 V NO harness between L06 (7) replace
L06 (7) and chassis
• Turn starting switch and AL2 (15)
ground normal?
ON.
• Max. 3 V
• Turn starting switch NO
ON.
c) Monitor lamp does not light up

Cause Remedy
WA600-3 20-433
(11)
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM
(K MODE)
Electrical circuit diagram for maintenance monitor ............................................................................. 20-502

K- 1 When starting switch is turned ON, all lamps on maintenance monitor do not light up
for 3 seconds
Maintenance monitor does not work .......................................................................................... 20-504
a) No lamps on maintenance monitor light up ....................................................................... 20-504
b) Some lamps do not light up ................................................................................................. 20-504
K- 2 When starting switch is turned ON, all lamps on maintenance monitor light up but
do not go out even after 3 seconds ............................................................................................ 20-505
K- 3 When engine is started immediately after starting switch is turned ON
within 3 seconds, no lamps on maintenance monitor go out .................................................. 20-506
K- 4 When engine is stopped and starting switch is turned ON, CHECK item display flashes ..... 20-507
a) Engine oil level display flashes ............................................................................................. 20-507
b) Engine coolant level display flashes .................................................................................... 20-508
K- 5 When engine is stopped and starting switch is turned ON, CAUTION item display
flashes ........................................................................................................................................... 20-509
a) Engine oil pressure display flashes ...................................................................................... 20-509
b) Battery charge display flashes .............................................................................................. 20-510
c) Brake oil pressure display flashes ........................................................................................ 20-511
d) Air cleaner clogged display flashes ...................................................................................... 20-512
K- 6 CAUTION item display is flashing, but caution buzzer does not sound .................................. 20-513
K- 7 No monitor display lights up, but caution buzzer sounds ........................................................... 20-514
K- 8 CAUTION item display is flashing, but central CHECK lamp or central CAUTION lamp
does not flash ............................................................................................................................... 20-515
a) CHECK lamp ........................................................................................................................... 20-515
b) CAUTION lamp ....................................................................................................................... 20-515
K- 9 No maintenance monitor display lights up, but central CHECK lamp or central
CAUTION lamp lights up ............................................................................................................. 20-516
a) CHECK lamp ........................................................................................................................... 20-516
b) CAUTION lamp ....................................................................................................................... 20-516
K-10 Only night lighting of monitor does not light up when lamp switch is turned ON ................ 20-517
K-11 Night lighting of monitor lights up even when lamp switch is OFF ........................................ 20-518
K-12 Service meter does not work ....................................................................................................... 20-519
K-13 Service meter is running even when engine is stopped ........................................................... 20-519
K-14 Abnormality in gauges ................................................................................................................. 20-520
a) Abnormality in fuel gauge .................................................................................................... 20-520
b) Abnormality in engine coolant temperature gauge ............................................................ 20-521
c) Abnormality in torque converter oil temperature gauge ................................................... 20-522
WA600-3 20-501
(16)
TROUBLESHOOTING K-4
b) Engine coolant level display flashes

fl Before starting troubleshooting, check the engine coolant level again.
(Check that the engine coolant level is correct.)
Cause Remedy
3 YES Defective monitor module

Replace
Is resistance bet- of maintenance monitor
YES ween L18 (female)
2 (8) and chassis Defective contact or discon-
ground normal? nection in wiring harness
Is resistance bet- Repair or
YES ween G01 (female) between L18 (female) (8) –
• Max. 1 Ω NO LR3 (2) – GR1 (3) – G01 replace
(1) and chassis • Turn starting switch (female) (1)
1 ground normal? OFF. Defective contact or discon-
Is resistance • Disconnect L18.
• Max. 1 Ω nection in wiring harness Repair or
between G01
(male) (2) and (1) • Turn starting switch NO between G01 (female) (2) – replace
OFF. GR1 (2) – chassis ground
normal?
• Disconnect G01.
• Max. 1 Ω
• Turn starting switch Defective coolant level
Replace
OFF. NO sensor
• Disconnect G01.
K-4 b) Related electrical circuit diagram
20-508 WA600-3
(16)
TROUBLESHOOTING K-14
b) Abnormality in engine coolant temperature gauge

(1) Nothing is displayed
Cause Remedy
YES Defective engine coolant

Replace
1 temperature sensor
Does engine coolant
temperature gauge
show minimum level
when E04 is 2 YES Defective monitor module
Replace
disconnected? Is resistance bet- of maintenance monitor
• Disconnect E04. ween E04 (female)
Short circuit with chassis
• Turn starting NO (1) and chassis ground in wiring harness
switch ON. ground normal? between E04 (female) (1) – Repair or
• Min. 1 MΩ NO ER1 (6) – LR4 (1) – L18 replace
• Turn starting switch (female) (4) (contact with
OFF. chassis ground)
• Disconnect L18 and E06.
(2) Display shows lowest level Cause Remedy
YES Defective engine coolant

Replace
temperature sensor
1
When short connec-
tor is connected to E04
(female), does engine
3 YES Defective monitor module
Replace
coolant temperature Is resistance between of maintenance monitor
gauge display area L18 (female) (4) and
rise one stage at a YES chassis ground nor-
time, and finally do all mal when short con-
2 Defective contact or discon-
lamps go out? nector is connected
to E04 (female)? nection in wiring harness Repair or
Is resistance bet- between E04 (female) (1) –
• Disconnect E04. replace
ween E04 (female) • Max. 1 Ω NO ER1 (6) – LR4 (1) – L18
• Connect short
(2) and chassis • Turn starting switch OFF.
connector to E04 NO ground normal? (female) (4)
• Connect short connector to E04 (female).
(female). Defective contact or discon-
• Turn starting • Disconnect L18. nection in wiring harness Repair or
• Turn starting
switch ON. switch OFF. NO between E04 (female) (2) – replace
• Disconnect E04. ER1 (7) – chassis ground
• Max. 1 Ω
K-14 b) Related electrical circuit diagram
WA600-3 20-521
(16)
TROUBLESHOOTING E-1
b) Starting motor turns
YES
4 YES
Is resistance
YES between E03
(female) (8) and
chassis normal?
1 • Max. 1 Ω NO
3 • Turn starting
Does engine stop Is voltage switch OFF.
motor work? YES between E03 (7) • Disconnect E03.
YES
and chassis
normal?
• Turn starting switch
ON ↔ OFF and • 20 – 30 V
check visually. • Connect T-adapter
5
to E03.
• Turn starting Does engine stop
motor work when YES
switch ON.
NO engine stop relay 7
2 is replaced? Is resistance
Is voltage between • Replace engine stop YES between L62
E03 (female) (4) relay (L62) with stop (female) (2) and
NO and chassis lamp relay (L53). 6 chassis normal?
normal? • Turn starting Is voltage between • Max. 1 Ω
• 20 – 30 V switch ON ↔ OFF L62 (female) (1) • Turn starting NO
• Turn starting and check NO and chassis switch ON.
switch OFF. visually. normal? • Disconnect L62.
• Disconnect E03. • 20 – 30 V
• Disconnect L62.
• Turn starting NO
switch ON.
• Turn kill
switch ON.
NO
20-614 WA600-3
(16)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
POWER TRAIN
H- 1 Machine does not start ................................................................................................................ 20-702
H- 2 Travel speed is slow, or lacks power in all speed ranges ......................................................... 20-703
H- 3 Excessive time lag when starting machine or shifting gear ..................................................... 20-704
H- 4 Torque converter oil temperature is high ................................................................................... 20-705
STEERING SYSTEM
H- 5 Steering wheel does not turn ...................................................................................................... 20-706
H- 6 Steering does not turn [machine with joystick] ......................................................................... 20-707
H- 7 Turning, response of steering is poor ......................................................................................... 20-708
H- 8 Turning, response of steering is poor [machine with joystick] ................................................. 20-710
H- 9 Steering is heavy .......................................................................................................................... 20-712
H-10 Joystick is heavy [machine with joystick] .................................................................................. 20-712
H-11 Steering wheel shakes or jerks .................................................................................................... 20-713
H-12 Steering shakes or there is excessive shock [machine with joystick] ...................................... 20-714
H-13 Turning radius is different between left and right at maximum steering ................................ 20-714
BRAKE SYSTEM
H-14 Wheel brakes do not work or braking effect is poor ................................................................. 20-716
H-15 Wheel brakes are not released or brakes drag .......................................................................... 20-718
H-16 Parking brake does not work or braking effect is poor ............................................................. 20-719
H-17 Parking brake is not released or brake drags (including emergency release system) ........... 20-720
WORK EQUIPMENT
H-18 Neither lift arm nor bucket move ................................................................................................ 20-721
H-19 Both lift arm and bucket are slow or lack power ....................................................................... 20-722
H-20 Lift arm does not move ................................................................................................................ 20-723
H-21 Lift arm does not move [machines with remote lift arm control] ............................................ 20-724
H-22 Lift arm is slow or lift arm lacks power ...................................................................................... 20-725
H-23 Lift arm is slow or lift arm lacks power [machines with remote lift arm control] ................... 20-726
H-24 Lift arm cannot be set to FLOAT or cannot be released from FLOAT ...................................... 20-727
H-25 Lift arm drops momentarily when control lever is operated from HOLD to RAISE ................ 20-727
H-26 Remote lift arm control does not work [machines with remote lift arm control] ................... 20-728
H-27 Excessive hydraulic drift of lift arm ............................................................................................ 20-729
H-28 Bucket does not move .................................................................................................................. 20-730
H-29 Bucket is slow or lacks power ..................................................................................................... 20-731
H-30 Excessive hydraulic drift of bucket ............................................................................................. 20-732
H-31 ECSS does not work, and there is pitching and bouncing [machines with ECSS] [*] ............ 20-733
* : Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check
WA600-3 20-701
(16)
TROUBLESHOOTING H-1
H-1 Machine does not start

Ask the operator the following questions.
c.)
• Did the problem suddenly start?
t
re, e
Yes → Internal part seized, broken
ring
seizu
Was there any abnormal noise when this hap-
e sp
pened?
ers,
ss)
)
eed
valv
Yes → Part broken
matt
htne
d sp
ing
reign
l-tig
r 2n
duc
Checks before troubleshooting
e oi
of fo
it (fo
e re
• Does the main monitor function properly?
ve
ctiv
o
ol
lve
tion
ssur
• Is the transmission oil level correct? Is the type
ircu
spo
e
r gr
latin elief va
(Suc
of oil correct?
e
t pre
ch c
d) (d
ng o
alve
• Is the transmission filter or strainer clogged?
ses
pool
clut
alve
o
pee
v
i
r
l
r
i
• Does the electrical transmission control circuit
of m ulating
Cau
p
g
seal
ump
ve s
y
v
s
n of
r
work normally?
oid
d
a
l val
utch
t
n
sion
utch
of p
n ro
atio
odu
olen
• Is the transmission oil deteriorated? Does the oil
mod
ntro
o
n cl
ng i
mis
n cl
r
end
f
smell of burning?
ch (
of s
e op
of co
n of
ssio
s
ssio
al ri
• Is there any damage or leakage of oil that can be
n
low
clut
ion
tion
e tra
ctiv
ratio
smi
ation
t se
smi
seen externally? at b
erat
tary
mp
pera
defe
nsid
Defe of tran
f
ope
n
• Is the drive shaft broken?
oper
e pu
e tra
e op
n in
e sh
e ro
o
i
• Is the wheel brake or parking brake locked?
r
e
e
e
blow
ctive
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
kag
ctiv
gue
ure
Defe
Defe
Defe
Defe
Defe
Brea
Defe
Defe
Seiz
Fati
Air
Tank –
Pump Transmission
a b c d e f g h i j k l
Remedy × × × × × × ×
No.
Problems × ×
1 Abnormal noise comes from circuit between pump and filter
2 Does not start in any transmission range (Item 1 is normal)
3 Does not start in certain transmission ranges
4 Machine does not start when transmission oil temperature rises
5 Modulation pressure Pressure is low in all speed ranges
6 of transmission is Pressure is low in certain speed ranges
7 low Gauge fluctuates, oil pressure is not stable.
8 Pilot pressure is insufficient
Note 1) When the valve spool does not move even if the solenoid valve and oil pressure are normal, the
cause of this trouble is “¬”.
Note 2) When the transmission clutch pressure is low and the cause of this problem is not found in the
above table, the valve or transmission may be cracked.
20-702 WA600-3
(16)
TROUBLESHOOTING H-5
H-5 Steering wheel does not turn

Yes = Related equipment broken
pened? Where did the noise come from?

• Is the oil level in the hydraulic tank correct?
Is the type of oil correct?
• Is the steering shaft broken?
• Is the stop valve stopper properly adjusted?
• Has the safety bar been removed from the
ses
ol
l
mp
poo
frame?
spo
Cau
h pu
s
and
ing
alve
t c
teer
dem
w i
on v
nd s
of s
e
n of
valv
ucti
seal
mp
alve
ng a
ion
ll
atio
t-ro
ty-s
C pu
rge
ston
op v
tuat
eeri
Defe ve Orbi
actu
safe
cha
e PP
e ac
e st
e pi
e st
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Hydraulic Charge Orbit- Stop Steering Cylin-
pump valve roll valve valve der
a b c d e f g h i
Remedy
No. × × ×
Problems × × × × × ×
1 Steering wheel does not turn in both directions (left and right)
2 Steering wheel turns only in one direction (left or right)
3 Steering wheel is heavy in both directions (left and right)
4 Work equipment moves
5 Work equipment does not move
6 Abnormal noise comes from around PTO
7 Abnormal noise comes from around PPC pump or hydraulic tank
Oil pressure is low or there is no pressure
8 When steering in both directions (left and right)
relief pressure
is measured Oil pressure is low or there is no pressure
9
in one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is
10
found to be low or there is no oil pressure
11 When PPC valve (Orbit-roll) Oil pressure is low
12 basic pressure is measured There is no oil pressure
fl There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20-706 WA600-3
(16)
TROUBLESHOOTING H-6
H-6 Steering does not turn [machine with joystick]


• Is the steering shaft broken?
e
valv
• Is the stop valve stopper properly adjusted?
oid
ses
• Has the safety bar been removed from the
ump
ol
o l
olen
frame?
spo
spo
Cau
alve
of p
ck s
• Is the operation of the steering and the steer-
alve
d
ing
lve
n
op v
a
end
ing mode switch correct?
ysti
teer
ston trictor v
m
a
on v
e
t
of jo
of d
of s
ion
of s
e
valv
ucti
seal
mp
suct
res
ion
ion
ion
tion
oll
ty-s
C pu
arge
bit-r
tuat
t
t
y
Defe ed in at
a
a
Defe e actua
Defe e 2-wa
suck TO
actu
actu
safe
r
e PP
filte
e Or
e ch
e ac
e pi
eP
e
e
e
ctiv
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Clog
Defe
Defe
Defe
Defe
Defe
Air
Hydraulic Charge Orbit- Stop Steering Cylin-

pump Joystick Valve
valve roll valve valve der
a b c d e f g h i j k l m
Remedy C
No. × × × ×
Problems × × × × × × × ×
1 When steering Steering does not move (steering wheel mode only)
2 mode switch Steering does not move (joystick mode only)
3 is switched Steering does not move in either mode
4 Steering wheel does not turn in both directions (left and right)
5 Steering wheel turns only in one direction (left or right)
7 Steering wheel is heavy in one direction (left or right)
Oil pressure is low, or there is no pressure
relief pressure
is measured Oil pressure is low, or there is no pressure
13
in one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure

14
is found to be low or there is no oil pressure
When joystick solenoid valve output pressure is measured,
15
oil pressure is found to be low or there is no oil pressure
16 When PPC valve (Orbit-roll) Oil pressure is low
17 basic pressure is measured There is no oil pressure
WA600-3 20-707
(16)
TROUBLESHOOTING H-7
H-7 Turning, response of steering is poor

• Did the problem gradually appear?
Yes = Wear of related parts, defective seal

ses
ool
poo
pum
Cau
g sp
e
nd s
valv
d of
alve
erin
ema
stop
n en
alve
on v
e
p
t
of d
s
m
mp
e
v
o
n of
f
valv
al
u
ucti
o
i
p
f
suct
ng p
relie
n se
h pu
pum
ion
tion
roll
atio
ty-s
arge
tuat
n at
isto
rbit-
eeri
ctua
witc
ain
suck TO
u
PPC
safe
t
e ch
e ac
e ac
m
ve p
ed i
e st
eP
a
s
e
e
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ecti
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
IDef
Air
Charge Orbit- Stop Cylin-

Hydraulic pump valve roll valve Steering valve der
a b c d e f g h i j k l m
Remedy
No. × × × ×
Problems × × × × × × × ×
1 Turning, response of steering is poor in both directions (left and right)
2 Turning, response of steering is poor in one direction (left or right)
3 Steering wheel is heavy in both directions
8 Abnormal noise comes from around steering pump or hydraulic tank
9 Abnormal noise comes from around switch pump or hydraulic tank
Oil pressure is low or there is no pressure
relief pressure
is measured Oil pressure is low or there is no pressure
11 in one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure

12
is found to be low
13 When PPC valve (Orbit-roll) basic pressure is measured,

oil pressure is found to be low
20-708 WA600-3
(16)
TROUBLESHOOTING H-8
H-8 Turning, response of steering is poor [machine with joystick]

• Was there previously any symptom, such as
difficulty in steering?
Yes = Wear of related equipment, defective
seal
e
valv
oid
ses
ump
ool
olen
Cau
p
lve
of p
s
ck s
and
p va
end
ysti
dem
lve
f sto
p
of jo
f va
ion
m
mp
e
f
valv
u
o
o
mp
suct
relie
p
h pu
ion
ion
tion
-roll
ing
C pu
arge
tuat
tuat
n at
ctua
witc
ain
teer
Clog e Orbit
suck TO
er
e PP
e ch
e ac
e ac
em
ed i
t
eP
s
s
a
f i
e
e
e
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
Charge Orbit- Stop Steering

Hydraulic pump valve roll
Joystick valve valve
a b c d e f g h i j k l
Remedy C
No. × × × ×
Problems × × × × × × ×
1 When steering Abnormality only in steering wheel mode
2 mode switch is Abnormality only in joystick mode
3 switched Abnormality in both modes
4 Turning, response of steering is poor in both directions (left and right)
5 Turning, response of steering is poor in one direction (left or right)
11 Abnormal noise comes from around steering pump or hydraulic tank
12 Abnormal noise comes from around switch pump or hydraulic tank
13 When steering Oil pressure is low in both directions (left and right)
relief pressure
14 is measured Oil pressure is low in one direction (left or right)
15 When Orbit-roll output pressure is measured, oil pressure is found to be low
When joystick solenoid valve output pressure is measured,
16 oil pressure is found to be low
When PPC valve (Orbit-roll) basic pressure is measured,
17 oil pressure is found to be low
20-710 WA600-3
(16)
TROUBLESHOOTING H-14
H-14 Wheel brakes do not work or braking effect is poor

Checking for abnormalities
• Measure the actual brake performance, and
check if there is actually an abnormality or
ator
whether it is just the feeling of the operator.
mul
For details, see TESTING AND ADJUSTING,
Measuring brake performance.
accu
rom
as f
of g
ing
leed
ses
ump
e
ve b
Cau
ton
valv
of p
brak ake pis

i
fect
rge
end
seal
cha
r de
e
v
lve
br
l
r
ion
e va
e
al o
ator
e
a
f
s
v
o
o
mp
suct
adju
t
brak
e
tion
n se
s
l
i
u
C pu
p
a
ccum
side
ft br
n at
rake
• Is the brake pedal play correct?
ctua
k
isto
ght
suck TO
c
e sla
e PP
e in
• Is there any leakage of oil from the brake tube?
ed i
e le
eP
b
i
a
a
r
e
e
e
e
e
ctiv
ctiv
Is there any deformation of the tube?
ctiv
kag
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
• Is the tire inflation pressure and tread pattern
Defe
Brea
Defe
Defe
Defe
Defe
Defe
Defe
Air
correct? Charge Accu- Brake Slack

PPC pump valve adjuster
Wheel brake
valve mulator
a b c d e f g h i j k
Remedy
No. ×
Problems × × × × × × × × ×
1 Brake has no effect only when left brake pedal is depressed
2 Left brake pedal is light when it is depressed
3 Right brake pedal is light when it is depressed
4 Left brake pedal is heavy when it is depressed
5 Right brake pedal is heavy when it is depressed
6 Abnormally large operating force is needed to obtain specified braking force
7 Abnormal noise is heard from brake when brake is applied
8 Work equipment, steering also do not work
9 Movement of work equipment, steering is slow
12 Many metal particles are found in oil drained from axle case
13 When accumulator charge pressure is measured, oil pressure is found to be low
14 Brake stops having effect immediately when engine is stopped
15 There is a time lag before brake takes effect
16 When brake oil pressure is measured, it is found to be low
17 When drop in brake piston pressure is measured, it is found to be excessive
18 When wear of brake disc is measured, it is found to be excessive
19 When air is bled from brake line, air comes out
fl The PPC pump is used for the wheel brake actuation pressure in the same way as for the work
equipment circuit and steering circuit, so if any abnormality is felt in the wheel brake, check the
condition of actuation of the work equipment and steering also (the circuit set pressure is different).
20-716 WA600-3
(16)
×
brake
Wheel
Defe
ctiv
×
Defe e br
ake
WA600-3
l m n
ctiv
Others
pist
Brea e actua on s
kag tion eal
e in
side o f bra
brak ke p
e isto
n
TROUBLESHOOTING
6
H-14
20-717
H-15 Wheel brakes are not released or brakes drag


• Does the brake pedal come back fully?
• Is the parking brake still applied?
ses
ster
ton
Cau
adju
, pla ake pis
lack
e
valv
ve
br
of s
te
e rig ake val
n of
rake
ion
atio
disc
ht b
tuat
ft br
Seiz ve actu
rake
e ac
e le
ed b
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Defe
Brake Slack Wheel

valve adjuster brake
a b c d e
Remedy ×
No.
Problems × × × ×
1 Machine cannot travel at all
2 Machine can travel a small amount
When remaining pressure is released from brake accumulator
3
circuit with left brake pedal only, brake is released
When remaining pressure is released from brake accumulator

4
circuit with right brake pedal only, brake is released
When air bleed plug in wheel portion is loosened, oil flows
5
out and brake is released
6 When air bleed plug is loosened, a large amount of oil flows out
When brake disc wear is measured and brake pedal is
7
released, piston returns
When brake disc wear is measured and brake pedal is

8
released, piston does not return
20-718 WA600-3
(16)
H-16 Parking brake does not work or braking effect is poor

lve
e va
• Is parking brake emergency release switch
on
open? (Normally it is open)
leas
pist
e
• Is parking brake mechanical release operation
ses
y re
valv
ake
being carried out?
Cau
c
gen
noid
g br
mer
rkin
sole
ke e
f pa
ake
ring
a
on o
g br
g br
e sp
uati
rkin
rkin
disc
brak
t
e pa
e pa
e ac
ake
e
ctiv
ctiv
ctiv
n br
ctiv
Defe
Defe
Defe
Defe
Wor
Parking
SOL Value
brake
a b c d e
Remedy × × ×
No.
Problems × ×
1 Parking brake does not work when engine is stopped
When parking brake disc wear is measured, disc thickness is
2
found to be less than specified value
There is no oil pressure when parking

When parking brake brake switch is ON (normal)
3 inlet port pressure
is measured There is oil pressure when parking
brake switch is ON
When parking brake There is no oil pressure when parking

solenoid valve brake switch is ON (normal)
4
output pressure There is oil pressure when parking
is measured brake switch is ON
WA600-3 20-719
(16)
H-18 Neither lift arm nor bucket move


ses
ump
Cau
of p
end
lve
f va
ion
alve
mp
t
relie
u c
ge v
C pu
s
n at
ain
suck TO
Defe ve char
e PP
em
ed i
eP
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Air
Hydraulic Cont-
Charge rol
pump valve valve
a b c d e
Remedy
No.
Problems × × × × ×
1 Steering also does not work
When PPC valve output pressure is measured, oil pressure is
4
found to be normal
When PPC valve (Orbit-roll) basic pressure is measured, oil
5
pressure is low or there is no oil pressure
WA600-3 20-721
(16)
H-19 Both lift arm and bucket are slow or lack power
ses
ump
alve
Cau
nd v
of p
ema
end
lve
mp
of d
ion
f va
mp
alve
c pu
e
valv
mp
suct
relie
h pu
tion
ge v
l i
C pu
t-off
ydra
n at
ctua
witc
Defe e main
suck TO
a r
e PP
e ch
e cu
ed i
eP
a
s
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
Charge Cont- Steer- Cut-

Hydraulic pump rol ing off
valve valve valve valve
a b c d e f g h i
Remedy
No.
Problems × × × × × × × ×
1 Lift arm and bucket movement takes approx. 1.5 times standard value
2 Lift arm and bucket movement takes approx. 3 times standard value
3 Steering works normally
4 Response of steering is also poor
6 Abnormal noise comes from around hydraulic pump or hydraulic tank
7 found to be normal
When PPC valve (Orbit-roll) basic pressure is measured, oil
8 pressure is found to be low
20-722 WA600-3
(16)
H-20 Lift arm does not move

lve
ses
k va
l
poo
Cau
c
ms
e
d ch
e
ft ar
kag
f loa
r lin
of li
lve
e
seal
v
o
l
n va
leve
lve
a
tion
ion
v
der
C va
d
tuat
o
nloa
a
vel
ucti
n
actu
l i
e PP
e tra
e ac
e cy
u
s
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC
valve Control valve Boom Others
a b c d e f g
Remedy
No. A
1 Does not move in both directions (RAISE and LOWER)
2 Does not move in one direction (RAISE or LOWER)
Oil pressure is low or there is no pressure in
3 When lift arm both directions (RAISE and LOWER)
relief pressure
is measured Oil pressure is low or there is no pressure in
4
one direction (RAISE or LOWER)
5 found to be low or there is no pressure
When operating effort of lift arm control lever is measured,
6 lever is found to be heavy
7 When travel of lift arm control lever is measured, it is found to be short
WA600-3 20-723
(16)
H-21 Lift arm does not move [machines with remote lift arm control]
ol
spo
oid
alve
ses
olen
l
ool
of lo m spoo
ck v
Cau
ng s
le sp
ge
h
mpi
ad c
nka
hutt
r
lift a
f da
er li
of s
lve
alve
eal
o f
o
l lev
lve
n va
er s
ion
tion
ion
ion
v
C va
load
ntro
tuat
tuat
tuat
lind
Defe e suctio
t u a
e PP
e un
e ac
e ac
e ac
e ac
e cy
e co
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Shuttle
valve valve Control valve Boom Others
a b c d e f g h i
Remedy
No. × A
Problems × × × × × × ×
3 When lift arm both directions (RAISE and LOWER)
relief pressure
4
one direction (RAISE or LOWER)
5 found to be low or there is no pressure

20-724 WA600-3
(16)
H-22 Lift arm is slow or lift arm lacks power

lve
ses
k va
l
poo
Cau
c
ms
e
ge
d ch
ft ar
nka
f loa
er li
of li
lve
e
seal
v
o
l
l lev
n va
lve
a
tion
ion
v
der
C va
ntro
tuat
o
nloa
a
ucti
n
actu
l i
e PP
e ac
e cy
e co
u
s
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Cylin-
valve Control valve der
Others
a b c d e f g
Remedy
No. A
3 When lift arm Oil pressure is low in both directions (RAISE and LOWER)
relief pressure
4 is measured Oil pressure is low in one direction (RAISE or LOWER)
5 When PPC valve output pressure is measured, oil pressure is found to be low
6 When hydraulic drift of boom is measured, it is found to be excessive
7
lever is found to be heavy
WA600-3 20-725
(16)
H-23 Lift arm is slow or lift arm lacks power

[machines with remote lift arm control]
ol
spo
oid
e
ses
valv
olen
ol
ool
Cau
spo
s
eck
le sp
ing
ge
h
tion lift arm
amp
nka
hutt
a d
er li
of lo
of d
of s
alve
alve
eal
n of
l lev
lve
er s
ion
tion
on v
ad v
o
C va
ntro
tuat
lind
a
ctua
ctua
ucti
o
actu
l
e PP
e un
e ac
e co
e cy
a
a
s
e
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Shuttle Cylin-
valve valve Control valve der
Others
a b c d e f g h i
Remedy
No. × A
Problems × × × × × × ×
3 When lift arm Oil pressure is low in both directions (RAISE and LOWER)
relief pressure
4 is measured Oil pressure is low in one direction (RAISE or LOWER)
5 When PPC valve output pressure is measured, oil pressure is found to be low
6 When hydraulic drift of lift arm is measured, it is found to be excessive
7
20-726 WA600-3
(16)
TROUBLESHOOTING H-24, H-25
H-24 Lift arm cannot be set to FLOAT or cannot be released from FLOAT

• Can other operations of lift arm (RAISE, HOLD,
LOWER) be carried out normally?
e
valv
ses
ctor
lve
Cau
d va
sele
ge
nloa
nka
oat
er li
of u
of fl
l lev
lve
ion
tion
C va
ntro
tuat
a
actu
e PP
e ac
e co
e
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
PPC Control Others

valve valve
a b c d
Remedy
No. A
Problems × × ×
1 When PPC valve output pressure is measured Oil pressure is normal
2 (lift arm control lever at FLOAT position) Oil pressure is low
3 When PPC valve output pressure is measured Oil pressure is normal
4 (lift arm control lever at LOWER position) Oil pressure is low
H-25 Lift arm drops momentarily when control lever is operated from
HOLD to RAISE
Checking for abnormalities
• With the engine running at low idling, if the lift arm control lever is gradually moved from HOLD to
RAISE, the lift arm moves down momentarily under its own weight.
• If the control lever is operated fully to the RAISE position, the condition becomes normal.
Causes and Remedy

• Defective slow return check valve for control valve lift arm spool (t×).
WA600-3 20-727
(16)
H-26 Remote lift arm control does not work

[machines with remote lift arm control]
ol
spo
ool
ol
ool
spo
noid
• Does the main monitor function properly?
le sp
le sp
ses
• Is any failure code for the electrical system
ttle
sole
hutt
Cau
hutt
shu
displayed on the main monitor?
ER s
ing
SE s
ent
amp
OW
RAI
et
of d
of d
of L
n of
ion
ion
ion
atio
tuat
tuat
tuat
actu
e ac
e ac
e ac
e
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Shuttle valve
a b c d
Remedy
No. A
Problems × × ×
1 Lift arm does not stop in both directions (RAISE and LOWER)
2 Lift arm does not stop in RAISE direction
3 Lift arm does not stop in LOWER direction
20-728 WA600-3
(16)
H-27 Excessive hydraulic drift of lift arm

ol
ses
spo
Cau
arm
f lift
ss o
seal
htne
ston
l tig
e oi
e pi
ctiv
ctiv
Defe
Defe
Cont- Cylin-
rol
valve der
a b
Remedy ×
No.
Problems ×
1 When lift arm control lever is operated in Hydraulic drift increases
RAISE direction from lift arm maximum
2 raise with engine stopped (See Note) No change in hydraulic drift
Note : Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low
idle for 5 – 10 seconds, then stop the engine.
WA600-3 20-729
(16)
H-28 Bucket does not move

e
ses
valv
ool
Cau
eck
t sp
ge
lve
d ch
ucke
nka
n va
f loa
er li
of b
o
eal
i
o
t
l lev
c
lve
er s
tion
ion
y-su
C va
ntro
tuat
lind
a
afet
actu
e PP
e co
e ac
y
s
c
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
PPC Cylin-
valve Control valve der
Others
a b c d e f
Remedy
No. × A
1 Does not move in both directions (TILT and DUMP)
2 Does not move in one direction (TILT or DUMP)
3 When bucket both directions (TILT and DUMP)
relief pressure
4
one direction (TILT or DUMP)

5
found to be low or there is no pressure
When operating effort of bucket control lever is measured,
6
When travel of bucket control lever is measured, it is found to
7
be short
20-730 WA600-3
(16)
H-29 Bucket is slow or lacks power

lve
ses
k va
ol
Cau
spo
hec
ge
e
ket
valv
ad c
nka
buc
er li
of lo
tion
seal
n of
l lev
-suc
lve
ion
atio
der
C va
ntro
tuat
fety
cylin
actu
e PP
e co
e ac
e sa
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
PPC Cylin-
valve
Control valve der
Others
a b c d e f
Remedy
No. × A
1 Does not move in both directions (TILT and DUMP)
2 Does not move in one direction (TILT or DUMP)
3 When bucket Oil pressure is low in both directions (TILT and DUMP)
relief pressure
4 is measured Oil pressure is low in one direction (TILT or DUMP)
5 found to be low
6 When hydraulic drift of bucket is measured, it is found to be excessive
When operating effort of bucket control lever is measured,
8 When travel of bucket control lever is measured, it is found to be short
WA600-3 20-731
(16)
H-30 Excessive hydraulic drift of bucket

ses
ol
spo
Cau
cket
f bu
ss o
seal
htne
ston
l tig
e oi
e pi
ctiv
ctiv
Defe
Defe
Cont- Cylin-
rol
valve der
a b
Remedy ×
No.
Problems ×
1 When bucket control lever is Hydraulic drift increases
operated in DUMP direction with
2 engine stopped (See Note) No change in hydraulic drift
Note : Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low
idle for 5 – 10 seconds, then stop the engine.
20-732 WA600-3
(16)
H-31 ECSS does not work, and there is pitching and bouncing
[machines with ECSS]
Serial No. : 50001 – 52000

ccum ator
or
ulat
ul
OL2
L3)
ccum
(SO
e (S
essu 5)
re a
alve
valv
re a
L1)
L
(SO
(SO
id v
essu
noid
lve
leno
a lv e
h-pr
r
a
sole
p
gas enoid v
-
low
o
id v
g
ses
h i
sure
sure
leno
om
rom
Cau
• Is operation of ECSS switch correct?
l
e so
pres
r
r
s
e
• Is DIP switch 4 on the back side of the main
f
as f
f so
ll
r
o
w-p
harg
igh-
monitor set correctly?
ontr
g
i e
e of
f
l
ge o
of re
of lo
of h
(See TESTING AND ADJUSTING, Adjusting
of c
sor
of c
kag
eaka
main monitor (speedometer module).)
sen
ion
ion
ion
ion
, lea
atio
tuat
tuat
tuat
eed
t
al, l
Defe e actua
Defe ve actu
seal
e ac
e sp
e ac
e ac
e se
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Defe
Defe
Defe
Accumu- Cont- Sen-
Solenoid valve lator roller sor
a b c d e f g h
Remedy d0 d1 d2 d3 — — — —
No.
Problems
Speed (5 km/h) for start of actuation of ECSS is greatly out of
1 adjustment
2 ECSS does not work when traveling loaded
3 ECSS does not work when traveling unloaded
When ECSS is actuated when traveling loaded, lift arm drops
4 greatly (more than 30 cm)
5 ECSS does not work at all
WA600-3 20-733
(16)

or
or
ulat
ulat
cum
cum
e ac
e ac
L1)
ssur
ssur
(SO
-pre
-pre
alve
high
low
id v
ses
• Is operation of ECSS switch correct?
leno
rom
from
Cau
• Is DIP switch 4 on the back side of the main
r
olle
as f
o
monitor set correctly?
gas
ef s
ontr
of g
(See TESTING AND ADJUSTING, Adjusting
e of
l
of re
sor
of c
age
main monitor (speedometer module).)
g
eaka
sen
ion
leak
tion
tuat
eed
al, l
ctua
,
seal
e sp
e ac
e se
a
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Sole- Accumu- Cont- Sen-

noid
valve lator roller sor
a b c d e
Remedy d0 — — — —
No.
Problems
Speed (5 km/h) for start of actuation of ECSS is greatly out of
1 adjustment
2 ECSS does not work when traveling loaded
3 ECSS does not work when traveling unloaded
When ECSS is actuated when traveling loaded, lift arm drops
4 greatly (more than 30 cm)
5 ECSS does not work at all
20-734 WA600-3
(16)
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
METHOD OF DISPLAYING ACTION

CODE AND FAILURE CODE
1. Outline
The speedkometer display on the main monitor
is used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, fail-
ure code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit.
2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately.
There are two types of action code: E00 + CALL
and CALL. If a failure occurs suddenly, one of
these codes is shown on the speedometer dis-
play.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which
controller has failed, so carry out troubleshoot-
ing for the applicable controller.
4. Saving failure code

The transmission controller writes the failure
codes to memory.
1) A total of 9 failure codes can be saved in
memory.
2) The data that is saved to memory is as fol-
lows: (1) Failure code
(2) Time elapsed since failure
(up to 1,000 hours)
3) The failures are saved in the order that they
occur. If a failure code already exists in the
memory, the repeat failure code is not saved.
4) If there are already 9 items in memory, and
a 10th failure occurs, the oldest item is de-
leted and the new item is saved.
fl It is possible to display the failure code and
time elapsed since failure for items saved in
memory by operating the main monitor set
switch.
WA600-3 20-801-2
(16)
TROUBLESHOOTING JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM
Self-diagnostic display (abnormality display)
Short circuit, disconnection in joystick directional switch system
Short circuit, disconnection in engine speed sensor system

Short circuit, disconnection in directional switch system
Abnormality in network signal system or main monitor

Abnormality in transmission cut-off signal system
Short circuit, disconnection in shift switch system
Short circuit, disconnection in backup lamp relay
Abnormality in kickdown switch signal system

Disconnection in travel speed sensor system
Short circuit, disconnection in 2nd solenoid
Short circuit, disconnection in 3rd solenoid
Short circuit, disconnection in 4th solenoid
Abnormality in alarm buzzer signal system

Short circuit, disconnection in 1st solenoid
Short circuit, disconnection in R solenoid
Short circuit, disconnection in F solenoid
Abnormality in neutralizer signal system

Location of failure
Trouble-
Abnormality in network signal system

shooting
code when
no abnor-
mality
display is
given
Failure
code
Failure mode
10 12 13 14 15 16 17 19 20 21 22 23 — — — — — —
1 Travel is impossible c c c c c c t t t E-1, H-1
2 Directional lever and direction of travel are c

different
3 Machine travels forward when directional c c

lever is not at F
4 Machine travels in reverse when directional c c

lever is not at R.
5 There is excessive gearshifting shock c c H-2, H-3
6 There is shift hunting when traveling c
7 There is shift hunting when shifting gear c
8 Speed range cannot be controlled with speed c

control lever
9 Backup lamp and buzzer do not work c
10 Kickdown does not work c T-14, E-9
11 Transmission is not cut off with left brake c T-15, E-14
12 It is possible to travel even when parking c T-16, E-5

brake is applied
13 If F-R lever is operated when traveling at high c T-17

speed, alarm buzzer does not sound
14 Alarm buzzer continues to sound c T-17, J-1
15 Main monitor does not display transmission control- c T-18

ler information (alarm buzzer, failure code, etc.)
Troubleshooting code when failure code is displayed T-1 T-2 T-3 T-4 T-5 T-6 T-7 T-8 T-9 T-10 T-11 T-12 — — — — — —
20-802 WA600-3
(16)
TROUBLESHOOTING T-9
T-9 Related electrical circuit diagram

Serial No.: 50001 – 52000
20-820 WA600-3
(16)
TROUBLESHOOTING T-9

WA600-3 20-821
(16)
TROUBLESHOOTING T-18
T-18 Abnormality in network system

fl Always turn the starting switch OFF before disconnecting the connector or connecting the T-
adapter (or socket).
Cause Remedy
Defective transmission &

2 YES joystick steering Replace
Is resistance between
controller
YES C3B (female) (4), (12)
and L08 (female) (1), Defective contact or
1 (3) or LM1 (female) disconnection in wiring
Is resistance (5) normal? harness between C3B Repair or
between C3B (female) (4), (12) and L08
• Max. 1 Ω NO replace
(female) (4), (12) (female) (1), (3), or LM1
and chassis • Turn starting switch OFF.
(male) (5)
normal? • Disconnect C3B, L08 and
LM1. Short circuit with chassis
• Min. 1 MΩ Repair or
ground in wiring harness
• Turn starting NO replace
betwen C3B (female) (4),
switch OFF.
(12) and L08 (female) (1),
• Disconnect C3B, (3), or LM1 (male) (5)
L08 and LM1.
WA600-3 20-831
(16)
TROUBLESHOOTING OF ECSS
(ELECTRONICALLY CONTROLLED
SUSPENSION SYSTEM)
(D MODE)
Action taken by transmission controller when abnormality occurs and problems on machine ...... 20-952
Electrical circuit diagram for ECSS ........................................................................................................ 20-954
D-1 ECSS does not work ....................................................................................................................... 20-955
a) Error code [d0] is displayed .................................................................................................... 20-956
b) Error code [d1] is displayed .................................................................................................... 20-956
c) Error code [d2] is displayed .................................................................................................... 20-957
d) Error code [d3] is displayed .................................................................................................... 20-957
e) Error code [d4] is displayed .................................................................................................... 20-958
f) Error code [d5] is displayed .................................................................................................... 20-958
g) Error code [d6] is displayed .................................................................................................... 20-960
h) No abnormality display is given ............................................................................................. 20-963
D-2 ECSS cannot be canceled .............................................................................................................. 20-969
fl Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check
Notes:
• Hot short circuit
Harness which is not connected to power source (24V) circuit is in contact with power source
(24V) circuit.
• Short circuit
Independent harnesses are in contact with each other abnormally.
WA600-3 20-951
(16)
ACTION TAKEN BY TRANSMISSION CONTROLLER WHEN
TROUBLESHOOTING ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Serial No. : 50001 – 52000
Failure code Abnormal system Nature of abnormality
1) Defective ECSS (Sol 1 &) relay

2) Hot short, short circuit with ground, defective contact, or dis-
Short circuit or disconnection in connection in wiring harness between AL1 (female) (2) and
d0 relay A system L56 (female) (1)
3) Defective contact or disconnection in wiring harness between
L56 (female) (2) and chassis ground
4) Defective ECSS controller
1) Defective solenoid 2 (high-pressure)
connection in wiring harness between AL1 (female) (20) –
Short circuit or disconnection in ECSS (5) – AF2 (female) (1)
d1 solenoid 2 (high pressure) 3) Defective contact or disconnection in wiring harness between
AF2 (female) (2) and chassis ground
1) Defective solenoid 3 (low-pressure)

d2 solenoid 3 (low pressure) 3) Defective contact or disconnection in wiring harness between
1) Defective speed sensor

Disconnection in travel speed 2) Hot short, short circuit with ground, defective contact, or dis-
d3 sensor system connection in wiring harness between AL3 (female) (4), (12)
– TL1 (11), (12) – T05 (female) (1), (2)
1) Defective model selection connector
2) Defective contact or disconnection in wiring harness between
AL4 (male) (4) and ECSS (male) (8)
d4 Defective model selection signal 3) Defective contact or disconnection in wiring harness between
AL2 (female) (1) and AL4 (5)
4) Short circuit with ground in wiring harness between AL2 (fe-
male) (2), (3), (4) – AL4 (female) (2), (3), (1)
1) Defective solenoid 5 (high-pressure)
d5 solenoid 5 (charge) 3) Defective contact or disconnection in wiring harness between

connection in wiring harness between L04 (female) (5) and
AL2 (female) (11)
AL2 (female) (12)
AL2 (female) (13)
d6 Defective speed range signal 4) Hot short, short circuit with ground, defective contact, or dis-
AL2 (female) (14)
5) Defective lever
20-952 WA600-3
(16)
TROUBLESHOOTING ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller Problem that appears Trouble-

Condition when normal (voltage, current, resistance) when abnormality is on machine when shooting
detected there is abnormality code
1) Resistance of relay coil: 200 – 400 Ω
2) Resistance of wiring harness between transmission con-
troller C1 (female) (3) and ECSS relay L90 (female) (1): Max.
1Ω Shaking (Pitching
3) Voltage between transmission controller C1 (3) and chas- or bouncing) of D-1
sis ground: Less than 1 V (Command OFF); 20 V or above ECSS function: OFF machine during a)
(Command ON) travel at high speed
4) Resistance of wiring harness between ECSS relay L90 (fe- (2nd – 4th)
male) (2) and chassis ground: Max. 1 Ω
WA600-3 20-953-2
(16)
TROUBLESHOOTING D-1
D-1 ECSS does not work

Serial No. : 50001 – 52000
fl Carry out troubleshooting with the starting switch ON.
fl Check that the ECSS switch on the main monitor is ON.
Cause Remedy
Displaying [d0]. Go to Item a) —
Displaying [d1]. Go to Item b) —
2 5
YES Which code is

monitor Displaying [d2]. Go to Item c) —
displaying?
Displaying [d3]. Go to Item d) —
1 Displaying [d4]. Go to Item e) —
Is there an
abnormality
display? 8
Displaying [d5]. Go to Item f) —
Displaying [d6]. Go to Item g) —
Go to Item h) —
NO
WA600-3 20-955
(11)
TROUBLESHOOTING D-1
fl Carry out troubleshooting with the starting switch ON.
fl Check that the ECSS switch on the main monitor is ON.
Cause Remedy
YES Displaying [d0].

1 Go to Item a) —
Is there an
abnormality
display?
Go to Item b) —
NO
20-966 WA600-3
(11)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL .................... 30- 3 ENGINE AND TORQUE CONVERTER

PRECAUTIONS WHEN CARRYING OUT ASSEMBLY
OPERATION ................................................ 30- 4 Removal ...................................................... 30-48
SPECIAL TOOL LIST ..................................... 30- 6 Installation .................................................. 30-50
SKETCHES OF SPECIAL TOOLS .................. 30-14 TORQUE CONVERTER
STARTING MOTOR Removal and Installation ........................... 30-51
Removal and Installation ........................... 30-23 Disassembly ............................................... 30-52
ALTERNATOR Assembly .................................................... 30-57
Removal and Installation ........................... 30-24 TRANSMISSION
ENGINE OIL COOLER (Serial No.: 50001 – 52000) Removal ...................................................... 30-63
Removal and Installation ........................... 30-25 Installation .................................................. 30-65
FUEL INJECTION PUMP Disassembly ............................................... 30-66
(Serial No.: 50001 – 52000) Assembly .................................................... 30-81
Removal and Installation ........................... 30-26 TRANSMISSION VALVE
WATER PUMP (Serial No.: 50001 – 52000) Removal and Assembly ............................. 30-97
Removal and Installation ........................... 30-27 TRANSFER
NOZZLE HOLDER (Serial No.: 50001 – 52000) Disassembly ............................................... 30-98
Removal and Installation ........................... 30-28 Assembly .................................................. 30-107
TURBOCHARGER (Serial No.: 50001 – 52000) CENTER SUPPORT
Removal ...................................................... 30-29 Removal and Installation ......................... 30-118
Installation .................................................. 30-30 Disassembly ............................................. 30-120
ENGINE FRONT SEAL (Serial No.: 50001 – 52000) Assembly .................................................. 30-122
Replacement ............................................... 30-31 DRIVE SHAFT
ENGINE REAR SEAL (Serial No.: 50001 – 52000) Disassembly ............................................. 30-125
Replacement ............................................... 30-33 Assembly .................................................. 30-128
CYLINDER HEAD (Serial No.: 50001 – 52000) FRONT AXLE
Removal ...................................................... 30-35 Removal .................................................... 30-131
Installation .................................................. 30-40 Installation ................................................ 30-132
THERMOSTAT (Serial No.: 50001 – 52000) FRONT DIFFERENTIAL
Removal and Installation ........................... 30-42 Removal .................................................... 30-133
AFTERCOOLER CORE (Serial No.: 50001 – 52000) Installation ................................................ 30-134
Removal ...................................................... 30-43 REAR AXLE
Installation .................................................. 30-44 Removal .................................................... 30-135
RADIATOR Installation ................................................ 30-138
Removal ...................................................... 30-45 REAR DIFFERENTIAL
Installation .................................................. 30-47 Removal .................................................... 30-139
RADIATOR (with suction fan) Installation ................................................ 30-140
Removal ................................................... 30-47-5 DIFFERENTIAL GEAR
Installation ............................................... 30-47-8 Disassembly ............................................. 30-141
Assembly .................................................. 30-145
WA600-3 30-1
(15)
LIMITED SLIP DIFFERENTIAL LIFT CYLINDER AND DUMP CYLINDER
Disassembly .......................................... 30-152-1 Disassembly ............................................. 30-209
Assembly ............................................... 30-152-6 Assembly .................................................. 30-211
FINAL DRIVE CENTER HINGE PIN
Removal .................................................... 30-153 Removal .................................................... 30-214
Assembly .................................................. 30-155 Installation ................................................ 30-219
ORBIT-ROLL WORK EQUIPMENT
Removal and Installation ......................... 30-158 Removal .................................................... 30-222
STEERING CYLINDER Installation ................................................ 30-226
Removal .................................................... 30-159 BULKHEAD
Installation ................................................ 30-160 Removal .................................................... 30-228
Disassembly ............................................. 30-161 Installation ................................................ 30-229
Assembly .................................................. 30-163 FLOOR FRAME
STEERING VALVE Removal .................................................... 30-230
Removal .................................................... 30-165 Installation ................................................ 30-232
Installation ................................................ 30-166 COUNTERWEIGHT
CUT-OFF VALVE Removal and Installation ......................... 30-233
Removal and Installation ......................... 30-167 FUEL TANK
BRAKE VALVE Removal .................................................... 30-234
Removal and Installation ......................... 30-168 Installation ................................................ 30-235
BRAKE VALVE (R.H.) CAB
Disassembly ............................................. 30-169 Removal .................................................... 30-236
Assembly .................................................. 30-171 Installation ................................................ 30-238
BRAKE VALVE (L.H.) STOP VALVE
Disassembly ............................................. 30-173 Removal and Installation ......................... 30-239
Assembly .................................................. 30-175 ACCUMULATOR
SLACK ADJUSTER Removal and Installation ........................ 30-240
Removal and Installation ......................... 30-177 ACCUMULATOR CHARGE VALVE
Assembly .................................................. 30-179 PARKING BRAKE SOLENOID VALVE
BRAKE Removal and Installation ......................... 30-242
Removal and Installation ......................... 30-180 DIVERTER VALVE
Assembly .................................................. 30-184 EMERGENCY STEERING PUMP
HYDRAULIC PUMP Removal and Installation ......................... 30-244
Removal .................................................... 30-188 PARKING BRAKE
Installation ................................................ 30-189 Removal and Installation ......................... 30-245
HYDRAULIC TANK PARKING BRAKE CALIPERS
Removal .................................................... 30-190 Disassembly ............................................. 30-246
Installation ................................................ 30-191 Assembly .................................................. 30-247
HYDRAULIC FILTER PARKING BRAKE PAD
Removal and Installation ......................... 30-192 Removal and Installation ......................... 30-248
PPC VALVE REAR TIRES
Removal and Installation ......................... 30-193 Removal and Installation ......................... 30-249
Disassembly and Assembly .................... 30-194 AIR CONDITIONER COMPRESSOR
WORK EQUIPMENT VALVE Removal .................................................... 30-250
Removal .................................................... 30-195 Installation ................................................ 30-251
Installation ................................................ 30-196 AIR CONDITIONER CONDENSER
MAIN CONTROL VALVE Removal and Installation ......................... 30-252
Disassembly ............................................. 30-198 RECEIVER TANK
Assembly .................................................. 30-202 Removal and Installation ......................... 30-253
DUMP CYLINDER AIR CONDITIONER UNIT
Removal .................................................... 30-205 Removal .................................................... 30-254
Installation ................................................ 30-206 Installation ................................................ 30-255
LIFT CYLINDER MONITOR
Removal .................................................... 30-207 Removal and Installation ......................... 30-256
Installation ................................................ 30-208
30-2 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Nece- New/ Ske-

Component Symbol Part No. Part Name ssity Q’ty model
re-
tch Nature of work, remarks
790-501-5000 Unit repair stand
(100V) 1
or
Unit repair stand Torque converter.PTO repair
790-501-5200 (110 – 120V or 220 – 240V) 1 stand
1 790-901-4110 Bracket 1
793-310-2190 Plate 1 (Serial No.: 50001 – 52000)
793-617-1110 Plate 1 (Serial No.: 52001 and up)

Disassembly, assembly 790-101-5201 Push tool kit (B) 1
of torque converter, C
PTO • 790-101-5251 • Plate 1
2 Press fitting of bushing
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
790-201-2740 Spacer 1 Press fitting of bearing in
3
shaft
790-201-2840 Spacer 1
WA600-3 30-7
(16)
Nece- New/ Ske-

re-
790-101-5401 Push tool kit (C) 1
• 790-101-5431 • Plate 1 Press fitting of retainer oil
4 seal
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5401 Push tool kit 1
• 790-101-5481 • Plate 1 Press fitting of pump guide
5 bearing
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
Press fitting of pump sub-
6 793T-659-1110 Push tool 1 N assembly
790-201-2220 Plate 1 Press fitting of stator shaft
7 bearing inner race
790-201-2650 Plate 1
Disassembly, assembly 790-101-5401 Push tool kit (C) 1
of torque converter, C
PTO • 790-101-5441 • Plate 1 Press fitting of turbine in
8 bearing outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5401 Push tool kit 1
• 790-101-5451 • Plate 1 Press fitting of drive case
9 bearing
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5201 Push tool kit (B) 1
• 790-101-5231 • Plate 1 Press fitting of turbine in
10 drive case
• 790-101-5221 • Grip 1
• 01010-51240 • Bolt 1
11 790-102-1891 Nut wrench Disassembly of torque
1 converter
1 790-201-2750 Spacer 1 Removal of coupling
2 790-201-2760 Spacer 1 Removal of bearing

Check of operation of clutch
3 799-301-1500 Oil leak tester 1 piston
Press fitting of 1st clutch
4 793T-615-1160 Push tool 1 N carrier bushing
Disassembly, assembly 790-101-5401 Push tool kit (C) 1

of transmission D
• 790-101-5461 • Plate 1 Press fitting of bearing in
5
sun gear
• 790-101-5421 • Grip 1
• 0101-51240 • Bolt 1
6 790-101-2860 Spacer 1 Press fitting of bearing in shaft
7 793T-659-1110 Push tool 1 N Press fitting of carrier in shaft
30-8 WA600-3
(16)
Nece- New/ Ske-

re-
790-101-5201 Push tool kit (B) 1
• 790-101-5281 • Plate 1
Disassembly, assembly Press fitting of coupling in
of transmission D 21 • 790-101-5221 • Grip 1 cage
• 01010-51225 • Bolt 1
790-201-2660 Plate 1
790-101-5401 Push tool kit (C) 1
• 790-101-5551 • Plate 1 Press fitting of bearing
22 outer race in cage
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) 1
• 790-101-5441 • Plate 1
Press fitting of bearing
23 • 790-101-5421 • Grip 1 inner race in gear
• 01010-51240 • Bolt 1
790-201-2760 Spacer 1 For No. 3 shaft
Adjusting preload of No. 1
24 796-730-2300 Wrench 1 shaft bearing
Adjusting preload of No. 2
25 796-720-3800 Wrench 1 shaft bearing
793-615-1130 Wrench 1 Adjusting preload of No. 3
26 shaft bearing
796-730-2300 Wrench ass'y 1
Disassembly, assembly
of transfer D 796T-426-1130 Plate 1
Press fitting of oil seal of
27 • 790-101-5421 • Grip 1 output shaft cage
• 01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) 1
• 790-101-5551 • Plate 1 Press fitting of bearing of
28 output shaft cage
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-201-2260 Plate 1 Press fitting of coupling in
29 cage
790-201-2650 Plate 1
790-101-5401 Push tool kit (C) 1
• 790-101-5481 • Plate 1 Press fitting of bearing
30 outer race in transfer case
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
793T-659-1110 Push tool 1 Press fitting of bearing
31 inner race in shaft
790-201-2660 Plate 1
30-10 WA600-3
(13)
Nece- New/ Ske-

re-
790-201-1500 Push tool kit 1
• 790-201-1680 • Plate 1 Press fitting of oil seal in
Disassembly, assembly 32 cage
of transfer D • 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
Centering of transmission -
33 790-438-1120 Centering tool 1 center support
790-201-2850 Spacer 1 Press fitting of center
support main bearing
790-201-2750 Spacer 1
Press fitting of center
790-101-5401 Push tool kit 1 support sub bearing
1 • 790-101-5451 • Plate 1 Press fitting of center
support bearing outer race
• 790-101-5461 • Plate 1
Sub bearing
• 790-101-5421 • Grip 1
Main bearing
• 01010-51240 • Bolt 1
793T-620-1150 Plate 1 N
• 790-101-5431 • Plate 1 Press fitting of oil seal of
2 center support housing
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-501-5200 Unit repair stand 1 For overseas countries
3 790-901-4110 Bracket 1
of differential H 793-310-2190 Plate 1
Removal, installation of axle
4 793-560-1201 Rod 1 shaft
793T-623-1140 Push tool 1 N
Press fitting of differential
793T-623-1150 Spacer 1 N cage oil seal
5 Press fitting of differential
790-101-5221 Grip 1 case dust seal
01010-51240 Bolt 1
Pinion shaft main bearing
6 793T-623-1160 Push tool 1 N inner race
Pinion shaft sub bearing
7 793T-623-1170 Push tool 1 N inner race
790-101-5401 Push tool kit (C) 1
• 790-101-5621 • Plate 1 Press fitting of main
8 bearing outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) 1
• 790-101-5551 • Plate 1 Press fitting of sub bearing
9 outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
WA600-3 30-11
(14)
Nece- New/ Ske-

re-
Press fitting of differential
10 793T-622-1180 Push tool 1 N case bearing
Disassembly, assembly 792-525-1000 Micrometer 1

of differential H Adjusting preload of
11 792-525-1220 Adapter 1 bearing
792-533-1400 Wrench 1
Removal, installation of
1 793T-622-1190 Fixture 3 N wheel hub
793T-622-1210 Plate 1 N
Disassembly, assembly 2 • 790-101-5421 • Grip 1 Press fitting of oil seal

of rear brake J
• 01010-51240 • Bolt 1
792-520-2110 Installer 1
3 Fitting of floating seal
792-530-1600 Push tool 1
790-101-2300 Push puller 1
• 790-101-2310 • Block 1
• 790-101-2320 • Screw 1
• 790-101-2330 • Nut 1
• 790-101-2340 • Washer 1
• 790-101-2350 • Leg 2
• 790-101-2360 • Plate 4 Installation of upper center
1 hinge bearing
• 790-101-2410 • Joint 2
• 02215-11622 • Nut 2
793-520-2640 Push tool 1
790-438-1030 Guide 1
Installation of center 790-438-1050 Bar 2

hinge bearing K
Puller
790-101-2102 (294kN{30ton}) 1
790-101-1102 Pump 1
790-101-2300 Push puller 1
• 790-101-2310 • Block 1
• 790-101-2330 • Nut 1
• 790-101-2340 • Washer 1
• 790-101-2350 • Leg 2
Installation of lower center
2 • 790-101-2360 • Plate 4 hinge bearing
• 790-101-2410 • Joint 2
• 02215-11622 • Nut 2
790-438-1050 Bar 2
01580-12016 Nut 2
790-438-1010 Push tool 1
30-12 WA600-3
(16)
Nece- New/ Ske-

re-
790-438-1020 Guide 1
Installation of center 790-438-1040 Screw 1 Installation of lower center

hinge bearing K 2 hinge bearing
790-101-2102 Puller 1
790-101-1102 Pump 1
790-502-1003 Cylinder repair stand 1
Disassembly, assembly of
1 790-502-2000 Cylinder repair stand 1 cylinder
790-101-1102 Hydraulic pump 1
2 790-102-3802 Wrench 1 steering cylinder round head
3 790-302-1340 Socket (80mm) 1 steering cylinder nylon nut
790-201-1500 Push tool kit 1 Press fitting of dust seal
• 790-201-1620 • Plate 1 Steering cylinder
• 790-201-1680 • Plate 1 Lift cylinder

4
• 790-201-1690 • Plate 1 Bucket cylinder
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
790-201-1702 Push tool kit 1 Press fitting of roll bushing
of hydraulic cylinder U
• 790-201-1811 • Push tool 1 Steering cylinder
• 790-201-1871 • Push tool 1 Lift cylinder

5
• 790-201-1881 • Push tool 1 Bucket cylinder
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
6 790-720-1000 Expander 1 All cylinders
796-720-1670 Ring 1
7 Steering cylinder
07281-01279 Clamp 1
796-720-1720 Ring 1
8 Lift cylinder
07281-02429 Clamp 1
796-720-1710 Ring 1
9 Bucket cylinder
07281-02909 Clamp 1
793T-670-1110 Sleeve 1 N
791-679-1120 Plate 1
791-745-2110 Adapter 1
Removal of pins of
work equipment V 1 790-438-1110 Screw 1
791-112-1180 Nut 1 Removal of pins connecting
lift arm and bucket, and link
790-101-2540 Washer 1 and bucket
01010-81655 Bolt 1
WA600-3 30-13
(16)
Nece- New/ Ske-

re-
790-101-2102 Puller Removal of pins connecting
(294kN{30ton}) 1
1 lift arm and bucket, and link
690-101-1102 Pump 1 and bucket
793T-670-1130 Sleeve 1 N
791-735-1110 Adapter 1
790-438-1110 Screw 1
793T-670-1140 Plate 1 N
2 Removal of lift arm foot pin
791-112-1180 Nut 1
790-101-2540 Washer 1
790-101-2102 Puller
Removal of pins of (294kN{30ton}) 1
work equipment V
790-101-1102 Pump 1
793T-670-1120 Sleeve 1 N
791-735-1110 Adapter 1
790-738-1110 Screw 1
791-679-1120 Plate 1 Removal of pin connecting
3 lift arm and bell crank
791-112-1180 Nut 1
790-101-2540 Washer 1
790-101-2102 Puller 1
790-101-1102 Hydraulic pump 1
799-703-1200 Service tool kit 1
Vacuum pump
Air conditioner 799-703-1110 (220V) 1 Charging air conditioner with
assembly X 1 gas
Vacuum pump
790-703-1120 (240V) 1
799-703-1401 Gas leak detector 1
30-13-1 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note: Komatsu cannot accept any responsi-

bility for special tools manufactured
A8 Adaputer according to these sketches.
C6, D7, D31 Push tool
30-14 WA600-3
(13)
D18 Push tool
D27 Plate
30-16 WA600-3
(13)
H2 Plate
WA600-3 30-16-1
(13)
H10 Push tool
J1 Fixture
WA600-3 30-19
(14)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP
Serial No. : 50001 – 52000
¤ Stop the machine on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the ma-
chine from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Open the engine right side cover.

2. Remove coupling cover (1).
3. Disconnect fuel control rod (2). 1
4. Disconnect engine stop cable (3). 2
5. Disconnect hose (4).
9. Remove lubrication oil return tube (8).
10. Disconnect lubrication oil inlet tube (9).
11. Disconnect boost compensator tube (10).
12. Disconnect 6 fuel injection tubes (11).
13. Loosen lock bolt (12).
14. Remove 4 mounting bolts (13), then remove in-
jection pump (14). 3
0 Fuel injection pump: 31kg
15. Install tool A8 to the delivery valve holder, then

lift off the fuel injection pump assembly.
INSTALLATION OF FUEL
INJECTION PUMP
Serial No. : 50001 – 52000
• Carry out installation in the reverse order to re-
moval.
1
fl Adjust the control rod. For details, see AD-
JUSTING FUEL CONTROL CABLE.
2
fl Adjust the cable. For details, see ADJUST-
ING ENGINE STOP MOTOR CABLE.
3
fl Test and adjust the fuel injection timing. For
details, see TESTING AND ADJUSTING FUEL
INJECTION TIMING.
30-26 WA600-3
(13)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REPLACEMENT OF ENGINE
REAR SEAL
Serial No. : 50001 – 52000
chine from moving.
1. Remove the torque converter. For details, see

REMOVAL OF TORQUE CONVERTER.
2. Removal of engine rear seal

1) Sling and remove flywheel (1).
0 Flywheel: 48kg
2) Remove engine rear seal (2).
3. Installation of engine rear seal
• Installation of standard seal

fl Before installing the seal, check that the end
corners and lip sliding surfaces of the crank-
shaft and the housing are free from flaws,
burrs, rust, etc.
fl When installing the seal, apply grease to seal
lip very little, never fill grease in the groove
of seal. Wipe the all oil off the shaft.
1) Install seal (1) to crankshaft (2).
2) Tighten the 4 bolts with tool A5 until the cover
of seal (1) comes into contact with end sur-
face of flywheel housing (3).
8 Oil seal lip: Grease (G2-LI)
• Installation of rear seal having sleeve (For repair)

1) Press fit sleeve (4) to the crankshaft (2) by
using A4.
fl Tighten the 2 nuts evenly.
fl Press fit the seal until tool A4 comes into
contact with the crankshaft end.
WA600-3 30-33
7
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
2) Press fit front seal (6) to the front cover (3)

with tool A2.
fl Fill the lip with lithium grease (G2-LI) of
about 5cc.
fl Tighten the 3 bolts evenly.
4. Installation of crankshaft pully and damper

Tighten the mounting bolts in the order given in
the diagram on the right.
8 Mounting bolt: Lubricant (LM-P)
9 Mounting bolt:
1st step: 53.9 – 93.1Nm {7.5 ± 2.0kgm}
2nd step: 225 – 265Nm {25.0 ± 2.0kgm}
3rd step: 617 – 657Nm {65.0 ± 2.0kgm}
5. Adjustment of fan belt

1) Loosen the stop bolt and install the 3 belts.
2) Tighten the stop bolt until it comes into con-
tact with the tension bracket.
3) After the stop bolt comes into contact with
the tension bracket, further tighten it by two
turns.
9 Locknut:
245.0 – 108.7Nm {25.0 ± 31.5kgm}
30-32 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
2) Install seal (5) to sleeve (4).

3) Tighten 4 bolts until the cover of seal (5)
comes into contact with end surface of fly-
wheel housing (3).
8 Oil seal lip: Grease (G2-LI)
4. Installation of flywheel
1) For the tightening order, see the diagram on
the right.
8 Mounting bolt: Lubricant (LM-P)
9 Mounting bolt:
1st step: 98.0 ± 20.0Nm {10.0 ± 2.0kgm}
2nd step: 294.0 ± 20.0Nm {30.0 ± 2.0kgm}
3rd step: 539.0 ± 20.0Nm {65.0 ± 2.0kgm}

2) Measure the radial runout and face runout of
the flywheel.
Radial runout: Max. 0.15mm
Face runout: Max. 0.20mm
30-34 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY RADIATOR
27. Apply corrugated cardboard [1] to the radiator

side, and lower fan (28) slowly and tense rope [2]
so that the fan will not fall down outward.
0 Fan: 46kg
28. Remove mounting bolts (30), then sling and re-

move radiator (31).
0 Radiator: 450kg
INSTALLATION OF RADIATOR
moval.
• Refilling with water

Add water to the specified level. Run the engine
to circulate the water through the system. Then,
check the coolant level again.
WA600-3 30-47-4
(16)
REMOVAL OF RADIATOR
(with suction fan)
chine from moving.
1. Open right and left side covers (1), then remove

engine hood (2).
• Remove the right and left wire cables installed
between the radiator guard and handrail.
0 Engine hood: 80kg
2. Loosen drain valve (3) and drain the engine cool-

ing water.
= Engine cooling water: Approx. 155 ¬
3. Remove radiator duct (4).

• Remove radiator grill.
0 Duct and grille: 95kg
4. Disconnect radiator coolant level sensor connec-

tor (5) (G01).
5. Remove baffle plates (6), (7), (8) and (9).
6. Remove radiator guard mounting bolts (10).
30-47-5 WA600-3
(16)
7. Disconnect tail lamp connector (11) (GR1).
8. Remove baffle plates (12), (13), (14) and (15).
9. Remove radiator guard mounting bolts (16).
10. Remove right and left side pillar mounting bolts

(17).
11. Remove the mounting bolts, then remove the ra-

diator guard (18).
0 Radiator guard: 280kg
fl When slinging the radiator guard, take care
that radiator guard fitting portion will not in-
terfere with the radiator fitting portion.
12. Disconnect engine cooling water drain hose (19).
13. Disconnect 2 hoses (20) of the hydraulic oil cooler.

fl Prepare plugs to stop the oil from flowing out.
14. Disconnect hose (21) between the radiator and

water pump.
WA600-3 30-47-6
(15)
15. Disconnect 2 hoses (22) of the fuel cooler.
16. Disconnect aeration hose (23).
17. Disconnect engine cooling water return hose (24).
18. Disconnect sub-tank hose (25).
19. Disconnect two hoses (26) to after-cooler.
20. Remove fan guards (27).
21. Remove fan (28) and place it on the radiator side.
22. Disconnect right and left radiator supports (29)

from the radiator, then let it fall down on the en-
gine side.
23. Apply corrugated cardboard [1] to the radiator

side, and lower fan (28) slowly and tense rope [2]
so that the fan will not fall down outward.
0 Fan: 45kg
24. Remove mounting bolts (30), then sling and re-

move radiator (31).
0 Radiator: 550kg
30-47-7 WA600-3
(15)
INSTALLATION OF RADIATOR
(with suction fan)
moval.
• Refilling with water

Add water to the specified level. Run the engine
to circulate the water through the system. Then,
check the coolant level again.
WA600-3 30-47-8
(16)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
5. Drive case, turbine assembly

1) Using eyebolts 1, remove drive case and
turbine assembly (9).
2) Disassembly of drive case and turbine as-

sembly.
a. Using push tool 2, remove turbine
(10) from drive case (11).
b. Remove beaning inner race (12) from

tubine.
c. Remove beaning inner race (13).
30-62-2 WA600-3
(16)
d. Using push tool 3, remove beaning (14)

from drive case.
fl Beaning (14) and inner races (12 and
13) form a set, so keep the product
numbers and match marks in sets.
6. Stator
Remove mounting bolts, then remove stator (15).
7. Race
Remove snap ring (16), then remove race (17).
8. Pump assembly
1) Remove pump assembly (18).
2) Disassembly of pump assembly.

a. Remove mounting bolts, then remove
plate (19).
b. Remove gear assembly (20) from pump
(21).
WA600-3 30-62-3
(16)
c. Remove snap ring (22), then using push

tool (4) remove inner race (23) from gear
(24).
9. Retainer assembly
1) Remove mounting bolts, then remove retainer
assembly (25).
2) Remove oil seal (26) from retainer (27).
10. Turbine shaft assembly

1) Secure stator shaft with bolt 5.
2) Tap with a plastic hammer, and remove tur-
bine shaft assembly (28).
3) Disassembly of turbine shaft assembly.

a. Remove seal ring (29).
b. Remove snap ring (30), then remove
spacer (31).
c. Using push tool 6, remove bearing (32)
from shaft (33).
30-62-4 WA600-3
(16)
11. Stator shaft assembly

1) Tap with a plastic hammer, and remove sta-
tor shaft assembly (34).
2) Disassembly of stator shaft assembly.
a. Remove seal ring (35).
b. Using bearing puller 7, remove bearing

(36).
c. Remove bushing (37) from stator shaft
(38).
12. Pump drive gear assembly

1) Using tool C11, remove nut (39).
fl Secure with a bar to prevent the pump
drive gear from turning, then loosen the
nut.
2) Using push tool 8, pull out pump drive gear

(40), and remove bearing (41).
fl Set the push tool securely in contact with
the end face of the gear shaft, and take
care not to damage the thread when
knocking it out.
WA600-3 30-62-5
(16)
3) Remove ring (42), then remove beaning (43)

from pump drive gear (40).
4) Remove bearing outer races (44 and 45), and
ring (46) from housing (47).
fl Bearings (41 and 43), bearing outer races
(44 and 45), and rings (42 and 46) form a
set, so keep the product numbers and
match marks in sets.
5) Disassemble other pump drive gear assem-
bly in the same way as in Steps 1)-4).
30-62-6 WA600-3
(16)
ASSEMBLY OF TORQUE
CONVERTER
fl Clean all parts, and check for dirt or damage.
fl Put a drop of engine oil on the rotating surfaces
of all bearings before installing.
1. Housing
Set housing (47) on tool C1.
2. Pump drive gear assembly

fl The bearings of the pump drive gear form a
set. Mach the product numbers and match
marks of the inner and outer races and seats
to assembly.
1) Install ring (46) to housing (47).
2) Using push tool 9, press fit bearing outer
races (44 and 45).
3) Using push tool 0, press fit bearing (43)

to pump drive gear (40).
4) Assembly ring (42).
5) Set pump drive gear (40) in position, then

using push tool A, press fit bearing (41).
fl Support the end face of the pump
drive gear on a block, then press fit
the bearing.
fl When press fitting the bearing, be
careful not to damage the thread of
the gear shaft.
WA600-3 30-62-7
(16)
6) Using tool C11, tighten nut (39).

fl Secure with a bar to prevent the pump
drive gear from turning, then tighten the
nut.
3 Nut:
416.8 ± 24.5 Nm {42.5 ± 2.5 kgm}
7) Assemble other pump drive gear assembly
in the same way as in Steps 1) - 6).
3. Stator shaft assembly

1) Assembly of stator shaft assembly
a. Using push tool B, press fit bushing (37)
to stator shaft (38).
fl Press fit the bushing so that the cham-
fered inside diameter faces the out-
side.
b. Using push tool C, press fit bearing (36).

c. Install seal ring (35).
fl Coat the seal ring with grease (G2-LI),
and secure it so that it does not pro-
trude from the shaft.
2) Fit O-ring to housing end, and install stator

shaft assembly (34).
30-62-8 WA600-3
(16)
4. Turbine shaft assembly.

1) Assembly of turbine shaft assembly.
a. Using push tool D, press fit bearing (32)
to shaft (33).
b. Assemble spacer (31), and install snap
ring (30).
fl Check that the snap ring is fitted securely
in the groove.
2) Tap turbine shaft assembly (28) with a plastic

hammer, then install to stator shaft.
5. Retainer assembly
1) Using push tool E, press fit oil seal (26) to
retainer (27).
fl Coat the press-fitting surface of the oil seal
thinly with gasket sealant (LG-5), then
press fit. Wipe off all of the gasket seal-
ant that is squeezed out.
8 Lip of oil seal: Grease (G2-LI)
2) Fit O-ring and install retainer assembly (25).

8 Bolt thread: Thread tightener (LT-2)
9 Mounting bolt:
66.29 ± 7.36 Nm {6.76 ± 0.75 kgm}
WA600-3 30-62-9
(16)
6. Pump assembly
1) Assembly of pump assembly.
a. Install snap ring (22) to gear (24).
b. Using push tool F, press fit bearing inner
race (23).
c. Set pump (21) to gear assembly (20), then

fit plate (19) and tighten mounting bolts.
fl Install the plate so that the chamfered
side faces the inside.
8 Bolt thread:
Thread tightener (LT-2)
3 Mounting bolt:
66.20 ± 7.36 Nm{6.75 ± 0.75 kgm}
2) Install pump assembly (18).
7. Rase
Fit race (17) and install snap ring (16).
fl Check that the snap ring is fitted securely in
the groove.
8. Stator
Install stator (15).
3 Mounting bolt:
66.20 ± 7.36 Nm{6.75 ± 0.75 kgm}
30-62-10 WA600-3
(16)
9. Drive case, turbine assembly

1) Assembly of drive case and turbine assem-
bly.
fl The bearings connecting the drive case
and turbine form a set. Match the prod-
uct numbers and match marks of the in-
ner and outer races to assemble.
a. Using push tool G, press fit bearing (14)

to drive case (11).
b. Using push tool H, press fit bearing in-

ner race (12) to turbine (10).
c. Set turbine (10) on block I, and fit drive

case (11), then using push tool J, press
fit bearing inner race (13).
WA600-3 30-62-11
(16)
2) Using eyebolts 1, set drive case and turbine

assembly (9) to pump.
3) Tighten mounting bolts of pump and drive
case in turn on opposite side temporarily.
10. Pump, drive case mounting bolts

Turn over repair stand, and tighten 20 pump and
drive case mounting bolts (6).
9 Mounting bolt:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
11. Holder
Install holder (8).
3 Mounting bolt:
250.0 ± 24.5 Nm {25.5 ± 2.5 kgm}
12. Pilot
Install pilot (7).
3 Mounting bolt:
164.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
30-62-12 WA600-3
(16)
13. Torque converter assembly

1) Fit gasket and install plate (5).
8 Gasket: Gasket sealant (LG-1)
2) Fit gasket to both ends and install lubrication

tube (4).
3 Joint bolt:
24.5 ± 4.9 Nm {2.5 ± 0.5 kgm}
3) Fit O-ring and install torque converter regula-

tor valve assembly (3).
3 Mounting bolt:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
4) Install coupling (2).

5) Remove torque converter assembly (1) from
tool C1.
fl After assembling, cover the openings with
tape to prevent dirt or dust from enter-
ing.
WA600-3 30-62-13
(16)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
v) Remove snap ring (109).

vi) Set the assembly to the press, then re-
move sun gear (110) by using push tool
D12 (Inside diameter: 106mm).
vii) Remove snap ring (111), then remove

bearing (112) by using the push tool (Out-
side diameter: 130mm).
viii)Set the assembly to the press, then re-

move collar (113) by using the push tool
(Outside diameter: 95mm).
ix) Pull out the roll pin and remove pin (114),
then remove thrust washer (115), plan-
etary gear (116) and needle bearing (117).
WA600-3 30-79
(12)
ii) Install collar (113) by expansion fit.
iii) Set the assembly to the press, then press

fit bearing (112) to the No. 6 sun gear by
using push tool D9 (Outside diameter:
135mm).
iv) Install snap ring (111).
v) Install snap ring (109) to the shaft.

vi) Set the assembly to the press, then press
fit sun gear (110) by using push tool D12
(Inside diameter: 105mm).
vii) Install carrier (108) to the shaft with push

tool D7.
viii)Install snap ring (107).
WA600-3 30-83
(12)
10. Housing and carrier assembly

1) Assemble the housing and carrier assembly
according to the following procedure.
i) Install the assembly to the press, then
press fit bearing (95) by using push tool
D10 (Outside diameter: 175mm).
ii) Install snap ring (94).
iii) Install collar (93), the tighten the three

mounting bolts.
2 V-groove on periphery of collar:
Gasket sealant (LG-I)
3 Mounting bolt:
13.7 ± 1.0Nm {1.4 ± 0.1kgm}
iv) Set needle bearing (92), planetary gear
(91) and thrust washer (90) and install pin
(89), then install the roll pin.
v) Set the assembly to the press, then install

carrier assembly (88) with push tool D9
(Inside diameter: 135mm).
vi) Install snap ring (87).
WA600-3 30-85
(16)
DISASSEMBLY AND ASSEMBLY TRANSFER
3. No. 1 gear
2) Using push tool (Outside diameter: 105mm),
press fit 2 bearings (27) to gear (28).
fl Apply LM-G to the races and rollers of the
bearing.
3) Install gear (26).
i) Turn over the transfer case.
4. Cage
1) Using push tool (Outside diameter: 190mm),
press fit outer race (24) to cage (25).
2) Install the O-ring, then install cage (23).
5. Adjusting preload of No. 1 gear bearing

Set tool D24 and measure the preload with a
torque wrench.
fl Standard preload: 0.1 – 1.0Nm {0.01 – 0.1kgm}
fl If the preload is out of the standard range,
adjust it with shim (45).
30-108 WA600-3
(12)
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
ASSEMBLY OF DRIVE SHAFT

1. Yoke
1) Install bearing (14), and seal (15) to bearing
cap (13).
2 Bearing, seal : Grease (G2-LI)
2) Assemble plastic washer (16), and bearing cap

(13) to spider assembly (12)
fl Be careful not to damage bearing with
heat when welding strap.
2 Bearing cap : Grease (G2-LI)
3) Assemble spider assembly (12) to yoke (3).

fl Carefully align match marks.
fl Clean the mounting face of the bearing
cap by wiping with a clean cloth.
3 Mounting bolts :
157.0 – 196.0 Nm {16.0 – 20.0 kgm}
2. Shaft
1) Assemble bearing (8) and seal (9) in bearing
cap (6).
2 Bearing seal : Grease (G2-LI)
30-128 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
2) Assemble plastic washer (10) and bearing cap

(6) to spider assembly (5).
fl Be careful not to damage bearing with
heat when welding strap.
2 Bearing cap : Grease (G2-LI)
3) Assemble spider assembly (5) to shaft (2).

fl Carefully align match marks.
fl Clean the mounting face of the bearing
cap by wiping with a clean cloth.
3 Mounting bolt :
157.0 – 196.0 Nm {16.0 – 20.0 kgm}
4) Align match marks “a”, then install shaft (2)

to yoke (3).
fl Check that the direction of the spider as-
sembly is the same.
fl If the spline is worn, replace the whole
drive shaft assembly.
2 Spline : Grease (G2-LI)
WA600-3 30-129
(16)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL GEAR
8. Collar
Install collar (27).
9. Bearing
Using press fit kit H6 (Inner diameter: 76 mm),
install bearing (12).
ASSEMBLY OF DIFFERENTIAL ASSEMBLY
fl Set differential case on special tool H3.
10. Pinion assembly

1) Assemble shims (5) removed when disas-
sembled.
fl Standard shims thickness : 2.1 mm.
2) Using eye-bolts 5 (Thread dia. = 12 mm, Pitch
= 1.75 mm), install pinion assembly (4).
3) Install oil seal (3) and dust seal (3A) to case.

2 Lip of oil seal : Grease (G2-LI)
2 Lip of dust seal : Grease (G2-LI)
4) Fit O-ring to case, and install case (2).

2 Mounting bolt : Tread tightener (LT-2)
3 Mounting bolt :
245 – 309 Nm {25 – 31.5 kgm}
WA600-3 30-147
(16)
5) Insert coupling (28), fit O-ring and tighten

holder.
2 Mounting bolt :
Thread tightener (LT-2)
3 Mounting bolt :
824.0 – 1,030.0 Nm{84.0 – 105.0 kgm}
fl Fit the balancer 6 to bolt hole of coupling,

and measure the rotating torque.
fl Rotating torque :
50 N {5.1 kg} – 94.0 N {9.3 kg}
11. Differential gear assembly

Sling differential gear assembly (10) and install
case.
12. Nut, cap

1) Align nut (7) with differential case groove and
install.
2) Install cap (8) and tighten (9).

2 Mounting bolt :
Thread tigntener (LT-2)
3 Mounting bolt :
1,520 – 1,910 Nm {155 – 195 kgm}
fl Check match marks on bearing cup
before installing.
fl Rotate bevel gear 20 – 30 times to
settle in, then tighten bolts.
30-148 WA600-3
(16)
14. Lock
After adjusting tooth contact and backlash, install
lock (6).
2 Mounting bolt : Thread tightener (LT-2)
3 Mounting bolt:
98.0 – 123.0 Nm {10.0 – 12.5 kgm}
30-152 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY LIMITED SLIP DIFFERENTIAL
2) Adjustment of thrust washer and cover

Put thrust washer (21) in cover (20) and tem-
porarily tighten the cover fixing bolts at three
spots on the periphery. Then take measure-
ment of dimension C from thrust washer to
cover end and calculate the clearance.
Clearance of thrust washer: C = 0.2 – 0.4 mm
fl Select a thrust washer of right size from
among the two kinds of different thick-
ness, i.e. 426-22-27370 (t = 4.0) and 426-
22-27380 (t = 4.2).
fl Also adjust the clearance of thrust washer
on the other side in the same manner.
12. Cover
1) Remove cover (20) for adjusting the clearance
in thrust washer and hammer pin (29) until it
protrudes from the cover washer mounting
face as far as dimension a.
a = 3.5 mm
2) Press-fit bearing (19) into cover (20).
3) Fit selected thrust washer (21) to cover (20).

fl Be sure to fit the washer to the cover pin.
2 Thrust washer:
Coat grease (G2-LI) on both sides.
4) Install cover (20) and tighten bolt (20-1).
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
30-152-10 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY LIMITED SLIP DIFFERENTIAL
17. Lock
After adjusting tooth contact and backlash, install
lock (6).
2 Mounting bolt : Thread tightener (LT-2)
3 Mounting bolt:
98.0 – 123.0 Nm {10.0 – 12.5 kgm}
WA600-3 30-152-15
(16)
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
3. Set piston rod (8) in tool U1.
4. Assemble cylinder head assembly (7) and piston

assembly (6) no rod, then fit nut (5).
5. Using power wrench 1 and socket U3 tighten nut

(5).
2 Piston nut : Liquid adhesive
(LOCTITE No. 262 or equivalent)
3 Piston nut :
Power of power wrench 1 × 16
Width across flats of nut (5) 80 mm
3.97 ± 0.40
Tightening torque of nut {405.0 ± 40.5 kgm}
6. Remove piston rod and head assembly from tool

U1.
7. Set cylinder (4) in tool U1.
8. Raise piston rod and head assembly (3), and as-

semble in cylinder (4).
9. Using tool U2 , tighten cylinder head nut (2).

3 Cylinder head nut :
1.03 ± 0.10 kNm {105.0 ± 10.5kgm}
10. Bend lock into notch on cylinder side.
11. Remove cylinder assembly from tool U1.
30-164 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
4. Torque converter charging and PPC pump

1) Disconnect torque converter charging pump
suction hose (13).
2) Disconnect PPC pump suction hose (14).
3) Disconnect discharge tube (15) between the
torque converter charging pump and trans-
mission valve.
4) Disconnect discharge hose (16) between the
accumulator charge valve and PPC pump.
5) Remove 4 mounting bolts (17), then sling and

remove 2-unit pump (18).
0 2-unit pump: 24kg
INSTALLATION OF HYDRAULIC
PUMP
moval.
• Refilling with oil

Add oil to the specified level. Run the engine to
circulate the oil through the system. Then, check
the oil level again.
WA600-3 30-189-2
(16)
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
1. Check valve assembly

1) Assemble valve (50), seal (49), and spring (48)
in valve body (51), then fit O-ring and install
flange (47).
2 Flange surface : Thread tightener (LT-2)
2) Assemble check valve (46) and spring (45) in
valve body, then fit O-ring and install plate
(44).
3 Plate mounting bolt :
78.4 – 98.0 Nm {8.0 – 10.0 kgm}
2. Selector valve assembly

fl Assemble selector valve assembly.
1) Assemble piston (43), spring (42), and shim
(41) in sleeve (38), then fit O-ring and install
nipple (40).
3 Nipple : 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
Fit O-ring and install selector valve assembly (37).
3Selector valve :
58.8 – 78.4 Nm {6.0 – 8.0 kgm}
3. Suction valve assembly

fl Assemble suction valve assembly.
i) Assemble spring (35) in sleeve (36).
ii) Assemble seal (34) in valve (33), and in-
stall to sleeve (36).
Fit O-ring and install suction valve assembly (32).
3 Suction valve assembly :
294.0 – 314.0 Nm {30.0 – 32.0 kgm}
4. Safety valve assembly with suction

Fit O-ring and install safety valve assembly (31).
3 Safety valve :
294.0 – 314.0 Nm {30.0 – 32.0 kgm}
WA600-3 30-203
(16)
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
5. Main relief valve assembly

fl Assemble main relief valve.
i) Install backup ring (30) and O-ring to
sleeve (29).
ii) Assemble spring (28), valve (27), and re-
tainer (26) in sleeve (29), and install snap
ring (25).
iii) Fit backup ring (24) and O-ring, and as-
semble seat (23) in sleeve.
iv) Screw nut (21) into holder (22), then fit O-
ring and assemble in sleeve, and tighten
nut.
3 Holder :
29.4 – 49.0 Nm {3.0 – 5.0 kgm}
2 Nut thread : Thread tightener (LT-2)
3 Nut : 127.5 – 170.5 Nm {13.0 – 8.0 kgm}
v) Assemble poppet (20), spacer (19), spring
(18), and retainer (17), and screw in ad-
justment screw (16). Adjust protrusion
from end face of nut (15) to same dimen-
sion as at time of disassembly, then
tighten with nut (15).
2 Nut thread : Thread tightener (LT-2)
3 Nut : 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
Fit O-ring and install main relief valve assembly
(14).
3 Main relief valve assembly :
274.4 – 367.5 Nm {28.0 – 37.5 kgm}
6. Spool assembly
fl Assembly of spool assembly.
Install plugs (13) and (12) to spool (11).
2 Nut thread : Tightener (LT-2)
3 Nut : 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
1) Assemble spool assembly (10) in valve body.
2) Assemble spacer (9), spring (8), and piston (7).
3) Assemble retainer (6), spring (5), retainer (4),
and spring (3), then fit O-ring and install case
(2) and sleeve(1).
30-204 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER AND DUMP CYLINDER
6. Disassembly of piston assembly

Remove wear ring (12) and piston ring (13) from
piston (14).
7. Disassembly of cylinder assembly

1) Remove O-ring (15) and backup ring (16).
2) Remove snap ring, then remove dust seal
(17).
3) Remove rod packing (18).

4) Remove buffer ring.
5) Remove bushing (19).
30-210 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
15. Remove the lock bolt of steering cylinder head

pin (19) on right and left sides, then pull out the
pin. 1
fl If shims are installed, check its quantity.
fl Cut the hose and shorten the piston.
16. Disconnect drive shaft (20). 2

0 Drive shaft: 56kg
17. Place jacks (50ton) under the front frame and rear
frame, then adjust the height of the frames and
set support stand (1).
18. Using jacks (50ton × 2 units) under the counter

weight, set the support stand.
• Lower hinge pin

19. Remove the mounting bolt, then remove retainer
(21).
fl Check the number of shims installed between
the retainer and frame. 3
WA600-3 30-215
(16)
20. Adjust height carefully and set so that lower hinge

pin (22) can be removed easily by hand. 3
21. Remove spacer (23).
• Upper hinge pin

22. Remove 6 mounting bolts (24) and 4 mounting
bolts (25), then remove retainer (26). 4
23. Using puller, remove upper hinge pin (27) and

spacer (28).
30-216 WA600-3
(16)
24. Remove safety bar, then pull out front frame to-
wards front and disconnect frame.
fl Be careful not to let the spacer at the top of
the lower hinge get caught in the rear frame.
fl Carry out the operation carefully and pay at-
tention to maintaining the balance.
fl Move approx. 100 mm at a time.
• Front frame lower 5

25. Remove mounting bolts, then remove retainer
(29).
fl If there are shims between the retainer and
frame, check the number and thickness.
26. Remove dust seal (30) from retainer (29).
27. Remove spacer (31) and dust seal (32) from front
frame.
WA600-3 30-217
(16)
28. Remove bearing (33).
• Front frame upper 6

29. Remove retainer (34).
fl If there are shims between the retainer and
frame, check the number and thickness.
30. Remove dust seal (35) from retainer.

fl Remove dust seal (36) at the frame end.
31. Remove bearing (37).
30-218 WA600-3
(16)
INSTALLATION OF CENTER
HINGE PIN
moval.
1
fl Adjust the shims so that the clearance is in
the specified range.
Clearance a + b = Less than 1.0 mm
2
3 Drive shaft mounting bolt :
157 – 196 Nm {16 – 20 kgm}
3 Lower hinge pin

2 Outer circumference of hinge pin :
Grease (G2-LI)
fl Measure clearance c between the retainer and
frame at 4 places on the inside circumference,
and select a shim thickness to make the value
0.08 – 0.18 mm less than the measured value.
fl When adjusting the shim, temporarily tighten
the retainer mounting bolts to act as a stop-
per.
fl When tightening the mounting bolts, tighten
the retainer mounting bolts first to the speci-
fied torque, then tighten the pin mounting
bolts.
fl After selecting the shim, assemble the retainer
to the specified torque.
fl Remove all oil and grease from the mounting
bolts and mount holes.
2 Mounting bolt :
Thread tightener (Loctite 262)
3 Mounting bolt (33) when adjusting shims :
245 – 309 Nm {25.0 – 31.5 kgm}
3 Mounting bolt (34) :
409 – 608 Nm {50 – 62 kgm}
WA600-3 30-219
(16)
4 Upper hinge pin

fl Assemble spacer (30), insert upper hinge (29),
then tap three times with a copper hammer
to settle the parts.
fl Never coat spacer (30) with grease.
2 Outer circumference of hinge pin :
Grease (G2-LI)
Thread tightener (Loctite 262)
245 – 309 Nm {250.0 – 31.5 kgm}
409 – 608 Nm {50 – 62 kgm}
fl If the mounting bolts cannot be tightened to
the specified tightening torque, there may be
grease on spacer (28), so remove it and
tighten again.
5 Front frame lower

fl When using tool K2 to press fit the bearing
and spacer to the frame, be careful that the
bearing is not at an angle.
fl Fill the inside of the bearing with grease.
fl When assembling the bearing, be careful not
to forget to assemble the spacer.
fl The clearance of the bearing is adjusted, so
do not change the combination of bearing and
spacer.
When replacing, replace as a set.
fl Press fit so that the lip of the dust seal is fac-
ing the outside.
2
Lip of oil seal : Grease (G2-LI)
fl Measure clearance a between retainer (31)
and hinge at 4 places on the inside circumfer-
ence, and select a shim thickness to make the
value 0.08 – 0.18 mm less than the measured
value.
3 Mounting bolt (when adjusting shims) :
98.0 ± 9.8 Nm {10.0 ± 1.0 kgm}
3 Mounting bolt :
176.4 ± 19.6 Nm {18 ± 2.0 kgm}
30-220 WA600-3
(16)
6 Front frame upper

fl Using tool K1, press fit the bearing and spacer
to the frame.
fl When press fitting the bearing, be careful that
the bearing is not at an angle.
fl Fill the inside of the bearing with grease.
fl When assembling the bearing, be careful not
to forget to assemble the spacer.
fl The clearance of the bearing is adjusted, so
do not change the combination of bearing and
spacer.
When replacing, replace as a set.
fl Press fit so that the lip of the dust seal is fac-
ing the outside.
2 Lip of oil seal : Grease (G2-LI)
fl Measure clearance a between retainer (36)
and the hinge at 4 places on the inside cir-
cumference, and select a shim thickness to
make the value 0.08 – 0.18 mm less than the
measured value.
3 Mounting bolt (when adjusting shims) :
34.3 Nm {35 kgm}
3 Mounting bolt :
245 – 309 Nm {25.0 – 31.5 kgm}
fl After completion of mounting the hinge pin,
fill with oil and bleed the air.
1) Tighten the plug on the top of the hydraulic

tank filter, then add hydraulic oil through oil
filler to the specified level.
3 Plug on top of filter :
11.8 ± 1.0 Nm {1.2 ± 0.1 kgm}
5 Hydraulic oil : Approx. 255 ¬
Run the engine to circulate the oil
through the system. Then check the
oil level again.
2) Bleed the air from the brake system. For de-

tails, see TESTING AND ADJUSTING.
WA600-3 30-221
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
5
8 Bushing: Lubricant (LM-P)
fl Match the mounting holes of the front frame
and lift arm to each other, and insert shims
so that the clearance will be even.
fl a + b = max. 1.5mm
fl After installing the pin, set the support stand
at the lift arm end.
fl Supply grease to each pin.
WA600-3 30-227
(16)
DISASSEMBLY AND ASSEMBLY BULKHEAD
REMOVAL OF BULKHEAD
chine from moving.
fl Collect the air conditioner refrigerant.
1. Remove engine hood (1).

0 Engine hood: 80kg
2. Remove side covers (2) on both sides.
3. Remove inspection covers (3), (4) and (5).
4. Open transmission inspection cover (6) and re-

move the mounting bolt, then remove the cover
together with step (7).
5. Disconnect hose (8) between the receiver tank and

air conditioner unit.
6. Disconnect washer hose (9).

fl If any cleaning water is in the tank, bend the
hose and tie it with a tape, etc.
7. Disconnect hydraulic tank breather hose (10).
8. Disconnect hose (11) of the air compressor, then

remove clamp (12).
9. Disconnect air conditioner condenser connector

(13) (BR1).
10. Remove 2 rear mounting bolts (14).

11. Remove clamps (15) and disconnect dust indica-
tor hose (16). (Serial No.: 52001 and up)
30-228 WA600-3
(14)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

chine from moving.
1. Remove ROPS (1), cab (2), right and left ladders

(3) and side cover (4). For details, see REMOVAL
OF CAB.
2. Disconnect 2 heater hoses (5).

fl Plug the holes to prevent the engine coolant
water from flowing out.
3. Disconnect 2 air conditioner hoses (6).

fl Be sure to use 2 spanners to disconnect the
hoses.
4. Disconnect connector (7).

Connector: (LR1.2.3.4.5.6), (TL1), (FR1.2)
(Serial No.: 50001 – 52000)
: (LR1.2.3.4.5.6.7), (TL1), (FR1.2)
(Serial No.: 52001 and up)
5. Disconnect accelerator cable (8). 1

fl Disconnect the accelerator cable clamped
along the frame.
6. Disconnect 2 washer hoses (9).

fl If any cleaning water is in the washer tank,
bend the hoses and tie them with tape.
7. Disconnect hose (10) between the right-hand

brake valve and rear brake, and hose (11) between
the right-hand brake valve and front brake.
8. Disconnect hose (12) of the left-hand brake valve

accumulator.
9. Disconnect hose (13) between the orbit-roll and

accumulator, drain hose (14), hose (15) of right-
hand stopper valve and hose (16) of the left-hand
stop valve.
30-230 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
REMOVAL OF PARKING BRAKE

chine from moving.
1. Remove disc plate cover (1).
2. Disconnect drive shaft (2). 1
0 Drive shaft: 57kg
3. Turn adjustment bolt (3) clockwise to increase the
clearance between the pad and disc. 2
4. Pull out connecting pin (4).
6. Remove spring cylinder (6).
7. Disconnect plate (7). 3
fl Secure the calipers.
fl Since 2 dowel pins are installed, raise the cali-
pers a little, then remove the plate.
8. Remove pad (8).
9. Remove calipers (9).
0 Calipers: 32kg
10. Remove mounting bolts (10), then remove disc
(11).
0 Disc: 31kg 4
INSTALLATION OF PARKING
BRAKE
moval.
1
9 Mounting bolt: 157 – 196Nm {16 – 20kgm}
2
fl Adjust the parking brake. For details, see
TESTING AND ADJUSTING PARKING BRAKE
of TESTING AND ADJUSTING,.
3
8 Mounting bolt: Adhesive (LT-2)
9 Mounting bolt:
824.0 – 1030.0Nm {84.0 – 105.0kgm}
4
8 Mounting bolt: Adhesive (LT-2)
9 Mounting bolt:
490.0 – 608.0Nm {50.0 – 62.0kgm}
WA600-3 30-245
(16)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS
DISASSEMBLY OF PARKING
BRAKE CALIPERS
Remove the parking brake calipers. For details, see
REMOVAL OF PARKING BRAKE.
1. Remove snap ring (1), then pull out slack adjuster

(2).
2. Remove washers (3) and (4), and seal (5).
3. Remove bolts, then remove cap (6) and gasket

(7).
4. Remove piston shaft (8) and thrust bearing (9).
5. Remove piston (11) and piston seal (12) from cali-

pers (10).
30-246 WA600-3
2
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS
ASSEMBLY OF PARKING BRAKE

CALIPERS
1. Install piston seal (12) to calipers (10), then insert
piston (11).
2. Screw piston shaft (8) in the piston, then install

thrust bearing (9).
3. Install gasket (7), then install cap (6).
4. Install seal (5) and washers (3) and (4).

fl Fit the seal in the seal groove securely.
2 Seal: Grease (G2-LI)
5. Install slack adjuster (2), then secure it with snap

ring (1).
WA600-3 30-247
(16)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
chine from moving.
1. Disconnect connector (1) (E12).
2. Remove adapter bolts (2) and (3). Serial No.: 50001 – 52000
3. Remove bracket (4) and hoses (5) and (6) together.

fl Remove these parts without removing the
clamp.
4. Loosen mounting bolt (7) and adjustment bolt (8).
5. Turn down the air conditioner compressor toward

the engine, then remove belt (9).
30-250 WA600-3
(14)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
Serial No.: 50001 – 52000

6. Remove mounting bolt (10), then remove air con-
ditioner compressor assembly (11).
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
moval.
• Refilling air conditioner with refrigerant

Using tool X1, refill the air conditioner with new
refrigerant (R134a).
WA600-3 30-251
(16)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
chine from moving.
1. Open bulkhead cover (1).
2. Disconnect condenser connectors (2) (B03), (3)

(B04), (4) (B02) and (5) (B01).
3. Disconnect hose (6) of the receiver tank. 1

fl Be sure to apply spanners to the hose side
and condenser side.
4. Disconnect hose (7) of the air conditioner com-

pressor.
and condenser side.
5. Disconnect hose (8) between the upper and lower

condensers.
and condenser side.

ditioner condensers (10) and (11).
INSTALLATION OF AIR
CONDITIONER CONDENSER
moval.
1
fl Install each hose without twisting it.
fl When connecting each hose, take care that
dirt, dust, water, etc. will not enter it.
fl Refill the air conditioner with new refrigerant
(R134a).
30-252 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY RECEIVER TANK
REMOVAL OF RECEIVER TANK

chine from moving.
1. Open bulkhead cover (1).
2. Disconnect hose (2) of the air conditioner unit.
3. Disconnect hose (3). 1
4. Remove clamp (4), then remove receiver tank (5).
INSTALLATION OF RECEIVER
TANK
moval.
1
fl Install each hose without twisting it.
fl When connecting each hose, take care that
dirt, dust, water, etc. will not enter it.
fl Refill the air conditioner with new refrigerant
(R134a).
WA600-3 30-253
(16)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT
chine from moving.
1. Remove the cab . For details, see REMOVAL OF

CAB.
2. Disconnect operator’s seat suspension switch

connector (1) (ASS).
fl This connector is installed at the rear of the
seat.
3. Remove operator’s seat (2).

0 Operator’s seat: 50kg
4. Remove covers (3) and (4).
5. Remove console box (5).
6. Disconnect connectors (6) (A5), (7) (A7) and (8)

(A6).
7. Disconnect connectors (9) (A8B) and (10) (A8A).
8. Disconnect expansion valve switch connector (11)

(A15).
9. Disconnect tube (12) of the receiver tank.
10. Disconnect tube (13) of the air conditioner com-

pressor.
fl Take a measure to prevent dirt, water, etc.
from entering the tube.
11. Disconnect heater hot water inlet hose (14).
12. Disconnect heater hot water outlet hose valve.

fl Close the valve on the engine side.
fl Plug each disconnected hose.
30-254 WA600-3
(16)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
13. Remove screw (16).

ditioner unit (18).
fl Pull out the air conditioner unit to remove it.
INSTALLATION OF AIR
CONDITIONER UNIT
moval.
• Refilling air conditioner with refrigerant

Using tool X1, refill the air conditioner with new
refrigerant (R134a).
fl If the air conditioner is used without charg-
ing it with the refrigerant, its compressor may
be broken. Be extremely careful.
WA600-3 30-255
(16)
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITOR
chine from moving.
1. Remove cover (1).
2. Remove screw (2).
3. Remove covers (3) and (4) on both sides.
4. Remove bracket (5).
5. Disconnect connectors (6) (L08), (7) (L06), (8) (L07)

and (9) (L05).
6. Remove 12 screws (10), then remove monitor (11).
INSTALLATION OF MONITOR
moval.
30-256 WA600-3
(16)
40 MAINTENANCE STANDARD
Engine mount ............................................... 40- 2

Transmission mount ................................... 40-2-2
Torque converter .......................................... 40- 4
Torque converter regulator valve
(Serial No. : 52001 and up ) ...................... 40-4-3
Transmission ................................................. 40- 6
Transfer ......................................................... 40-10
Transmission control valve .......................... 40-12
Drive shaft ..................................................... 40-17
Center support .............................................. 40-18
Differential .................................................... 40-20
Limited slip differential (If equipped) ...... 40-23-1
Final drive ..................................................... 40-24
Axle mount ................................................... 40-26
Center hinge pin ........................................... 40-28
Steering column ........................................... 40-30
Steering valve ............................................... 40-31
Emergency steering pump .......................... 40-32
Diverter valve ................................................ 40-33
Steering cylinder mount .............................. 40-34
Brake valve .................................................... 40-35
Slack adjuster ............................................... 40-38
Brake .............................................................. 40-40
Parking brake ................................................ 40-42
Hydraulic pump ............................................ 40-44
PPC valve ...................................................... 40-46
Cut-off valve .................................................. 40-48
Main control valve ........................................ 40-50
Hydraulic cylinder ........................................ 40-52
Work equipment linkage .............................. 40-54
Bucket ............................................................ 40-56
Bucket positioner and boom kick-out ......... 40-57
ROPS canopy ................................................ 40-59
WA600-3 40-1
(16)
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance of side bearing size Shaft Hole clearance limit
1 outer race in differential
gear assembly 0 +0.030 0.060 –
225 –
– 0.030 – 0.016 –0.016
Clearance of side bearing
2 inner race in differential 150 +0.052 0 –0.027 – –
gear assembly +0.027 – 0.025 –0.077
Clearance of outer race of 190 0 +0.030 0.060 – –

3 pinion shaft bearing – 0.030 – 0.016 –0.016
Clearance of inner race of 111.125 +0.025 +0.069 0.069 – –

4 pinion shaft bearing 0 +0.047 0.022
Clearance of inner race of 90 0 +0.025 0.045 – –

5 pinion shaft bearing – 0.020 0 0
6 Clearance of outer race of 130 0 +0.039 0.014 – –

pilot bearing – 0.018 +0.014 0.057
7 Clearance of inner race of 60 0 +0.056 0.071 – –

pilot bearing – 0.015 +0.037 0.037
Replace
8 Clearance between differ- 255 +0.046 – 0.030 –0.040 – –
ential carrier and cage +0.010 – 0.070 –0.116
Clearance between spider
9 and differential pinion 46 – 0.13 – 0.13 0.03 – –
bushing – 0.16 – 0.18 –0.05
10 Backlash of bevel gear 0.33 – 0.46
Backlash of differential
11 gear 0.25 – 0.33
12 End play of pinion gear 0 – 0.196
Free rotating torque of

13 bevel gear 13.3 Nm {1.36 kgm}
14 Preload of bevel gear 9.81 – 19.61 KN {1,000 – 2,000 kg}
15 Rear face runout of bevel 0.1

gear
16 Standard thickness of Clearance "a" + (0.1±0.05)

shims for stop shaft
WA600-3 40-21
0
MAINTENANCE STANDARD LIMITED SLIP DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL (IF EQUIPPED)
40-23-1 WA600-3
(16)
MAINTENANCE STANDARD LIMITED SLIP DIFFERENTIAL
Unit: mm

Clearance of side bearing size Shaft Hole clearance limit
1 outer race in differential
gear assembly 0 +0.030 0.060 –
225 – 0.030 +0.016 0.016 –
Clearance of side bearing –0.027 –

inner race in differential +0.052 0
2 150 +0.027 – 0.025 –0.077 –
gear assembly
Clearance of outer race of 0 +0.030 0.060 –
3 pinion shaft bearing 190 – 0.030 – 0.016 –0.016 –
Clearance of inner race of +0.025 +0.069 0.069 –

4 pinion shaft bearing 111.25 0 +0.047 –0.022 –
Clearance of inner race of 0 +0.025 +0.045

5 pinion shaft bearing 90 – 0.020 0 0 –
Clearance of outer race of 0 +0.056 0.071 –

6 pilot bearing 60 – 0.015 +0.037 0.037 –
Clearance between differ- +0.046 – 0.030 –0.040 –

7 ential carrier and cage 255 +0.010 – 0.070 –0.116 –
Replace
8 Backlash of bevel gear 0.33 – 0.46
Backlash of differential
9 gear 0.25 – 0.33
10 End play of pinion gear 0 – 0.196
Free rotating torque of

11 bevel gear 13.3 Nm {1.36 kgm}
Rear face runout of bevel

12 gear 0.1
Standard thickness of
13 shims for stop shaft Clearance "a" + (0.1±0.05)
Standard size Tolerance Repair limit
14 Thickness of plate 3.4

± 0.03 3.3
3.5
15 Thickness of disc 3.605 ± 0.035 3.555
Clearance of disc, plate

16 (End play) 0.2 – 0.8
Thickness of washer 4.0

17
± 0.05 3.8
4.2
Wear of oil suriace 110 0

18 – 0.087 –
WA600-3 40-23-2
6
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
Serial No.: 50001 – 52018
40-24 WA600-3
(16)
40-25-1 WA600-3
(16)
Unit: mm
Tolerance
Standard Standard Clearance
size Shaft Hole clearance limit
1 Clearance between plan-
etary shaft and bearing
55 +0.015 0 –0.002 – –
+0.002 – 0.015 –0.030
Clearance between ring +0.052 +0.025 0.005 –

2 gear hub and bearing 257.175 –
+0.020 0 –0.052
Thickness of retainer at Replace
3
ring gear mount 22 ±0.1 21.6
Backlash between planet 0.21 – 0.45

4 gear and sun gear
Backlash between planet 0.22 – 0.46

5 gear and ring gear
6 Thickness of standard shim 2.1 ± 1.4

for wheel hub
Tightening First 62.8±4.9 Nm {6.4±0.5 kgm}[Preload 2,942–27,459 N {300–2,800 kg}]

torque of Retighten
7 mounting
bolt Second 279.0±29.4 Nm {28.5±3.0 kgm}
WA600-3 40-25-2
(16)
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
(LEFT)
Serial No.: 50001 – 52018
Unit: mm

Clearance between pedal size Shaft Hole clearance limit
1 mount hole and bracket
hole – 0.025 +0.1 0.175 –
10 – 0.075 0 0.025 0.25
Clearance between roller – 0.025 +0.1 0.175 –

2 10 – 0.075 0 0.025 0.25
and pin
3 Outside diameter of roller 0
30 29.2
– 0.5
Standard size Repair limit

Replace
Free length Test height Test load Free length Test load
4 Control spring
3.82 N
34 33.5 {0.39 kg} 33 –
Serial No. 11.8 N

Control 50001 – 52000 46.3 46.0 {1.2 kg} 45.3 –
5 spring
52001 and up 12.8 N
46.3 46.0 {1.3 kg} 45.3 –
60.8 N
Return 50001 – 52000 86.2 58 {6.2 kg} 78 –
6 spring 116.0 N
52001 and up 198 58 {11.8 kg} 179 –
7 Return spring 31.5 19.5 16.7 N 28 –

{1.7 kg}
WA600-3 40-35
(16)
(RIGHT)
Serial No.: 50001 – 52018
40-36 WA600-3
(16)
(LEFT)
Unit: mm

hole – 0.025 +0.1 0.175 –
10 – 0.075 0 0.025 0.25

2 10 – 0.075 0 0.025 0.25
and pin
30 29.2
– 0.5

Replace
4 Control spring
114 N
20 18 {11.6 kg} 19 –
103 N
5 Control spring 32.6 28 {10.5 kg} 31.6 –
37.2 N
6 Control spring 47.2 46 {3.8 kg} 46.2 –
60.8 N
7 Return spring 86.2 58 {6.2 kg} 78 –
16.7 N
8 Return spring 31.5 19.5 {1.7 kg} 28 –
40-37-1 WA600-3
(16)
(RIGHT)
40-37-3 WA600-3
(16)
Unit: mm

hole – 0.025 +0.1 0.175 –
10 – 0.075 0 0.025 0.25

2 and pin 10 – 0.075 0 0.25
0.025
30 29.2
– 0.5
4 Control spring
114 N Replace
20 18 {11.6 kg} 19
103 N
5 Control spring 32.6 28 {10.5 kg} 31.6
37.2 N
6 Control spring 47.2 46 {3.8 kg} 46.2
60.8 N
7 Return spring 86.2 58 {6.2 kg} 78
17.7 N
8 Spring 17 16.5 {1.8 kg} 16.2
16.7 N
9 Return spring 31.5 19.5 {1.7 kg} 28
WA600-3 40-37-4
(16)
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
Serial No.: 50001 – 52018
Unit: mm

1 Clearance between body
and piston
– 0.030 +0.074 0.030 –
55 – 0.076 0 0.150 0.25
Replace
2 Slack adjuster spring
118 N
230 88 {12 kg} – –
40-38 WA600-3
(16)
MAINTENANCE STANDARD SLACK ADJUSTER
Unit: mm

1 Clearance between body
and piston
– 0.030 +0.074 0.030 –
80 – 0.076 0 0.150 0.25
Replace
2 Slack adjuster spring
118 N
230 88 {12 kg} – –
WA600-3 40-39
(16)
MAINTENANCE STANDARD BRAKE
BRAKE
Serial No.: 50001 – 52018
40-40 WA600-3
(16)
Unit: mm
Free length Installation Installation Free length Installation

1 Return spring length load load
706 N 666 N
114.8 101 {72 kg} 105.5 {67.9 kg}
2 Thickness of plate
2.4 – 2.15
3 Thickness of disc 5.1 – 4.6
Total thickness of plate and

4 disc 69.9 – 59.9
5 Wear of contact surface of 0 Replace

seal 430 – 0.155 –
6 Wear of surface in contact +0.097

with piston seal 420 0 –


8 Deformation of friction sur-
face of plate and disc Max. 0.4 0.7
Backlash between outer

9 gear and plate 0.29 – 0.62
Backlash between inner

10 gear and disc 0.17 – 0.52
WA600-3 40-41
(16)
40-41-1 WA600-3
(16)
Unit: mm
Free length Installation Installation Free length Installation

1 Return spring length load load
677 N 642 N
104.8 92.4 {69 kg} 102.7 {65.5 kg}
2 Thickness of plate
2.4 – 2.15
3 Thickness of disc 5.1 – 4.6
Total thickness of plate and

4 disc 99.9 – 89.9
5 Wear of contact surface of 0 Replace

seal 430 – 0.155 –



8 Deformation of friction sur-
face of plate and disc Max. 0.4 0.7
Backlash between outer

9 gear and plate 0.29 – 0.62
Backlash between inner

10 gear and disc 0.17 – 0.52
WA600-3 40-41-2
(16)
MAINTENANCE STANDARD HYDRAULIC PUMP
SAL(4)-125 (Steering) + SAL(4)-100 (Switch) pump

Unit: mm
Model Standard clearance Clearance limit

1 Side clearance SAL(4)-125 0.11 – 0.16 0.19
SAL(4)-100 0.11 – 0.16 0.19
Clearance between inside diam- SAL(4)-125 0.06 – 0.14 0.20
2 eter of plain bearing and out-
side diameter of gear shaft SAL(4)-100 0.06 – 0.14 0.20
Model Standard size Tolerance Repair limit Replace
3 Insertion depth of pin SAL(4)-125 21 0 –

– 0.5
SAL(4)-100 21 0 –
– 0.5
Rotating torque of spline SAL(4)-125

4 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
shaft
SAL(4)-100
Discharge Standard Repair limit
Model Revolution pressure discharge discharge
(rpm) MPa{kg/cm2} (¶/min.) (¶/min.)
Discharge
– Oil: EO10-CD –
Temperature: 45 – 55°C SAL(4)-125 2,200 210 253 234
SAL(4)-100 2,200 210 205 190
WA600-3 40-44-1
(16)
SAL(4)-125 (Hydraulic) + SAL(4)-125 (Hydraulic) pump

Unit: mm

1 Side clearance SAL(4)-125 0.11 – 0.16 0.19
SAL(4)-125 0.11 – 0.16 0.19
– 0.5
SAL(4)-125 21 0 –
– 0.5
Rotating torque of spline SAL(4)-125

4 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
shaft
SAL(4)-125
Model Revolution Discharge

pressure
Standard
discharge
Repair limit
discharge
(rpm) MPa{kg/cm2} (¶/min.) (¶/min.)
Discharge
SAL(4)-125 2,000 210 253 234
40-44-2 WA600-3
(16)
SAL(3)-125 (Torque converter charging) + SAL(1)-32(PPC) pump

Unit: mm

Clearance between gear
1 case and side plate SAL(3)-125 0.13 – 0.18 0.22
SAL(1)-32 0.10 – 0.15 0.19

– 0.5
SAL(1)-32 10 0 –
– 0.5
4 Rotating torque of spline 8.8 – 16.7 Nm {0.9 – 1.7 kgm}

shaft
Revolution Discharge Standard Repair limit

Model (rpm)
pressure discharge discharge
Discharge MPa{kg/cm2} (¶/min.) (¶/min.)
SAL(1)-32 2,000 30 61 52
WA600-3 40-44-3
(16)

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SEBM013216

MACHINE MODEL SERIAL NUMBER

WA600-3 50001 and up

• WA600-3 mounts the SA6D170E-2 or SAA6D170E-3 engine.

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

10 STRUCTURE AND FUNCTION ........................................................... 10-1

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

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

40 MAINTENANCE STANDARD ............................................................... 40-1

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

( ) Page to be deleted Discard

Pages having no marks are those previously re-

LIST OF REVISED PAGES

b 00-1 (16) 01-12 (10) 10-24 10-61 (6) 10-96

10-133 b 10-165-5 (16) 10-205 (6) 20-114 (6) 20-210 (1)

30-175 (2) 30-229 (7) 40-21 (10) 90-3 (6)

IMPORTANT SAFETY NOTICE

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

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

k Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

! The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

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

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

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

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

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

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting