Sen02876 12 PDF

SEN02876-12
WHEEL LOADER WA500 -6R

SERIAL NUMBERS 60001 and up
SEN02885-12
WHEEL LOADER 1SHOP MANUAL
WA500-6R
Machine model Serial number

WA500-6R 60001 and up
00 Index and foreword 1

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

Table of contents ............................................................................................................................................. 4
WA500-6R 1
SEN02885-12 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN02876-12
00 Index and foreword SEN02877-12

Index SEN02885-12 q
Foreword and general information SEN02886-00
01 Specification SEN02878-01
Specification and technical data SEN02887-01
10 Structure, function and maintenance standard SEN02879-04

Engine and cooling system SEN02888-00
Power train, Part 1 SEN02889-00
Steering system SEN02891-01
Brake system SEN02892-02 q
Undercarriage and frame SEN02893-00
Hydraulic system, Part 1 SEN02894-00
Work equipment SEN02896-01
Cab and its attachments SEN02897-00
Electrical system, Part 1 SEN02898-02
20 Standard value table SEN02880-02

Standard service value table SEN02926-02
30 Testing and adjusting SEN02881-07

Testing and adjusting, Part 1 SEN02927-04 q
Testing and adjusting, Part 2 SEN02928-04 q
Testing and adjusting, Part 3 SEN02929-02
40 Troubleshooting SEN02882-05
Failure codes list and fuse locations SEN02931-02
General information on troubleshooting SEN02932-02
2 WA500-6R
Troubleshooting by failure code (Display of code), Part 1 SEN02933-00

Troubleshooting of electrical system (E-mode) SEN02944-02
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02945-00
Troubleshooting of engine (S-mode) SEN02946-02
50 Disassembly and assembly SEN02883-06

General information on disassembly and assembly SEN02903-02 q
Engine and cooling system (SAA6D140E-5) SEN02904-00
Engine (SAA6D140E-5) SEN02905-02
Brake system SEN02909-01 q
Hydraulic system SEN02911-01
Electrical system SEN02914-00
80 Appendix SEN06711-00
Air conditioner SEN06712-00
90 Diagrams and drawings SEN02884-06

Hydraulic diagrams and drawings SEN02901-03
Electrical diagrams and drawings SEN02902-03
WA500-6R 3
Table of contents 1
00 Index and foreword
Index SEN02885-12
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN02886-00
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table .............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN02887-01
Specification dimension drawing.............................................................................................. 2
Specifications........................................................................................................................... 3
Weight table ............................................................................................................................. 6
Table of fuel, coolant and lubricants ........................................................................................ 8
10 Structure, function and maintenance standard

Engine and cooling system SEN02888-00
Cooling system ........................................................................................................................ 2
Engine mount and transmission mount ................................................................................... 5
Power train............................................................................................................................... 2
Power train system diagram .................................................................................................... 3
Joint ......................................................................................................................................... 5
Drive shaft................................................................................................................................ 6
Power train piping diagram ...................................................................................................... 7
Torque converter...................................................................................................................... 8
Torque converter regulator valve ............................................................................................. 26
Transmission............................................................................................................................ 28
Transfer.................................................................................................................................... 48
Transmission control valve ...................................................................................................... 50
ECMV ...................................................................................................................................... 54
Main relief valve and torque converter relief valve .................................................................. 61
Lubrication relief valve ............................................................................................................. 63
Torque converter oil cooler ...................................................................................................... 2
Torque converter oil filter ......................................................................................................... 3
Center support ......................................................................................................................... 6
Axle.......................................................................................................................................... 8
Differential................................................................................................................................ 10
Limited slip differential ............................................................................................................. 19
Final drive ................................................................................................................................ 24
4 WA500-6R
Steering system SEN02891-01

Steering piping diagram........................................................................................................... 2
Steering column....................................................................................................................... 3
Steering control valve .............................................................................................................. 4
Steering valve .......................................................................................................................... 15
Stop valve ................................................................................................................................ 19
Joystick steering lever linkage (if equipped)............................................................................ 20
Steering cylinder ...................................................................................................................... 21
Emergency steering piping diagram (if equipped) ................................................................... 24
Diverter valve........................................................................................................................... 25
Brake system SEN02892-02
Brake piping diagram............................................................................................................... 2
Brake valve.............................................................................................................................. 4
Slack adjuster .......................................................................................................................... 9
Accumulator charge valve ....................................................................................................... 12
PPC relief valve ....................................................................................................................... 16
Accumulator (for brake) ........................................................................................................... 18
Brake ....................................................................................................................................... 20
Parking brake control............................................................................................................... 23
Parking brake .......................................................................................................................... 24
Parking brake solenoid valve................................................................................................... 26
Emergency parking brake release valve ................................................................................. 28
Axle mount............................................................................................................................... 2
Center hinge pin ...................................................................................................................... 7
Hydraulic piping diagram ......................................................................................................... 2
Work equipment control lever linkage ..................................................................................... 4
Hydraulic tank .......................................................................................................................... 5
Cooling fan motor .................................................................................................................... 7
Cooling fan pump .................................................................................................................... 14
Steering pump ......................................................................................................................... 21
Work equipment hydraulic pump ............................................................................................. 32
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 16
Each function and operation of each valve.............................................................................. 21
Accumulator (for PPC circuit) .................................................................................................. 32
Work equipment electric lever ................................................................................................. 33
Work equipment linkage .......................................................................................................... 2
Bucket...................................................................................................................................... 6
Bucket positioner and boom kick-out....................................................................................... 8
Work equipment lubrication ..................................................................................................... 9
Work equipment cylinder ......................................................................................................... 11
ROPS cab................................................................................................................................ 2
Air conditioner.......................................................................................................................... 4
Machine monitor system.......................................................................................................... 2
Machine monitor ...................................................................................................................... 10
Work equipment control system .............................................................................................. 2
Transmission controller system ............................................................................................... 36
Electric transmission control.................................................................................................... 2
Engine starting circuit .............................................................................................................. 6
WA500-6R 5
Engine stopping circuit............................................................................................................. 8

Preheating circuit ..................................................................................................................... 9
Parking brake circuit ................................................................................................................ 11
Backup and stop lamp circuits ................................................................................................. 16
Small lamp and head lamp circuits .......................................................................................... 18
Working lamp circuit ................................................................................................................ 19
Horn circuit............................................................................................................................... 20
Wiper and window washer circuits........................................................................................... 21
Sensor ..................................................................................................................................... 24
KOMTRAX terminal system (if equipped)................................................................................ 42
20 Standard value table

Standard service value table SEN02926-02
Standard service value table for engine................................................................................... 2
Standard service value table for chassis ................................................................................. 3
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting...................................................................... 3
Measuring engine speed ......................................................................................................... 10
Measuring exhaust gas color................................................................................................... 12
Measuring exhaust temperature .............................................................................................. 14
Adjusting valve clearance ........................................................................................................ 16
Testing compression pressure ................................................................................................. 17
Measuring blow-by pressure.................................................................................................... 19
Measuring engine oil pressure................................................................................................. 20
Measuring intake air (boost) pressure ..................................................................................... 21
Handling fuel system equipment.............................................................................................. 23
Releasing residual pressure in fuel system ............................................................................. 23
Testing fuel pressure................................................................................................................ 24
Testing return rate and leakage ............................................................................................... 25
Bleeding air from fuel circuit .................................................................................................... 28
Testing leakage in fuel system................................................................................................. 30
Handling reduced cylinder mode operation ............................................................................. 31
Handling no injection cranking operation................................................................................. 31
Handling controller voltage circuit............................................................................................ 32
Testing and adjusting alternator belt tension ........................................................................... 33
Testing and adjusting air conditioner compressor belt tension ................................................ 34
Adjusting transmission speed sensor ...................................................................................... 35
Measuring directional lever (Steering wheel specification) ...................................................... 37
Testing and adjusting power train oil pressure......................................................................... 38
Flushing procedure for torque converter and transmission hydraulic circuit............................ 51
Method of moving machine when transmission valve is broken.............................................. 54
Testing and adjusting steering stop valve ................................................................................ 3
Testing and adjusting steering wheel....................................................................................... 5
Testing steering oil pressure .................................................................................................... 7
Bleeding air from steering cylinder circuit ................................................................................ 10
Testing hydraulic drive fan ....................................................................................................... 11
Bleeding air from hydraulic drive fan circuit ............................................................................. 14
Measuring brake pedal ............................................................................................................ 16
Measuring brake performance................................................................................................. 17
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator 
with nitrogen gas ......................................................................................................... 18
Testing and adjusting accumulator charge pressure ............................................................... 25
Testing wheel brake oil pressure ............................................................................................. 27
Measuring wear of wheel brake disc ....................................................................................... 29
6 WA500-6R
Bleeding air from brake circuit ................................................................................................. 30

Releasing residual pressure in brake accumulator circuit ....................................................... 32
Testing parking brake performance ......................................................................................... 33
Measuring parking brake oil pressure ..................................................................................... 34
Testing wear of parking brake disc .......................................................................................... 37
Method of releasing parking brake manually ........................................................................... 38
Measuring and adjusting work equipment control lever .......................................................... 39
Testing and adjusting work equipment PPC oil pressure ........................................................ 40
Measuring work equipment oil pressure.................................................................................. 42
Bleeding air from work equipment circuit................................................................................. 48
Releasing residual pressure in work equipment circuit ........................................................... 49
Method of moving machine when removing operator cab (when splittable cab is used)......... 50
Testing and adjusting bucket positioner................................................................................... 51
Testing and adjusting lift arm position detecting lever ............................................................. 53
Checking proximity switch operation indication lamp .............................................................. 54
Procedure for testing diodes.................................................................................................... 55
Preparations for work on troubleshooting of electrical system ................................................ 56
Starting KOMTRAX terminal operations .................................................................................. 2
Indicator lamps of KOMTRAX terminal.................................................................................... 8
Machine monitor-based adjustment at replacement, disassembly and assembly,
and additional installation for each sensor and controller.......................................... 11
Special functions of machine monitor (EMMS)........................................................................ 13
Special functions of machine monitor (EMMS)........................................................................ 2
Pm clinic inspection table ........................................................................................................ 40
40 Troubleshooting
Failure codes list and fuse locations SEN02931-02
Failure codes list...................................................................................................................... 2
Fuse locations ......................................................................................................................... 13
General information on troubleshooting SEN02932-02
Points to remember when performing troubleshooting ............................................................ 2
How to proceed in troubleshooting .......................................................................................... 4
Testing before troubleshooting ................................................................................................ 6
Classification and procedures of troubleshooting.................................................................... 7
Information in troubleshooting table ........................................................................................ 11
Troubleshooting method for disconnecting wiring harness of pressure sensor system .......... 13
Phenomena looking like troubles and troubleshooting Nos..................................................... 16
Connection table for connector pin numbers ........................................................................... 18
T- branch box and T- branch adapter table ............................................................................. 54
Failure code [1500L0] (TORQFLOW transmission : Double meshing) ..................................... 3
Failure code [15B0NX] (Transmission filter: Clogged) .............................................................. 4
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) ...... 6
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) ..... 8
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) ...... 10
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) ..... 12
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON).... 14
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)... 16
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)... 18
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF).. 20
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) ... 22
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) .. 24
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) ... 26
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) .. 28
Failure code [2F00MA] (Parking brake: Malfunction)................................................................ 30
WA500-6R 7
Failure code [2G42ZG] (Front accumulator: Low oil pressure) ................................................. 32

Failure code [2G43ZG] Rear accumulator: Low oil pressure ................................................... 4
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree ....................................... 6
Failure code [AA1ANX] Air cleaner: Clogging.......................................................................... 10
Failure code [AB00L6] Alternator: Signal disagrees with operating state of engine................. 12
Failure code [AB00MA] Alternator: Malfunction ....................................................................... 14
Failure code [B@BAZG] Low engine oil pressure.................................................................... 16
Failure code [B@BAZK] Engine oil: Low level ......................................................................... 18
Failure code [B@BCNS] Coolant: Overheating ....................................................................... 20
Failure code [B@BCZK] Coolant: Low level ............................................................................ 22
Failure code [b@CENS] Torque converter oil: Overheating..................................................... 24
Failure code [B@CENS] Torque converter oil: Overheating .................................................... 25
Failure code [B@GAZK] Battery electrolyte: Low level............................................................ 26
Failure code [B@HANS] Hydraulic oil: Overheating ................................................................ 27
Failure code [CA111] Abnormality in engine controller............................................................. 28
Failure code [CA115] Engine Ne or Bkup speed sensor error ................................................. 31
Failure code [CA122] Charge (boost) pressure sensor high error ........................................... 32
Failure code [CA123] Charge (boost) pressure sensor low error............................................. 34
Failure code [CA131] Throttle sensor high error ...................................................................... 36
Failure code [CA132] Throttle sensor low error ....................................................................... 39
Failure code [CA135] Engine oil pressure sensor high error.................................................... 42
Failure code [CA141] Engine oil pressure sensor low error ..................................................... 44
Failure code [CA144] Coolant temperature sensor high error.................................................. 46
Failure code [CA145] Coolant temperature sensor low error ................................................... 48
Failure code [CA153] Charge (boost) temperature sensor high error ...................................... 50
Failure code [CA154] Charge (boost) temperature sensor low error ....................................... 52
Failure code [CA187] Sensor power supply 2 low error ........................................................... 54
Failure code [CA221] Atmospheric pressure sensor high error ............................................... 56
Failure code [CA222] Atmospheric pressure sensor low error................................................. 58
Failure code [CA227] Sensor power supply 2 high error ......................................................... 60
Failure code [CA234] Engine overspeed ................................................................................. 3
Failure code [CA238] Ne speed sensor power supply error .................................................... 4
Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 6
Failure code [CA265] Fuel Temp Sensor Low Error ................................................................ 8
Failure code [CA271] PCV1 Short circuit................................................................................. 10
Failure code [CA272] PCV1 Disconnection ............................................................................. 11
Failure code [CA273] PCV2 Short circuit................................................................................. 12
Failure code [CA274] PCV2 Disconnection ............................................................................. 13
Failure code [CA322] Injector #1 open/short error................................................................... 14
Failure code [CA342] Calibration code inconsistency ............................................................. 26
Failure code [CA351] Injectors drive circuit error..................................................................... 27
Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 28
Failure code [CA386] Sensor power supply 1 high error ......................................................... 30
Failure code [CA431] Idle validation switch error .................................................................... 31
Failure code [CA432] Idle validation action error..................................................................... 34
Failure code [CA441] Battery voltage low error ....................................................................... 36
Failure code [CA442] Battery voltage high error...................................................................... 37
Failure code [CA449] Common rail pressure high error 2 ....................................................... 38
Failure code [CA451] Rail Press Sensor High Error................................................................ 40
Failure code [CA452] Rail Press Sensor Low Error................................................................. 42
Failure code [CA553] Common rail pressure high error 1 ....................................................... 44
8 WA500-6R
Failure code [CA554] Common rail pressure sensor in range error ........................................ 45
Failure code [CA559] Supply pump pressure very low error 1 ................................................ 46
Failure code [CA689] Engine Ne speed sensor error.............................................................. 50
Failure code [CA731] Engine Bkup speed sensor phase error ............................................... 52
Failure code [CA757] All continuous data lost error ................................................................ 53
Failure code [CA778] Engine Bkup speed sensor error .......................................................... 54
Failure code [CA1633] KOMNET datalink timeout error.......................................................... 56
Failure code [CA2185] Throttle sensor supply voltage high error ........................................... 4
Failure code [CA2186] Throttle sensor power supply low error............................................... 6
Failure code [CA2249] Supply pump pressure very low error 2 .............................................. 8
Failure code [CA2555] Intake air heater relay open circuit error ............................................. 10
Failure code [CA2556] Intake air heater relay short circuit error ............................................. 12
Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit .............................. 14
Failure code [D191KA] Joystick steering neutral safety relay: Disconnection ......................... 16
Failure code [D191KB] Joystick steering neutral safety relay: Short circuit ............................ 18
Failure code [D192KA] ECSS solenoid: Disconnection........................................................... 20
Failure code [D192KB] ECSS solenoid: Short circuit .............................................................. 21
Failure code [D192KY] ECSS solenoid: Short circuit with power supply line .......................... 22
Failure code [D193KA] Joystick steering solenoid cut relay: Disconnection ........................... 24
Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit ............................... 26
Failure code [D193KY] Joystick steering solenoid cut relay: 
Short circuit with power supply line ............................................................................. 28
Failure code [D5ZHKA] Terminal C signal: Disconnection ...................................................... 30
Failure code [D5ZHKB] Terminal C signal: Short circuit .......................................................... 34
Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit ............................... 36
Failure code [D5ZHL6] Terminal C signal: Signal does not match 
engine running or stopped state .................................................................................. 38
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree .............................. 41
Failure code [DAF3KK] Machine monitor: Low source voltage (input) .................................... 44
Failure code [DAF5KP] Machine monitor: Low output voltage ................................................ 46
Failure code [DAFRKR] CAN communication with machine monitor: 
Communication error (Abnormality in target component system) ............................... 48
Failure code [DAQ0KK] Transmission controller: Low source voltage .................................... 49
Failure code [DAQ0KT] Transmission controller: Abnormality in controller............................. 52
Failure code [DAQ2KK] Transmission controller load power supply line: 
Low source voltage (input) .......................................................................................... 53
Failure code [DAQ9KQ] Transmission controller model selection: 
Disagreement of model selection signals .................................................................... 56
Failure code [DAQRKR] CAN communication with transmission controller: 
Failure code [DAQRMA] Transmission controller option setting: Malfunction ......................... 8
Failure code [DB2RKR] CAN communication from engine controller: 
Failure code [DB90KK] Work equipment controller: Low source voltage (input) ..................... 15
Failure code [DB90KT] Work equipment controller: Abnormality in controller......................... 18
Failure code [DB92KK] Work equipment controller load power supply line: 
Low source voltage (input) .......................................................................................... 19
Failure code [DB95KX] Work equipment controller power supply output: 
Out of input signal range ............................................................................................. 22
Failure code [DB99KQ] Work equipment controller model selection: 
Disagreement of model selection signals .................................................................... 24
Failure code [DB9RKR] CAN communication with work equipment controller: 
Failure code [DB9RMA] Work equipment controller option setting: Malfunction ..................... 26
Failure code [DB9RMC] CAN communication with work equipment controller: 
Defective operation ..................................................................................................... 27
WA500-6R 9
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ........ 28
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time ....... 30
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time ......... 32
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time ......... 34
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): 
Switch is kept pressed for long time ............................................................................ 36
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): 
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time ..... 40
Failure code [DD1FLD] Load meter mode selector switch (A/B): 
Failure code [DD1GLD] Load meter mode selector switch (+/–): 
Failure code [DD1HLD] Load meter display selector switch: 
Switch is kept pressed for long time ........................................................................................ 46
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree ......................... 48
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit............ 50
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit ....... 53
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree ........... 56
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time) ........................................................................... 4
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) ............................... 6
Failure code [DDK3KA] (Right FNR switch: Disconnection).................................................... 8
Failure code [DDK3KB] (Right FNR switch: Short circuit) ....................................................... 10
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection).................................. 12
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit) ..................................... 14
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) .. 16
Failure code [DDK6KA] (FNR lever switch: Disconnection) .................................................... 18
Failure code [DDK6KB] (FNR lever switch: Short circuit) ........................................................ 22
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) ..................... 24
Failure code [DDT4LD] (Transmission cut-off set switch:
Switch is kept pressed for long time) ........................................................................... 26
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) ................. 28
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) .......................... 30
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) ..... 32
Failure code [DF10KA] (Transmission shift lever switch: Disconnection)................................ 34
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) ................................... 38
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)...................... 40
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) ......................... 42
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)........... 44
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)......................... 46
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ........ 48
Failure code [DGT1KX] (Torque converter oil temperature sensor:
Out of input signal range) ............................................................................................ 50
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) ............ 52
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit) ................ 4
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor:
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) .. 8
Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range) .................... 10
Failure code [DHT2L6] (Transmission filter clogging sensor:
Signal disagrees with operating and stopped states of engine) .................................. 12
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) ................. 14
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main):
Short circuit with power supply line) ............................................................................ 18
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) ... 21
10 WA500-6R
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection).................. 24
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub):
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ................. 30
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main):
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) .. 36
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) .................. 39
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub):
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main):
Disconnection)............................................................................................................. 45
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main):
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main):
Analog signals disagree) ............................................................................................. 49
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub):
Disconnection)............................................................................................................. 52
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)... 6
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) ... 10
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):
Analog signals disagree) ............................................................................................. 14
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) .............................................. 18
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) ............................. 20
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line).............. 22
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) ........................................... 24
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) ................... 26
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree) .... 28
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit)..................... 30
Failure code [DLT4KX] (Transmission output shaft speed sensor:
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) ............................ 34
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) ............... 36
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) .............. 38
Failure code [DV00KB] (Alarm buzzer: Short circuit) .............................................................. 40
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) ................................... 42
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)....................................... 43
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) ... 44
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) .................................. 46
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...................................... 47
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) .. 48
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) ........................................ 50
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)............................................ 52
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) ....... 54
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) ................................... 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) ...................................... 4
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) ... 6
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) ............................................. 8
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)................................................. 10
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) ............ 12
WA500-6R 11
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) ...................... 14
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) .......................... 14
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid:
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) .................. 16
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) ...................... 18
Failure code [DWM1KY] (Work equipment neutral lock solenoid:
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) ................... 22
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) ....................... 24
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid:
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) .................... 28
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) ........................ 30
Failure code [DWN7KY] (Lift arm float magnet detent solenoid:
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)......................... 34
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) ............................ 36
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid:
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) ......................................... 40
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)............................................. 41
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)......... 42
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection) ......................................... 43
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit) ............................................. 44
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) .......................................... 45
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).............................................. 46
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line).......... 48
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)....................................... 50
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) .......................................... 52
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ...... 4
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) ..................................... 6
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) ......................................... 8
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)..... 10
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) ...................................... 12
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).......................................... 14
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...... 16
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)......................................... 18
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) ............................................ 20
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) ........ 22
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) ......................................... 24
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)............................................. 26
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)......... 28
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...................................... 30
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) ......................................... 32
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) ..... 34
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection) ........................ 36
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)............................ 37
Failure code [DXHJKY] (3-spool valve extract EPC solenoid: 
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) ........................ 39
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)............................ 40
Failure code [DXHKKY] (3-spool valve retract EPC solenoid:
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) ...................... 42
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit).......................... 44
12 WA500-6R
Failure code [DXHLKY] (Joystick steering right EPC solenoid:

Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) ....................... 48
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) ........................... 50
Failure code [DXHMKY] (Joystick steering left EPC solenoid:
Troubleshooting of electrical system (E-mode) SEN02944-02
Fuse locations ......................................................................................................................... 3
Information in troubleshooting table ........................................................................................ 6
E-1 Engine does not start ........................................................................................................ 7
E-2 Wiper does not operate..................................................................................................... 12
E-3 Windshield washer does not operate................................................................................ 16
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off ............. 19
E-5 Working lamp does not light up or go off........................................................................... 27
E-6 Turn signal lamp and hazard lamp do not light up or go off .............................................. 32
E-7 Brake lamp does not light or it keeps lighting up .............................................................. 38
E-8 Backup lamp does not light or it keeps lighting up ............................................................ 40
E-9 Backup buzzer does not sound or it keeps sounding ....................................................... 42
E-10 Horn does not sound or it keeps sounding ..................................................................... 44
E-11 Alarm buzzer does not sound or it keeps sounding ........................................................ 47
E-12 Air conditioner does not operate or stop ......................................................................... 49
E-13 KOMTRAX system does not work properly .................................................................... 52
E-14 Electric priming pump does not operate or does not stop automatically......................... 54
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02945-00
Method of using troubleshooting chart .................................................................................... 3
Table of failure modes and causes .......................................................................................... 6
H-1 Machine does not start ..................................................................................................... 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)]...................................................................... 12
H-3 Torque converter lockup is not switched ON 
[Machine with lockup clutch (if equipped)]...................................................................... 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is
weak, and gear is not shifted.......................................................................................... 14
H-5 Shocks are large at the times of starting and shifting gear ............................................... 16
H-6 Time lag is large at the times of starting and shifting gear................................................ 18
H-7 Torque converter oil temperature is high .......................................................................... 20
H-8 Steering does not turn....................................................................................................... 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)] ............................... 22
H-10 Steering response is low................................................................................................. 23
H-11 Turning response of steering is poor [machine with joystick steering (if equipped)] ....... 24
H-12 Steering is heavy ............................................................................................................ 25
H-13 When machine turns, it shakes or makes large shocks.................................................. 26
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)] ................................................................. 27
H-15 Wheel brake does not work or does not work well ......................................................... 28
H-16 Wheel brake is not released or it drags .......................................................................... 29
H-17 Parking brake does not work or does not work well ....................................................... 30
H-18 Parking brake is not released or it drags (including emergency release system)........... 31
H-19 Lift arm does not rise ...................................................................................................... 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient ........................................... 33
H-21 When rising, lift arm comes to move slowly at specific height ........................................ 34
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats).............................................. 34
H-23 Hydraulic drifts of lift arm occur often.............................................................................. 34
H-24 Lift arm wobbles during operation................................................................................... 34
H-25 Bucket does not tilt back................................................................................................. 35
H-26 Bucket speed is low or tilting back force is insufficient ................................................... 36
H-27 Bucket comes to operate slowly in the midst of tilting-back............................................ 37
H-28 Bucket cylinder cannot hold down the bucket................................................................. 37
WA500-6R 13
H-29 Hydraulic drifts of bucket occur often .............................................................................. 37

H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”) ....... 37
H-31 During operation of machine, engine speed lowers remarkably or engine stalls ............ 38
H-32 Large shocks are made when work equipment starts and stops .................................... 38
H-33 When work equipment circuit is relieved singly, other work equipment moves .............. 38
H-34 ECSS does not operate, and pitching and bouncing occur ............................................ 39
Troubleshooting of engine (S-mode) SEN02946-02
Method of using troubleshooting chart..................................................................................... 3
S-1 Engine does not start easily. ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operation .......................................................................................... 11
S-5 Engine does not rotate smoothly (Engine hunts.) ............................................................. 12
S-6 Engine lacks output (or lacks power) ................................................................................ 13
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................ 14
S-8 Oil is consumed much (or exhaust gas color is blue)........................................................ 15
S-9 Engine oil becomes contaminated quickly ........................................................................ 16
S-10 Fuel consumption is excessive ....................................................................................... 17
S-11 Coolant contains oil (blows back or reduces) .................................................................. 18
S-12 Oil pressure drops........................................................................................................... 19
S-13 Oil level rises (Water, fuel in oil) ...................................................................................... 20
S-14 Coolant temperature rises too high (Overheating) .......................................................... 21
S-15 Abnormal noise is made.................................................................................................. 22
S-16 Vibration is excessive...................................................................................................... 23
S-17 Air cannot be bled from fuel circuit.................................................................................. 24
50 Disassembly and assembly

General information on disassembly and assembly SEN02903-02
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tool list ......................................................................................................................... 7
Sketches of special tools ......................................................................................................... 11
Engine and cooling system (SAA6D140E-5) SEN02904-00
Removal and installation of engine assembly.......................................................................... 2
Removal and installation of radiator assembly ........................................................................ 7
Removal and installation of air aftercooler............................................................................... 9
Removal and installation of cooling fan and fan motor assembly............................................ 10
Removal and installation of radiator guard and cooling fan motor assembly .......................... 12
Removal and installation of fuel tank assembly ....................................................................... 15
Removal and installation of hood............................................................................................. 17
Engine (SAA6D140E-5) SEN02905-02
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of cylinder head assembly ............................................................... 6
Removal and installation of fuel injector assembly .................................................................. 17
Removal and installation of engine front seal .......................................................................... 20
Removal and installation of engine rear seal........................................................................... 24
Removal and installation of torque converter and transmission assembly .............................. 2
Disconnection and connection of power train unit ................................................................... 8
Disassembly and assembly of input transfer assembly ........................................................... 12
Disassembly and assembly of torque converter assembly (Lockup specification) .................. 19
Disassembly and assembly of torque converter assembly (Lockup-less specification) .......... 32
Disassembly and assembly of transmission assembly............................................................ 2
Disassembly and assembly of transfer and parking brake assembly ...................................... 32
Removal and installation of front axle assembly...................................................................... 49
Removal and installation of rear axle assembly ...................................................................... 51
14 WA500-6R

Removal and installation of front differential assembly............................................................ 2
Disassembly and assembly of differential assembly (LSD specification) ................................ 4
Disassembly and assembly of differential assembly (LSD-less specification)......................... 18
Disassembly and assembly of final drive assembly (Front and rear) ...................................... 29
Brake system SEN02909-01
Removal and installation of brake assembly (Front and rear) ................................................. 2
Disassembly and assembly of brake assembly (Front and rear)............................................. 6
Disassembly and assembly of slack adjuster assembly .......................................................... 12
Disassembly and assembly of brake accumulator charge valve assembly ............................. 13
Removal and installation of center hinge pin ........................................................................... 2
Removal and installation of large counterweight assembly ..................................................... 9
Removal and installation of small counterweight assembly .................................................... 10
Hydraulic system SEN02911-01
Removal and installation of hydraulic tank assembly .............................................................. 2
Removal and installation of cooling pump assembly ............................................................... 5
Removal and installation of fan pump assembly ..................................................................... 6
Removal and installation of work equipment pump assembly ................................................. 7
Removal and installation of steering, torque converter charge and EPC pump assembly ...... 9
Removal and installation of work equipment valve assembly ................................................. 10
Disassembly and assembly of work equipment control valve assembly ................................. 13
Disassembly and assembly of steering cylinder assembly...................................................... 16
Disassembly and assembly of lift arm and bucket cylinder assembly ..................................... 20
Removal and installation of steering valve assembly .............................................................. 26
Removal and installation of work equipment assembly ........................................................... 2
Removal and installation of operator's cab assembly
(Separate cab and floor specification) ....................................................................... 2
Removal and installation of operator's cab and floor frame assembly
(Cab-floor unit specification)...................................................................................... 7
Removal and installation of operator's cab glass (Stuck glass)............................................... 11
Disassembly and assembly of operator's seat assembly ........................................................ 20
Electrical system SEN02914-00
Removal and installation of engine controller assembly.......................................................... 2
Removal and installation of transmission controller assembly ................................................ 3
Removal and installation of work equipment controller assembly ........................................... 4
Removal and installation of air conditioner unit assembly ....................................................... 5
80 Appendix
Air conditioner SEN06712-00
Precautions for refrigerant ....................................................................................................... 3
Troubleshooting procedure...................................................................................................... 4
Circuit diagram and arrangement of connector pins................................................................ 6
System diagram....................................................................................................................... 11
Detail of air conditioner unit ..................................................................................................... 13
Parts and connectors layout .................................................................................................... 15
Testing with self-diagnosis function (indication on control panel) ............................................ 19
Testing temperature control ..................................................................................................... 22
Testing vent (mode) changeover ............................................................................................. 23
Testing Fresh/Recirc changeover ............................................................................................ 25
Testing inside air temp. sensor and outside air temp. sensor.................................................. 27
Testing evaporator temperature sensor................................................................................... 29
Testing sunlight sensor ............................................................................................................ 30
Testing relays........................................................................................................................... 31
Troubleshooting chart 1 ........................................................................................................... 32
WA500-6R 15
Troubleshooting chart 2 ........................................................................................................... 33

Information in troubleshooting table......................................................................................... 36
Troubleshooting for power supply system (Air conditioner does not operate) ......................... 37
Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................ 40
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ............. 43
Troubleshooting for temperature control.................................................................................. 49
Troubleshooting for vent (mode) changeover .......................................................................... 52
Troubleshooting for Fresh/Recirc air changeover.................................................................... 55
Troubleshooting with gauge pressure...................................................................................... 57
Connection of service tool ....................................................................................................... 59
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ....... 60
Handling of compressor oil ...................................................................................................... 62
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN02901-03
Power train hydraulic circuit diagram....................................................................................... 3
Brake hydraulic circuit diagram................................................................................................ 7
Work equipment hydraulic circuit diagram ............................................................................... 11
Electrical diagrams and drawings SEN02902-03
Engine electrical circuit diagram ............................................................................................. 2
Air conditioner electrical circuit diagram .................................................................................. 3
Electrical circuit diagram.......................................................................................................... 5
Connector arrangement diagram............................................................................................. 19
16 WA500-6R
WA500-6R 17
SEN02885-12
WA500-6R Wheel loader

Form No. SEN02885-12
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 07-19 (01)
18
SEN02886-00
WA500-6R

WA500-6R 60001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
WA500-6R 1
Safety notice 1 (Rev. 2007/03)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 WA500-6R
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
WA500-6R 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 WA500-6R
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
WA500-6R 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refriger-
ant (R134a) from the air condi-
tioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 WA500-6R
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

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

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

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

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

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

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

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
WA500-6R 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

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

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 WA500-6R
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

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

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

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
WA500-6R 9
2. Standard clearance and standard value 5. Clearance limit

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

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 WA500-6R
Handling of electric equipment and hydraulic component 1

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

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

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

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
WA500-6R 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 WA500-6R
3. Removing, installing, and drying connec-

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

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

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

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
WA500-6R 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 WA500-6R
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
WA500-6R 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 WA500-6R
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
WA500-6R 17
Points to remember when handling hydraulic equipment

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

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

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

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 WA500-6R
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
WA500-6R 19
Handling of connectors newly used for engines 1

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

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 WA500-6R
3. Push lock type

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

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

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

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

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
WA500-6R 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 WA500-6R
How to read electric wire code 1

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

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

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

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
WA500-6R 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 WA500-6R
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
WA500-6R 25
Precautions when carrying out operation 1

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

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

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 WA500-6R
2. Precautions when carrying out installation work

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

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
WA500-6R 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 WA500-6R
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
WA500-6R 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 WA500-6R
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
WA500-6R 31
Standard tightening torque table 1

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

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

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
a Fig. A a Fig. B
32 WA500-6R
2. Table of tightening torques for split flange bolts

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

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

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

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

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

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
WA500-6R 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
34 WA500-6R
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

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
WA500-6R 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

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

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 WA500-6R
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
WA500-6R 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 WA500-6R
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
WA500-6R 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 WA500-6R
WA500-6R 41
SEN02886-00
WA500-6R GALEO Wheel loader

© 2007 KOMATSU
All Rights Reserved
42
SEN02887-01
WA500-6R

WA500-6R 60001 and up
01 Specification 1
Specification and technical data
Specification dimension drawing..................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 6
Table of fuel, coolant and lubricants................................................................................................................ 8
WA500-6R 1
SEN02887-01 01 Specification
Specification dimension drawing1
2 WA500-6R
Specifications 1
Machine model name WA500-6R

Serial number 60001 and up
Operating weight kg 33,360
Weight
Front wheel load kg 15,740

Rear wheel load kg 17,620
3
Bucket capacity (Heaped) m 5.6 (with Bolt-on cutting edge)
Rated load kN {kg} 90.7 {9,250}
E mode P mode
Travel speed F1 km/h 7.3 7.7
Travel speed F2 km/h 12.5 (13.5) 12.5 (14.2)
Performance
Travel speed R1 km/h 8.1 8.6

Travel speed R2 km/h 13.0 (15.1) 13.0 (15.9)
Maximum drawbar pull (Forward) kN {kg} 288.3 {29,400}
Maximum drawbar pull (Reverse) kN {kg} 256.4 {26,150}
Gradeability deg. 25
Min. turning radius
Center of outside tire mm 6,430
Outside most portion of machine
mm 7,650 (with BOC)
body
Overall length mm 9,815 (with BOC)
Overall width mm 3,190
Bucket width mm 3,400 (with BOC)
Overall height (ROPS at cab top) mm 3,785
Overall height with bucket lifted up mm 6,430
Wheelbase mm 3,780
Dimension
Tread mm 2,400
Minimum ground clearance mm 450
Max. hinge pin height of bucket mm 4,755
Dumping clearance mm 3,295 (with BOC)
Dumping reach mm 1,500 (with BOC)
Bucket tilt-forward angle deg. 46
Bucket tilt-back angle 
deg. 50
(Operating posture)
Digging depth (Approx. 10°) mm 435
a BOC: Abbreviation for Bolt-On Cutting edge.
WA500-6R 3

Model name SAA6D140E-5
4-cycle, water-cooled, direct injection type with turbo-
Type
charger, air-cooled aftercooler
Number of cylinders – Bore x Stroke mm 6 – 140 x 165
Total piston displacement l {cc} 15.2 {15,240}
E mode P mode
Flywheel horsepower
253{339}/1,800 263{353}/1,900
• Net [ISO 9249/SAE J1349] (*1) kW{HP}/rpm
Engine
256{343}/1,800 266{357}/1,900
Performance
• Gross [SAE J1995] (*2)

Max. torque (*1) Nm{kgm}/rpm 1,789{182.4}/1,250 1,789{182.4}/1,250
g/kWh
Min. fuel consumption 208.7{153.5} 211.4{155.5}
{g/HPh}
Max. speed at no load rpm 2,000 2,120
Min. speed at no load rpm 790 790
Starting motor 24 V, 11 kW
Alternator 24 V, 75 A
Battery (*3) 12 V, 136 Ah x 2
Torque converter 3-element, 1-stage, 2-phase
Power train
Transmission Planetary type, multi-disc type, forward-reverse 4-stage

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

Rear axle Center pin support type, full-float type
Size 29.5-25-22PR(L3)
Rim size 25.00 x 25WTB
Tires
Inflation pressure (Front wheel) kPa 450 {4.5}

(Rear wheel) {kg/cm2} 400 {4.0}
Independent front and rear wheel brakes,
Foot brake enclosed wet multi-disc type
Brake
Full hydraulic type

Drive shaft braking system of wet disc type
Hand brake
Hydraulically released spring-driven type
*1: Indicates the value at the minimum speed of cooling fan.

*2: Indicates the value of the engine alone (without cooling fan).
*3: The battery capacity (Ah) indicates the 5-hour rate value.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output
measured of an indepedent engine. While, net denotes the value measured of an engine under the con-
dition essentially the same as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
E-mode: 238 kW {318 HP} /1,800rpm
P-mode: 248 kW {332 HP} /1,900rpm
4 WA500-6R

Steering system
steering
system
Type Articulated steering

Structure Fully-hydraulic power steering
l/min
Cylinder Control valve Hydraulic pump delivery
Work equipment hydraulic pump 321 (Variable displacement piston pump HPV190)
Steering pump l/min 120 (Variable displacement piston pump LPV90)
Cooling fan pump l/min 70 (Variable displacement piston pump LPV45)
Power train pump l/min 189 (Gear pump SAR (3) 112)
Hydraulic cooling pump l/min 94 (Gear pump SAL (3) 80)
l/min
Hydraulic system
EPC and brake pump 54 (Gear pump SAR (1) 28)
Set pressure for work equipment MPa {kg/cm2} 3-spool type (with HI valve) 34.3 {350}
Set pressure for steering system MPa {kg/cm2} Spool type 24.5 {250}
Number of lift cylinders – Bore x Stroke mm Double-acting piston type 2 – 160 x 898
Number of bucket cylinders – Bore x Stroke mm Double-acting piston type 1 – 185 x 675
Number of steering cylinders – Bore x Stroke mm Double-acting piston type 2 – 100 x 486
Motor
Fan motor Fixed displacement piston type: LMF40
equipment
Work equipment
Work
Type of link Single link

Shape of bucket cutting edge Straight bolt on cutting edge
WA500-6R 5
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine (dry weight) 1,680
Radiator (including air conditioner condenser) (dry weight) 326
Torque converter (including drive gear) (dry weight) 558
Transmission (dry weight) 1,106
Center drive shaft 45
Front drive shaft 45
Rear drive shaft 40
Center support 42
Front axle 2,250
Rear axle 2,084
Front differential 368
Rear differential 390
Planetary carrier assembly (1 piece) 69
Wheel hub (1 piece) 114
Axle pivot (front) 104
Axle pivot (rear) 126
Wheel (1 piece) 267
Tire (standard: 29.5-25-22PR L3) (1 piece) 532
Steering demand valve 24
Steering cylinder (1 piece) 53
Hydraulic tank (dry weight) 412
Work equipment hydraulic pump 106
Power train, EPC pump 22
Steering pump 39
Hydraulic cooling pump 13
Cooling fan pump 25
Torque converter oil cooler 70
Fan motor 13.4
Fan 29.1
6 WA500-6R
Unit: kg
Work equipment valve 110
Lift cylinder (1 piece) 282
Bucket cylinder 289
Engine hood 265
Radiator guard 355
Front frame 2,565
Rear frame 2,650
Bucket link (including bushing) 157
Bell crank (including bushing) 754
Lift arm (including bushing) 2,105
3
Bucket (5.2 m with teeth and segment edge) 2,960
Bucket (5.6 m3 with bolt-on cutting edge) 3,005
Counterweight 2,480
Fuel tank 220
Battery (1 piece) 56
Cab (including console box and dashboard) 987
Air conditioner unit 33
Operator seat 36
WA500-6R 7
Table of fuel, coolant and lubricants 1

a For details of notes (Note 1, No. 2 ...) in the table, see Operation and Maintenance Manual.
q ASTM: American Society of Testing and Material

Supply points
Engine oil Transmis- Hydraulic Cooling
Front axle Rear axle Fuel tank
pan sion case system system
Capacity
Specified
(l) 45 95 460 95 95 120 473
capacity
Refill capacity (l) 45 (37) 76 337 95 95 — —
Value in ( ) applies to oil level of engine oil pan alone.
8 WA500-6R
WA500-6R 9
SEN02887-01

Form No. SEN02887-01

© 2017 KOMATSU
All Rights Reserved
10
SEN02888-00
WA500-6R

WA500-6R 60001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Cooling system ............................................................................................................................................... 2
Engine mount and transmission mount........................................................................................................... 5
WA500-6R 1
SEN02888-00 10 Structure, function and maintenance standard
Cooling system 1
1. Radiator A: Aftercooler outlet

2. Aftercooler B: Coolant inlet
3. Hydraulic oil cooler C: Coolant inlet
4. Coolant sub-tank D: Aftercooler inlet
5. Coolant level sensor E: Hydraulic oil cooler outlet
6. Torque converter oil cooler F: Hydraulic oil cooler inlet
7. Air conditioner G: Coolant outlet
8. Cooling fan
9. Cooling fan motor
10. Fan guard
2 WA500-6R
Specifications
Hydraulic oil Hydraulic oil Torque converter
Radiator Aftercooler
cooler (1) cooler (2) oil cooler
Aluminum tube in Straight fin
Core type PTO-OL PTO-OL PTO-LS
4-column 10-hole tube type
150 × 620 ×
Fin pitch (mm) 4.0/2P 100 × 385 × 17 100 × 558 × 17 6.0/2P
20-stage
Total heat dissipation
59.90 1.2187 1.829 21.57 3.254
surface (m2)
Cross sectional area
50.845 — — — —
of flow (cm2)
Pressure valve crack-
ing pressure 70 ± 15 — — — —
(kPa {kg/cm2})
Vacuum valve crack-
ing pressure 0–5 — — — —
(kPa {kg/cm2})
WA500-6R 3
4 WA500-6R
Engine mount and transmission mount 1
Unit: mm
No Check item Criteria Remedy
Shim thickness: 0.5 mm, 1.0 mm
1 Shim thickness of mount (Shim thickness and number of shims used shall be the
same as that employed on the actual machine.)
Clearance between stopper and A clearance of 1.5 mm minimum shall be provided between
2
support the stopper and support.
Adjust
Shim thickness: 0.5 mm, 1.0 mm
3 Shim thickness of mount (Shim thickness and number of shims used shall be the
same as that employed on the actual machine.)
Clearance between stopper bolt A clearance of 1 to 1.5 mm minimum shall be provided
4
and bracket between the stopper and bracket.
WA500-6R 5
SEN02888-00

© 2007 KOMATSU
All Rights Reserved
6
SEN02889-00
WA500-6R

WA500-6R 60001 and up

Power train, Part 1
Power train...................................................................................................................................................... 2
Power train system diagram ........................................................................................................................... 3
Joint ................................................................................................................................................................ 5
Drive shaft....................................................................................................................................................... 6
Power train piping diagram ............................................................................................................................. 7
Torque converter ............................................................................................................................................. 8
Torque converter regulator valve .................................................................................................................. 26
Transmission................................................................................................................................................. 28
Transfer......................................................................................................................................................... 48
Transmission control valve............................................................................................................................ 50
ECMV............................................................................................................................................................ 54
Main relief valve and torque converter relief valve........................................................................................ 61
Lubrication relief valve .................................................................................................................................. 63
WA500-6R 1
Power train 1
Outline
q The power from engine (1) is transmitted to q Multi-disc type parking brake (10) is installed
torque converter (2) through the flywheel and on transmission. The power from the front side
ring gear. Torque converter (2) converts the output shaft is transmitted through center drive
transmitted toque according to the fluctuation shaft (11) and front drive shaft (13) to front dif-
of the load by using oil as a medium and then ferential (14). On the rear side, the power is
transmits the power to the input shaft of trans- transmitted to rear differential (19) from rear
mission (3). drive shaft (18).
The engine power is also transmitted through q The power being transmitted to front differen-
the pump drive gear (PTO) of torque converter tial (14) and rear differential (19) is then trans-
(2) to steering pump (4), torque converter mitted to the axle shaft.
charging pump (5), EPC pump (6), cooling q The power from the axle shaft is reduced in
pump (7), work equipment pump (8) and fan speed by final drives (15) and (20) and then
pump (9) to drive these pumps. transmitted to tires (17) and (22) through the
q Transmission (3) operates 6 hydraulic clutches planetary carrier.
through the solenoid valve-based operation of
the directional spool and gearshift spool to
select one of 4 gear speeds in the forward or
reverse travel direction.
Selection of a speed is done by use of the
electrically controlled switch.
2 WA500-6R
Power train system diagram 1

Without lockup clutch
1. Engine 12. Center support

2. Torque converter 13. Front drive shaft
3. Transmission 14. Front differential
4. Steering pump 15. Front final drive
5. Torque converter charging pump 16. Wet-type multi-disc brake
6. EPC and break pump 17. Front tire
7. Hydraulic cooling pump 18. Rear drive shaft
8. Work equipment pump 19. Rear differential
9. Cooling fan pump 20. Rear final drive
10. Parking brake 21. Wet-type multi-disc brake
11. Center drive shaft 22. Rear tire
WA500-6R 3
With lockup clutch
1. Engine 13. Front drive shaft

2. Torque converter 14. Front differential
3. Transmission 15. Front final drive
4. Steering pump 16. Wet-type multi-disc brake
5. Torque converter charging pump 17. Front tire
6. EPC and brake pump 18. Rear drive shaft
7. Hydraulic cooling pump 19. Rear differential
8. Work equipment pump 20. Rear final drive
9. Cooling fan pump 21. Wet-type multi-disc brake
10. Parking brake 22. Rear tire
11. Center drive shaft 23. Lockup clutch (if equipped)
12. Center support
4 WA500-6R
Joint 1
1. Ring gear
Unit: mm
No. Check item Criteria Remedy
Backlash of engine side drive gear and
2 0.059 – 0.240 Replace
torque converter case gear
Outline
q The ring gear is installed to the flywheel of the
engine.
The internal teeth of the ring gear are meshed
with the external teeth of the torque converter
lockup clutch housing to transmit the power
from the engine to the torque converter.
WA500-6R 5
Drive shaft 1
1. Front drive shaft Outline

2. Center support q The power from the engine is transmitted
3. Center drive shaft through the torque converter, transmission and
4. Rear drive shaft transfer. From the transfer, part of the power is
then transmitted to the rear axle through rear
drive shaft (4). And the remaining portion of the
power is transmitted to the front axle through
center drive shaft (3), center support (2) and
front drive shaft (1).
q The drive shafts have the following purpose
besides simple power transmission.
q When the positions of the transmission and
front and rear axles change because of the
traveling impacts or working impacts during
articulation or travel of the machine, the drive
shaft absorbs the fluctuations in the angle and
length by use of the universal joint and slip
joint so that the power may be transmitted
without damaging the parts.
6 WA500-6R
Power train piping diagram 1
1. Transmission
2. Torque converter
3. Transmission control valve
4. Power train pump
5. Torque converter oil cooler
6. Torque converter oil filter
WA500-6R 7
Torque converter 1
(Torque converter, PTO, and input transfer)
8 WA500-6R
A: From main relief valve

B: From transmission control valve
C: Torque converter outlet oil pressure pickup port
D: To transfer case
1. Hydraulic and brake cooling pump (if equipped)

mounting port
2. Cooling fan pump mounting port
3. Transmission input shaft speed sensor
4. Input transfer
5. Torque converter and PTO
6. Work equipment hydraulic pump mounting port
7. Steering pump, power train pump and EPC
brake pump mounting port
8. Torque converter regulator valve
Specifications
Type 3-element, 1-stage, 1-phase

Stall torque ratio 2.84
WA500-6R 9
1. Flywheel 9. Torque converter output shaft

2. Pilot 10. Input transfer drive gear (Number of teeth: 59)
3. Drive case 11. Transmission input shaft
4. Turbine 12. Input transfer driven gear (Number of teeth: 47)
5. Stator 13. PTO drive gear (Number of teeth: 88)
6. Pump 14. Spacer
7. PTO idler gear (Number of teeth: 51) 15. Boss
8. Stator shaft
10 WA500-6R
Unit: mm
Backlash between PTO idler
1 0.192 – 0.492
gear and PTO gear A
2 0.192 – 0.492
gear and PTO gear B
Tolerance
Standard size
Shaft Hole
Tolerance for fitness
3 of bearing in PTO Outside –0.000 –0.010
100
gear A (Small) diameter –0.015 –0.045
Inside +0.030 –0.000
55
diameter +0.011 –0.015
Outside –0.000 +0.026 Replace
Tolerance for fitness 150
diameter –0.018 –0.014
4 of bearing in PTO
gear A (Large) Inside +0.035 –0.000
85
diameter +0.013 –0.020
Outside –0.000 –0.010
diameter –0.015 –0.045
5 of bearing in PTO
gear B (Small) Inside +0.030 –0.000
55
diameter +0.011 –0.015
Outside –0.000 +0.026
diameter –0.018 –0.014
6 of bearing in PTO
gear B (Large) Inside +0.030 –0.000
70
diameter +0.011 –0.015
7. PTO gear A (Number of teeth: 84)

8. PTO gear B (Number of teeth: 84)
WA500-6R 11
12 WA500-6R
Unit: mm
Standard size Tolerance Repair limit
1 Outside diameter of pilot –0.040 Repair by hard
80 79.92
–0.070 chromium-plating
Inside diameter of sleeve seal +0.030 or replace
65 65.1
ring contact surface –0.000
–0.01
2 Width 3 2.7
Wear of output shaft –0.03
Replace
seal ring Thick-
2.7 ±0.1 2.55
ness
Repair by hard
Inside diameter of PTO drive +0.040
3 170 170.5 chromium-plating
gear seal ring contact surface –0.000
or replace
Tolerance
Standard size
Shaft Hole
4 of PTO idler gear Outside –0.000 –0.028
125
bearing diameter –0.020 –0.068
Inside +0.012 –0.000
70
diameter –0.007 –0.015
Outside –0.000 –0.012
Tolerance for fitness diameter 150
–0.020 –0.052
5 of input transfer drive
gear bearing (Large) Inside +0.059 –0.000
85
diameter +0.037 –0.020
Outside –0.000 –0.012
Tolerance for fitness diameter 140
–0.020 –0.052
6 of input transfer drive
gear bearing (Small) Inside +0.051 –0.000
80
diameter +0.032 –0.015
Replace
Outside –0.000 –0.012
diameter –0.020 –0.052
7 of input transfer
driven gear bearing Inside +0.051 –0.000
80
diameter +0.032 –0.015
Backlash between PTO drive
8 0.192 – 0.492
gear and PTO idler gear
Backlash between input trans-
9 0.190 – 0.486
fer drive gear and driven gear
Standard clearance Clearance limit
Clearance between cage and
10 0.40 – 1.60
case of input transfer drive gear —
(Standard shim thickness: 1.0)
0.60 – 1.80
11 case of input transfer driven —
gear
WA500-6R 13
Power transmitting route
q The power from engine is transmitted to drive

case (2) through flywheel (1).
q The power being transmitted to drive case (2)
rotates pump (3) and PTO drive gear (4).
q The power being transmitted to pump (3)
rotates turbine (6) and boss (7) using oil as the
medium, and then transmitted to output shaft
(8).
q The power being transmitted to output shaft (8)
is then transmitted to transmission input shaft
(11) through drive gear (9) and driven gear
(10).
q The power being transmitted to PTO drive gear
(4) is then transmitted through PTO idler gear
(5) and PTO gear and then used as the pump
driving power.
14 WA500-6R
Oil flow
q The oil flows to the torque converter relief

valve through the main relief valve and there
its pressure is regulated to below the set pres-
sure by the valve. The oil flows to pump (4)
through inlet port (A) and oil passage of case
(1), stator shaft (2) and spacer (3).
q The oil is given a centrifugal force by pump (4),
and then it enters turbine (5) to transmit its
energy to turbine (5).
q The oil from turbine (5) is sent to stator (6), and
then returned to pump (4). Part of this oil is
sent to the oil cooler through stator (6), oil pas-
sage of stator shaft (2), outlet port (B) and
torque converter regulator valve.
WA500-6R 15
With lockup clutch

(Torque converter, PTO, and input transfer)
16 WA500-6R
A: From main relief valve

B: From lockup clutch ECMV
C: From transmission control valve
D: Torque converter outlet oil pressure pickup port
E: To transfer case
1. Hydraulic and brake cooling pump (if equipped)

mounting port
2. Cooling fan pump mounting port
4. Input transfer
5. Torque converter and PTO
6. Work equipment hydraulic pump mounting port
7. Steering, power train and PPC pump mounting
port
8. Torque converter regulator valve
Specifications
Type 3-element, 1-stage, 2-phase

Stall torque ratio 2.73
WA500-6R 17
1. Flywheel 11. Input transfer drive gear (Number of teeth: 59)

2. Pilot 12. Transmission input shaft
3. Lockup clutch housing 13. Input transfer driven gear (Number of teeth: 47)
4. Turbine 14. PTO drive gear (Number of teeth: 88)
5. Stator 15. Spacer
6. Drive case 16. Free wheel
7. Pump 17. Race
8. PTO idler gear (Number of teeth: 51) 18. Lockup clutch disc
9. Stator shaft 19. Lockup clutch piston
10. Torque converter output shaft 20. Boss
18 WA500-6R
Unit: mm
1 0.192 – 0.492
gear and PTO gear A
2 0.192 – 0.492
gear and PTO gear B
Tolerance
Standard size
Shaft Hole
3 of bearing in PTO Outside –0.000 –0.010
100
gear A (Small) diameter –0.015 –0.045
Inside +0.030 –0.000
55
diameter +0.011 –0.015
Outside –0.000 +0.026 Replace
diameter –0.018 –0.014
4 of bearing in PTO
gear A (Large) Inside +0.035 –0.000
85
diameter +0.013 –0.020
Outside –0.000 –0.010
diameter –0.015 –0.045
5 of bearing in PTO
gear B (Small) Inside +0.030 –0.000
55
diameter +0.011 –0.015
Outside –0.000 +0.026
diameter –0.018 –0.014
6 of bearing in PTO
gear B (Large) Inside +0.030 –0.000
70
diameter +0.011 –0.015
7. PTO gear A (Number of teeth: 84)

8. PTO gear B (Number of teeth: 84)
WA500-6R 19
20 WA500-6R
Unit: mm
1 Outside diameter of pilot –0.040 Repair by hard
80 79.92
–0.070 chromium-plating or
replace
Inside diameter of pilot seal ring +0.025
40 40.1
contact surface –0.000
2 –0.01
Wear of output shaft Width 3 2.7
–0.03 Replace
seal ring
Thickness 1.7 ±0.1 1.55
Repair by hard
Inside diameter of stator shaft seal +0.030
65 65.1 chromium-plating or
ring contact surface –0.000
replace
3
–0.01
Wear of output shaft Width 3 2.7
–0.03 Replace
seal ring
Thickness 2.7 ±0.1 2.55
Repair by hard
Inside diameter of PTO drive gear +0.040
4 170 170.5 chromium-plating or
seal ring contact surface –0.000
replace
Inside diameter of race free wheel
5 102.555 ±0.008 102.585
transfer surface
Inside diameter of stator shaft free +0.004
6 83.6 83.57
wheel transfer surface –0.009
Inside diameter of sliding portion of +0.015
7 83.71 83.79
bushing –0.000
8 Thickness of sliding portion of bushing 6 ±0.05 5.5
9 Thickness of clutch disc 5.4 ±0.1 4.9
Tolerance
Standard size
Shaft Hole
Tolerance for fitness of Outside –0.000 –0.028
10 125
PTO idler gear bearing diameter –0.020 –0.068
Inside +0.012 –0.000
70
diameter –0.007 –0.015
Outside –0.000 –0.012
Tolerance for fitness of 150
diameter –0.020 –0.052
11 input transfer drive gear
bearing (Large) Inside +0.059 –0.000
85 Replace
diameter +0.037 –0.020
Outside –0.000 –0.012
diameter –0.020 –0.052
12 input transfer drive gear
bearing (Small) Inside +0.051 –0.000
80
diameter +0.032 –0.015
Outside –0.000 –0.012
diameter –0.020 –0.052
13 input transfer driven
gear bearing Inside +0.051 –0.000
80
diameter +0.032 –0.015
Backlash between PTO drive gear
14 0.192 – 0.492
and PTO idler gear
Backlash between input transfer
15 0.190 – 0.486
drive gear and driven gear
Clearance between cage and case
16 0.40 – 1.60
of input transfer drive gear —
Clearance between cage and case 0.60 – 1.80
17 —
of input transfer driven gear (Standard shim thickness: 1.0)
WA500-6R 21

When lockup clutch is “disengaged”
Drive case (3) is disconnected from boss (9) and turbine (8) and lockup torque converter works as an ordi-
nary torque converter.
The power from engine o (from left bottom)

O O
Flywheel (1) Output shaft (10)
O O
Clutch housing (2), drive case (3), pump (5) and Drive gear (11)
PTO drive gear (6) rotate together O
O Driven gear (12)
Oil is used as medium O
O Transmission input shaft (13)
Turbine (8) and boss (9)
O
(To right top) o
q The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and
PTO gear and then used as the pump driving power.
22 WA500-6R
When lockup clutch is “engaged“
Drive case (3) is connected to boss (9) and turbine (8) and lockup torque converter is locked up.
The power from engine o (from left bottom)

O O
Flywheel (1) Output shaft (10)
O O
Clutch housing (2), drive case (3), pump (5) and Drive gear (11)
PTO drive gear (6) rotate together O
O Driven gear (12)
Lockup clutch (4) O
O Transmission input shaft (13)
Boss (9)
O
(To right top) o
q The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and
PTO gear and then used as the pump driving power.
WA500-6R 23
Oil flow
q The oil flows to the torque converter relief

valve through the main relief valve and there
its pressure is regulated to below the set pres-
sure by the valve. The oil flows to pump (4)
through inlet port (A) and oil passage of case
(1), stator shaft (2) and spacer (3).
q The oil is given a centrifugal force by pump (4),
and then it enters turbine (5) to transmit its
energy to turbine (5).
q The oil from turbine (5) is sent to stator (6), and
then returned to pump (4). Part of this oil is
sent to the oil cooler through stator (6), oil pas-
sage of stator shaft (2), outlet port (B) and
torque converter regulator valve.
24 WA500-6R
WA500-6R 25
Torque converter regulator valve 1
Unit: mm
Standard Tolerance Standard Clearance
Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.050 +0.025 0.050 –
32 0.111
–0.066 +0.000 0.091
Standard size Repair limit Replace
Installed Installed Installed
Free length Free length
2 Valve spring length load load
205 N 195 N
126.6 106.5 122.8
{20.9 kg} {19.9 kg}
3. Spool Outline
4. Valve body q This valve is provided at the torque converter
outlet circuit in order to secure an optimum
A: From torque converter performance of the torque converter by adjust-
B: To oil cooler ing its set oil pressure.
C: Drain Set pressure:
D: Torque converter outlet port oil pressure pickup 0.42 ± 0.05 MPa {4.3 ± 0.5 kg/cm2}
port
26 WA500-6R
Operation
q The oil from the torque converter is conducted

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

(D) becomes larger than the tension of spring
(1), spool (2) is pressed rightward, opening
port (A) and port (B).
WA500-6R 27
Transmission 1
(Transmission, transfer and parking brake)
a Transmission with lockup clutch
28 WA500-6R
A: To torque converter M: From F clutch ECMV (to F clutch)

B: To parking brake emergency release valve N: To 4th clutch
C: To lockup clutch (if equipped) P: From R clutch ECMV (to R clutch)
D: To parking brake emergency release valve R: From 3rd clutch ECMV (to 3rd clutch)
(To parking brake) S: To 2nd clutch
E: From oil cooler T: To transmission and transfer lubrication
F: From power train pump U: From lubrication relief valve
G: From parking brake emergency release valve V: From 2nd clutch ECMV
H: To input transfer lubrication W: From 4th clutch ECMV
J: Parking brake oil pressure pickup port X: To 1st clutch
K: From main relief valve Y: From 1st clutch ECMV
L: From lockup clutch ECMV (if equipped)
1. Transfer 8. Transmission control valve

2. Parking brake 9. Torque converter drain tube mounting port
3. Transmission 10. Drain valve
4. Emergency steering pump mounting port 11. Drain plug
5. Oil filler tube mounting port 12. Transmission lubricant temperature sensor
6. Speed sensor 13. Strainer
7. Lubrication relief valve
WA500-6R 29
30 WA500-6R
1. Transmission input shaft Outline

2. Tie bolt q The transmission employed consists of the
3. R ring gear (Hub) united planetary gear mechanism and disc
4. R planetary pinion (Number of teeth: 24) clutch that provides “4 forward gear speeds
5. R ring gear (Number of inside teeth: 70) and 4 reverse gear speeds”.
6. F planetary pinion (Number of teeth: 23) q The transmission selects a single rotating
7. F ring gear (Number of inside teeth: 75) direction and a single gear speed by fixing the
8. 4th ring gear (Number of inside teeth: 73) planetary gear mechanism and 2 of 6 disc
9. 4th planetary pinion (Number of teeth: 28) clutches by use of ECMV.
10. 3rd planetary pinion (Number of teeth: 20) q The transmission transmits the power being
11. 3rd ring gear (Number of inside teeth: 76) transmitted to the transmission input shaft to
12. 2nd ring gear (Number of inside teeth: 76) the output shaft after selecting a single speed
13. 2nd planetary pinion (Number of teeth: 20) from the 1st to 4th speeds both in the forward
14. 1st hub and reverse travel. In this case, the gear speed
15. Transmission output shaft (4th sun gear) change is done by F and R clutches plus com-
(Number of teeth: 17) binations of 4 speed clutches.
16. Transfer input gear (Number of teeth: 50)
17. 2nd sun gear (Number of teeth: 36)
18. 1st clutch housing Number of plates and disc used
19. 1st clutch piston
20. 2nd carrier Clutch No. Number of plates Number of discs
21. 3rd sun gear (Number of teeth: 36)
R clutch 6 7
22. 1st piston return spring
23. 2nd clutch housing F clutch 6 7
24. 2nd piston return spring 4th clutch 3+2 4
25. 2nd clutch piston 3rd clutch 2+2 3
26. 2nd clutch housing
2nd clutch 2+1 3
27. 3rd and 4th carriers
28. 3rd piston return spring 1st clutch 3+2 4
29. 3rd clutch piston
30. 3rd and 4th clutch housings
31. 4th clutch piston Combinations of clutches at respective gear
32. 4th piston return spring speeds and reduction ratio
33. F and 4th clutch cages
34. F piston return spring Gear speed Clutch used Reduction ratio
35. F sun gear (Number of teeth: 29)
Forward 1st speed F x 1st 3.586
36. F carrier
37. F clutch piston Forward 2nd speed F x 2nd 1.935
38. R and F clutch housings Forward 3rd speed F x 3rd 1.153
39. R clutch piston Forward 4th speed F x 4th 0.677
40. Washer spring
Neutral — —
41. R piston return spring
42. R carrier Reverse 1st speed R x 1st 3.182
43. Clutch disc Reverse 2nd speed R x 2nd 1.717
44. Clutch plate Reverse 3rd speed R x 3rd 1.023
45. R clutch cage
Reverse 4th speed R x 4th 0.601
46. R sun gear (Number of teeth: 22)
WA500-6R 31
1. Transfer idler gear (Number of teeth: 71)

2. Transfer output gear (Number of teeth: 72)
3. Output shaft
4. Front coupling
5. Rear coupling
6. Parking brake
32 WA500-6R
WA500-6R 33
Unit: mm
Standard size Repair limit
Installed
Free length Installed load Free length Installed load
1 R clutch spring (10 springs) length
48.1 N 41.2 N
77 70.2 72.4
{4.9 kg} {4.2 kg}
37.3 N 31.4 N
2 F clutch spring (10 springs) 77 71.7 72.4
{3.8 kg} {3.2 kg}
59.8 N 51.0 N
3 4th clutch spring (10 springs) 48.5 44.2 45.6
{6.1 kg} {5.2 kg}
94.1 N 80.4 N
4 3rd clutch spring (10 springs) 39.8 33 37.4
{9.6 kg} {8.2 kg}
67.7 N 57.9 N
5 2nd clutch spring (10 springs) 39.8 34.9 37.4
{6.9 kg} {5.9 kg}
110 N 93.2 N
6 1st clutch spring (10 springs) 46 39 43.2
{11.2 kg} {9.5 kg}
Total assembled thickness of 7 Standard size Tolerance Repair limit

7
discs and 6 plates for R clutch 54.2 ±0.36 50.5
Total assembled thickness of 7
8 54.2 ±0.36 50.5
discs and 6 plates for F clutch
9 45.0 ±0.30 41.8
discs and 5 plates for 4th clutch
10 35.0 ±0.26 32.6
discs and 4 plates for 3rd clutch
11 26.4 ±0.24 24.8
discs and 3 plates for 2nd clutch
Total assembled thickness of 4 Replace
12 45.0 ±0.30 41.8
discs and 5 plates for 1st clutch
R, F,
5.0 ±0.1 4.5
2nd
13 Thickness of clutch disc
4th, 3rd,
5.0 ±0.1 4.2
1st
R, F 3.2 ±0.1 2.9
4th, 3rd,
Thickness of clutch 5.0 ±0.1 4.5
14 1st
plate
3.2 ±0.1 2.9
2nd
5.0 ±0.1 4.5
–0.01
Wear of R spacer seal Width 4.5 4.05
15 –0.03
ring
Thickness 5.2 ±0.12 5.05
–0.01
Wear of R clutch cage Width 4.0 3.60
16 –0.03
seal ring
Thickness 5.0 ±0.15 4.85
–0.01
Wear of F clutch cage Width 4.0 3.60
17 –0.04
seal ring
Thickness 5.0 ±0.15 4.85
–0.01
Wear of seal ring of 3rd Width 4.0 3.60
18 –0.04
and 4th carrier
Thickness 5.0 ±0.15 4.85
–0.01
Wear of 3rd spacer seal Width 3.0 2.70
19 –0.03
ring
Thickness 3.3 ±0.1 3.15
34 WA500-6R
Unit: mm
Wear of 1st clutch cage Width –0.01
20 4.5 4.05
seal ring –0.03
Thickness 5.8 ±0.15 5.65
–0.01
Wear of output shaft Width 3.0 2.70
21 –0.03
seal ring
Thickness 3.1 ±0.1 2.95
–0.01
Wear of output shaft Width 2.5 2.25
22 –0.03
seal ring
Thickness 1.7 ±0.1 1.55
Backlash between sun R, F 0.13 – 0.32
23 gear and planetary pin-
ion 3rd, 2nd 0.12 – 0.33
Backlash between out-

24 put shaft and planetary 4th 0.11 – 0.30
pinion
Backlash between plan- R, F 0.15 – 0.38

Replace
25 etary pinion and ring 4th, 3rd,
gear 0.13 – 0.36
2nd
Backlash between transfer input
26 0.19 – 0.48
gear and idler gear
Tolerance
Standard size
Shaft Hole
Tolerance for fitness of
27 transfer input gear bear- Outside 160
0 –0.012
ing (Rear) diameter –0.025 –0.052
Inside +0.045 0
90
diameter +0.023 –0.020
Outside 0 0
diameter –0.025 –0.040
28 transfer input gear bear-
ing (Front) Inside +0.045 0
90
diameter +0.023 –0.020
29 Clearance between cage and case 1.61 – 2.39
—
WA500-6R 35
36 WA500-6R
Unit: mm
Outside diameter of coupling oil
1 –0.000 Repair by hard
seal contact surface (Rear) 105 104.8
–0.087 chromium-plating
Outside diameter of coupling oil –0.000 or replace
2 105 104.8
seal contact surface (Front) –0.087
Backlash between idler gear
3 0.19 – 0.48
and output gear
Tolerance
Standard size
Shaft Hole
Tolerance for fitness Outside –0.000 –0.000
4 180
of idler gear bearing diameter –0.025 –0.040
Inside +0.059 –0.000
100
diameter +0.037 –0.020
Outside –0.000 –0.014
diameter –0.030 –0.060
5 of output shaft bear-
Inside +0.059 –0.000 Replace
ing (Rear) 105
diameter +0.037 –0.020
Outside –0.000 –0.020
diameter –0.020 –0.040
6 of output gear bear-
ing (Front) Inside +0.045 –0.000
85
diameter +0.023 –0.020
7 0.63 – 1.37
case —
Clearance between cover and 0.48 – 1.32
8 —
cage (Standard shim thickness: 0.5)
WA500-6R 37
Disc clutch
Structure Operation
When clutch is “engaged” (fixed)
q Disc clutch is used for fixing ring gear (1). It q The oil from ECMV is sent with pressure to the
consists of piston (2), plate (3), disc (4), pin (5), rear side of piston (2) through the oil passage
return spring (6) and washer (8). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
When clutch is “disengaged” (released)
q As the oil from ECMV is stopped, piston (2) is

pushed back rightward by return spring (6).
q The friction force between plates (3) and discs
(4) is released and ring gear (1) is released.
q Washer spring (8) is installed between plate (3)
of the pin block and plate (3). This spring
quickens return of piston (2) as the clutch is
disengaged by providing smooth separation of
plate (3) and disc (4). At the same time, it is
used for preventing the dragging.
38 WA500-6R
WA500-6R 39

Forward 1st gear speed
40 WA500-6R
F ring gear (4) of F clutch and 1st hub (16) of 1st clutch are fixed hydraulically.
The power from torque converter

O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
3rd and 4th carrier (11)
O
3rd planetary pinion (12)
O
3rd ring gear (13) 3rd sun gear (20)
O
2nd carrier (14)
O
1st clutch housing (15)
O
1st hub (16)
O
Output shaft (23)
WA500-6R 41
Forward 2nd gear speed
42 WA500-6R
F ring gear (4) of F clutch and 2nd ring gear (18) of 2nd clutch are fixed hydraulically.

O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
O
O
O
2nd carrier (14)
O
2nd planetary pinion (17)
O
2nd sun gear (19)
O
Output shaft (23)
WA500-6R 43
Forward 3rd gear speed
F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed hydraulically.
O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
O
O
3rd sun gear (20)
O
Output shaft (23)
44 WA500-6R
Forward 4th gear speed
F ring gear (4) of F clutch and 4th ring gear (22) of 4th clutch are fixed hydraulically.

O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
O
4th planetary pinion (21)
O
Output shaft (23)
WA500-6R 45
Reverse 1st gear speed
46 WA500-6R
R ring gear (7) of R clutch and 1st hub (16) of 1st clutch are fixed hydraulically.

O
Input shaft (1)
O
R sun gear (5)
O
R planetary pinion (6)
O
R ring gear (9)
(R carrier (8) is fixed with R ring gear (7) =
R ring gear (9) rotation direction is opposite to
input shaft (1))
O
F carrier (10)
O
O
O
O
2nd carrier (14)
O
1st clutch housing (15)
O
1st hub (16)
O
Output shaft (23)
WA500-6R 47
Transfer 1
Outline
q The transfer is installed in the output side of
the transmission and fixed to the transmission
case with the bolt.
Operation
Transmission output shaft (1)

O
Transfer input gear (2)
O
Transfer idler gear (3)
O
Transfer output gear (4)
O
Output shaft (5)
O
Center drive shaft
O
Front drive shaft Rear drive shaft
O O
Front axle Rear axle
48 WA500-6R
WA500-6R 49
Transmission control valve 1

50 WA500-6R
A: 1st clutch oil pressure pickup port Operation table of ECMV

B: 4th clutch oil pressure pickup port
C: 3rd clutch oil pressure pickup port ECMV
F R 1st 2nd 3rd 4th
D: F clutch oil pressure pickup port Gear speed
E: R clutch oil pressure pickup port A Q
F: Torque converter relief pressure pickup port N
M Q Q Q Q
G: Main relief oil pressure pickup port
H: From power train pump F1 Q Q
J: 2nd clutch oil pressure pickup port F2 Q Q
K: To PTO and input transfer lubrication F3 Q Q
L: To parking brake emergency release valve
F4 Q Q
(To parking brake)
M: To parking brake emergency release valve R1 Q Q
R2 Q Q
1. 1st clutch ECMV R3 Q Q
2. 4th clutch ECMV
R4 Q Q
3. 3rd clutch ECMV
4. F clutch ECMV A: Automatic shifting
M: Manual shifting
5. Parking brake solenoid valve
6. R clutch ECMV
7. Main relief valve and torque converter relief a With the directional lever is in the N (Neutral)
valve position during manual shifting, the speed
8. Last chance filter clutch for the gear speed selected with the
9. 2nd clutch ECMV gear shift lever operates.
10. Check valve
Outline
q The oil from the pump flows to the transmis-
sion control valve through the oil filter. Then oil
flow is divided into the main relief circuit and
clutch actuation circuit.
q The pressure of the oil sent to the clutch actua-
tion circuit is regulated by the main relief valve,
and then used to actuate the clutch and park-
ing brake through the last chance filter. The oil
relieved from the main relief valve is supplied
to the torque converter.
q When the transmission gear is shifted, the
ECMV increases the clutch oil pressure
smoothly according to the command current
from the transmission controller to reduce the
gear shifting shocks. The ECMV also keeps
the clutch pressure constant during travel.
q If the F, R, or 1st – 4th ECMV is selected, the
regulated oil pressure is supplied to the
selected clutch to set the transmission in the
desired gear speed.
WA500-6R 51
With lockup clutch
52 WA500-6R
A: 1st clutch oil pressure pickup port Operation table of ECMV

B: 4th clutch oil pressure pickup port
C: 3rd clutch oil pressure pickup port ECMV
F R 1st 2nd 3rd 4th L/U
D: F clutch oil pressure pickup port Gear speed
E: R clutch oil pressure pickup port A Q
F: Torque converter relief pressure pickup port N
M Q Q Q Q
G: Main relief oil pressure pickup port
H: From power train pump F1 Q Q
J: Lockup clutch ECMV oil pressure pickup port F2 Q Q Q
K: 2nd clutch oil pressure pickup port F3 Q Q Q
L: To PTO and input transfer lubrication
F4 Q Q Q
M: To parking brake emergency release valve
(To parking brake) R1 Q Q
N: To parking brake emergency release valve R2 Q Q Q
R3 Q Q Q
1. 1st clutch ECMV
R4 Q Q Q
2. 4th clutch ECMV
3. 3rd clutch ECMV L/U : Lockup clutch ECMV
A : Automatic shifting
4. F clutch ECMV
M : Manual shifting
6. R clutch ECMV
7. Main relief valve and torque converter relief a With the directional lever is in the N (Neutral)
valve position during manual shifting, the speed
8. Last chance filter clutch for the gear speed selected with the
9. Lockup clutch ECMV gear shift lever operates.
10. 2nd clutch ECMV
11. Check valve
Outline
q The oil from the pump flows to the transmis-
sion control valve through the oil filter. Then oil
flow is divided into the main relief circuit and
clutch actuation circuit.
q The pressure of the oil sent to the clutch actua-
tion circuit is regulated by the main relief valve,
and then used to actuate the clutch and park-
ing brake through the last chance filter. The oil
relieved from the main relief valve is supplied
to the torque converter.
q When the transmission gear is shifted, the
ECMV increases the clutch oil pressure
smoothly according to the command current
from the transmission controller to reduce the
gear shifting shocks. The ECMV also keeps
the clutch pressure constant during travel.
q If the F, R, or 1st – 4th ECMV is selected, the
regulated oil pressure is supplied to the
selected clutch to set the transmission in the
desired gear speed.
q In the 2nd, 3rd and 4th speed travel, the lockup
clutch ECMV operates at a speed higher than
the speed being specified from the transmis-
sion controller.
WA500-6R 53
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
For F, R, 1st, 2nd, 3rd, and 4th clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1:
P: From pump Clutch used Letters printed on nameplate
T: Drain
F, R, 1st, 2nd, 3rd, and 4th D*******
Dr: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector

2. Proportional solenoid connector
3. Flow rate pickup valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
54 WA500-6R
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command cur-
transmission controller with a proportional rent from the controller.
solenoid, and then converts it into oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is Current – propulsion force characteristics of
applied or not while oil pressure is applied to proportional solenoid
the clutch.
Propulsion force - Hydraulic pressure charac-

teristics of proportional solenoid
Range A: Before shifting gear (When draining)

Range B: During filling
Range C: Pressure regulation ECMV and fill switch
Range D: During filling (During triggering) q For each ECMV, 1 fill switch is installed.
Point E: Start of filling If the clutch is filled with oil, the fill switch is
Point F: Finish of filling turned “ON” by the pressure of the clutch. The
oil pressure is built up according to this signal.
a The logic is so made that the controller will not
recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
WA500-6R 55
Operation of ECMV Before shifting gear (when draining)

q ECMV is controlled with the command current (Range A in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q While no current is flowing in proportional sole-

noid (1), pressure control valve (3) drains the
oil from clutch port (A) through drain port (T).
At this time, since no oil pressure is applied to
flow rate pickup valve (4), fill switch (5) is
turned “OFF”.
Range A: Before shifting gear (When draining)
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
56 WA500-6R
During filling (Range B in chart) Pressure regulation (Range C in chart)
q If a current is given to proportional solenoid (1) q If current flows in proportional solenoid (1), the
while there is no oil in the clutch, a hydraulic solenoid generates thrust in proportion to the
force balanced with the solenoid force is current. This thrust of the solenoid is balanced
applied to chamber (B) and it pushes pressure with the sum of the thrust generated by the oil
control valve (3) to the left. This conducts oil pressure in clutch port and the repulsive force
through pump port (P) and orifice (a) of flow of pressure control valve spring (2), and thus
rate pickup valve (4) to start filling the oil to the the pressure is settled.
clutch chamber. At this time, differential pres-
sure is generated between the upper stream
and down stream of orifice (a) of flow rate
pickup valve (4). This differential pressure
pushes flow rate pickup valve (4) leftward. As
the clutch chamber is filled up with oil and oil
flow from pump port (P) to clutch port (A) is
stopped, differential pressure before and after
orifice (a) of flow rate pickup valve (4) disap-
pears. As the result, flow rate pickup valve (4)
is pushed rightward, turning “ON” fill switch (5).
WA500-6R 57
For lockup clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1:
P: From pump Clutch used Letters printed on nameplate
T: Drain
Lockup K*******
Dr: Drain
P1: Clutch oil pressure pickup port
1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate (*1)
58 WA500-6R
Outline
ECMV for lockup clutch
q This valve is used to switch the clutch in order
to regulate the clutch oil pressure to the set
pressure.
Since the modulation waveform is used for the
pressure application characteristics to the
clutch, ECMV is capable of connecting the
lockup clutch smoothly, thereby reducing
shocks resulting from gear shift. Above also
prevents generation of peak torque in the
power train. These arrangements make the
machine comfortable to operator and enhance
durability of the power train.
When changing from torque converter travel to

direct travel
At gear shift (in direct travel)
WA500-6R 59
Operation
When clutch is “disengaged” (released) When clutch is “engaged” (fixed)
q While no current is flowing in to proportional q As current is conducted to proportional sole-

solenoid (1), pressure control valve (3) drains noid (1), the oil pressure being balanced with
the oil from clutch port (A) through drain port the solenoid force is applied to chamber (B),
(T). pushing pressure control valve (3) leftward.
Above opens pump port (P) and clutch port (A)
to start filling oil to the clutch.
q As the clutch is filled with oil, the solenoid
thrust is balanced with the sum of the thrust
generated from oil pressure of the clutch port
and the tension of the pressure control valve
spring (2), and then the pressure is settled.
60 WA500-6R
Main relief valve and torque converter relief valve 1
Unit: mm
Clearance between main relief size Shaft Hole clearance limit
1
vale and valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 +0.000 0.058
Clearance between torque con- –0.035 +0.013 0.035 –
2 22 0.078
verter relief vale and valve body –0.045 +0.000 0.058
Installed Installed Installed Replace
Main relief valve spring Free length Free length
3 length load load
(Outside)
479.1 N 456 N
128 78.3 124.2
{48.9 kg} {46.5 kg}
365.5 N 347 N
4 Main relief valve spring (Inside) 108 78.3 104.8
{37.3 kg} {35.4 kg}
Torque converter relief valve 134.3 N 127 N
5 50 43 48.5
spring {13.7 kg} {13.0 kg}
6. Body A: Drain (Torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief oil pressure pickup port
P2: Torque converter relief pressure pickup port
WA500-6R 61
Outline Operation of main relief valve
Torque converter relief valve

q The torque converter relief valve regulates the
torque converter inlet circuit pressure below
the set pressure to protect the torque converter
from abnormally high pressure.
Set pressure: 0.84 MPa {8.55 kg/cm2}
(Cracking pressure)
Main relief valve

q The main relief valve regulates the pressure in
the transmission and brake hydraulic circuits
below the set pressure.
Set pressure: 3.64 MPa {37.1 kg/cm2} q The oil from the hydraulic pump flows to cham-
(At rated engine speed) ber (F) through the filter, port (C) of the relief
valve and orifice (a) of main relief valve (1).
Operation
Operation of torque converter relief valve
q As the oil pressure in the circuit goes beyond

the set pressure, the oil conducted to chamber
(F) pushes piston (2) and the resulting resist-
q The oil from the main relief valve is conducted ing force pushes spool (1) leftward, opening
to the torque converter through port (E) and, at ports (C) and (E).
the same time, also conducted to chamber (G) Above operation conducts the oil from port (E)
through orifice (b) of torque converter relief to the torque converter.
valve (3).
q As the oil pressure to the torque converter
goes beyond the set pressure, the oil con-
ducted to chamber (G) pushes piston (4) and
the resulting resisting force pushes torque con-
verter relief valve (3) rightward, opening ports
(E) and (A).
As the result, the oil in port (E) is drained
through port (A).
62 WA500-6R
Lubrication relief valve 1
Unit: mm
Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.035 +0.013 0.035 –
22 0.078
–0.045 +0.000 0.058
Standard size Repair limit Replace
2 Valve spring length load load
97.4 N 92.6 N
59.7 37 57.9
{9.94 kg} {9.44 kg}
3. Valve body Function

4. Spool q The Lubrication relief valve is installed to the
transmission valve and used for maintaining
A: From oil cooler the pressure of the lubrication circuit below the
B: Drain set pressure.
C: Lubricant pressure pickup port Set pressure: 0.26 MPa {2.7 kg/cm2}
(Cracking pressure)
WA500-6R 63
SEN02889-00

© 2007 KOMATSU
All Rights Reserved
64
SEN02890-00
WA500-6R

WA500-6R 60001 and up

Power train, Part 2
Torque converter oil cooler.............................................................................................................................. 2
Torque converter oil filter................................................................................................................................. 3
Center support ................................................................................................................................................ 6
Axle ................................................................................................................................................................. 8
Differential ..................................................................................................................................................... 10
Limited slip differential .................................................................................................................................. 19
Final drive ..................................................................................................................................................... 24
WA500-6R 1
Torque converter oil cooler 1
1. Torque converter oil cooler Outline

q Oil from the torque converter is heated by
A: Inlet port power transmitting energy. This torque con-
B: Outlet port verter oil cooler enters the torque converter oil
C: Coolant inlet cooler through inlet port (A) to be cooled by
D: Coolant outlet engine coolant. Then it flows into the transmis-
sion lubrication system through outlet port (B).
2 WA500-6R
Torque converter oil filter 1
1. Relief valve
2. Element
3. Drain plug
A: Inlet port
B: Outlet port
WA500-6R 3
Specifications
q Filtering area : 8,900 cm2 x 2
q Relief pressure : 0.32 MPa {3.25 kg/cm2}
Operation
q Oil from the torque converter charge pump
enters filter inlet port (A). It passes from out-
side to inside of element (2), and flows to outlet
port (B).
q When element (2) is clogged with foreign mat-

ters, or when low oil temperature has caused
pressure at inlet port (A) to increase, oil from
inlet port (A) opens relief valve (1) to flow to
outlet port (B) directly, preventing the pump
and element (2) from being damaged.
4 WA500-6R
WA500-6R 5
Center support 1
1. Front coupling Outline

2. Case q The center support is installed between the
3. Breather center drive shaft and front drive shaft that are
4. Rear coupling provided on the front frame.
q With the articulating frame, this part is con-
stantly twisting from side to side, so there is lia-
ble to be large stress on the drive shaft.
Therefore, the center support is used to trans-
mit the power smoothly, to reduce the stress
on the drive shafts, and in this way improve the
durability of the drive shafts.
6 WA500-6R
Unit: mm
Clearance between case and size Shaft Hole clearance limit
1
bearing –0.000 –0.036 –0.018 –
140 –0.015
–0.018 –0.061 –0.061
Clearance between case and –0.000 –0.036 –0.018 – Replace
2 130 –0.015
bearing –0.018 –0.061 –0.061
Clearance between coupling +0.051 –0.000 0.032 –
3 80 0.029
shaft and bearing +0.032 –0.015 0.066
Clearance between coupling +0.051 –0.000 0.032 –
4 75 0.029
shaft and bearing +0.032 –0.015 0.066
Wear of oil seal contact sur-
5 –0.000 Repair by chro-
face 95 –0.18
–0.087 mium-plating or
Wear of oil seal contact sur- –0.000 replace
6 105 –0.18
face –0.087
7 End play of coupling shaft Preload 3.9 Nm {0.4 kgm} max. Replace
WA500-6R 7
Axle 1
Front axle
1. Oil filler plug 5. Front brake

2. Front axle 6. Final drive
3. Level plug 7. Drain plug
4. Front differential
8 WA500-6R
Rear axle
1. Level plug 5. Rear brake

2. Oil filler plug 6. Final drive
3. Rear axle 7. Drain plug
4. Rear differential 8. Oil temperature sensor
WA500-6R 9
Differential 1
Front differential
1. Pinion gear (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 38)
10 WA500-6R
Front differential
(with limited slip differential)

3. Shaft
WA500-6R 11
Rear differential

3. Shaft
12 WA500-6R
Rear differential
(with limited slip differential)

3. Shaft
WA500-6R 13
a This diagram shows the front differential mechanism.
14 WA500-6R
Unit: mm
Clearance in side bearing outer size Shaft Hole clearance limit
1
race of differential gear assembly –0.000 +0.012 –0.013 –
200 —
–0.015 –0.013 0.027
Clearance in side bearing inner +0.090 –0.000 –0.065 –
2 130 —
race of differential gear assembly +0.065 –0.025 –0.115
Clearance in outer race of bevel –0.000 –0.050 –0.020 –
3 215 —
pinion shaft bearing –0.030 –0.079 –0.079
Clearance in inner race of bevel +0.045 –0.000 –0.023 –
4 100 —
pinion shaft bearing +0.023 –0.020 –0.065
Clearance in outer race of bevel +0.21 +0.063 –0.037 –
5 165 —
6 75 —
pinion shaft bearing +0.020 –0.015 –0.054 Replace
Clearance between differential –0.018 +0.057 0.018 –
7 320 —
carrier and cage –0.075 –0.000 0.132
Clearance between spider and dif- –0.13 +0.03 0.021 –
8 40 —
ferential pinion bushing –0.18 –0.02 –0.11
Clearance between pinion and dif- –0.025 +0.03 0.005 –
9 46
ferential pinion bushing –0.050 –0.02 0.080
10 Backlash of bevel gear 0.30 – 0.45
11 Backlash of differential gear 0.36 – 0.51
12 End play of bevel pinion gear Max. 0.64
Free rotational torque of bevel
13 Max. 8.34 Nm {0.85 kgm}
gear
14 Rear runout of bevel gear 0.1
15 Clearance between bolt and cap 0.08 – 0.13
WA500-6R 15
16 WA500-6R
Unit: mm
1 Thickness of side gear washer
4 ±0.05 3.8
Thickness of bevel pinion gear Replace
2 3 ±0.08 1.35
washer
0
3 Wear of oil seal contact surface 105 —
–0.087
WA500-6R 17
Outline While machine is turning

q The power from the engine is transmitted q While the machine is turning, the right and left
through the torque converter, transmission, wheels rotate at different speeds. Accordingly,
and drive shafts to the front and rear axles. pinion gears (4) and side gears (3) in the differ-
q In each axle, the direction of the power is ential assembly rotate and transmit the power
changed by 90° and the rotation speed is of carrier (6) to axle shafts (2), depending on
reduced by bevel pinion (1) and bevel gear (5). the difference in rotation speed between the
Then, the power is transmitted through differ- right and left wheels.
ential mechanism to axle shafts (2).
q The power of the axle shaft is further reduced
in speed by the final drive of the planetary gear
type, and then transmitted to the wheels.
While machine is traveling straight

q While the machine is traveling straight, the
right and left wheels rotate at the same speed.
Accordingly, pinion gears (4) in the differential
assembly do not rotate and the power of car-
rier (6) is transmitted through pinion gears (4)
and side gears (3) to right and left axle shafts
(2) evenly.
18 WA500-6R
Limited slip differential 1

(if equipped)
1. Washer
2. Disc
3. Plate
4. Pressure ring
5. Cover
6. Shaft
7. Side gear
8. Shaft
9. Case
10. Pinion
11. Bevel gear
WA500-6R 19
Operation of limited slip differential <While machine is traveling straight>

The power from the transmission is transmitted 1. When drive forces of right and left wheels
through bevel gear (11), case (9), pressure rings are balanced
(4), shaft (8), pinion (10) to side gears (7), and then [When the road conditions (coefficients of friction)
distributed to the right and left shafts (6). Brake under both wheels and the wheel loads are even
mechanism consisting of disc (2) and plate (3) is and the center of load is at the center of the bucket]
installed to back side of each side gear (7). It gen- The power from the transmission is distributed
erates braking torque in proportion to the torque evenly by the differential gears to the right and left.
transmitted from pressure rings (4) to shaft (8). Under this condition, the slip limits of the right and
Since the brake torque restricts the rotation of side left wheels are the same. Accordingly, when the
gears (7) and case (9), right and left side gears (7) power from the transmission exceeds the slip limits,
cannot rotate freely, thus the operation of the differ- both wheels slip and the differential does not work.
ential is restricted. No load is applied to the brake on the back side of
each side gear.
<Mechanism of generation of braking torque by
right and left side gears (7)>
Shaft (8) is supported on the cam surfaces made
on the surfaces of pressure rings (4) which are fac-
ing each other. The power (= torque) transmitted
from pressure rings (4) to shaft (8) is transmitted on
the cam surfaces. Force (Fa) to separate both pres-
sure rings (4) is generated by inclination of the cam
surfaces in proportion to the transmitted torque.
Separating load (Fa) acts on the brake on the back
side of each side gear (7) to generate braking
torque.
20 WA500-6R
2. When drive forces of right and left wheels Difference of wheel drive force in each type of dif-
are unbalanced ferential when either wheel slips
[When the road conditions (coefficients of friction)
Wheel drive force
under both wheels and the wheel loads are uneven (Drive force of slipping wheel is 1)
and either wheel slips more easily]
Slipping Locked Total
Example 1: When either wheel is on soft ground in
wheel wheel (Ratio)
digging work
Example 2: When either wheel is on snow and the Limited slip differential
1 2.64 3.64 (1.82)
(if equipped)
other one is on asphalt in snow remov-
ing work Ordinary differential 1 1 2 (1)
Example 3: When the right and left wheel loads are
unbalanced in travel on a slope On a road where either wheel slips easily, the drive
force of the limited slip differential is 1.82 times as
The power from the transmission is distributed large as that of the ordinary differential.
evenly by the differential gears to the right and left.
If the distributed drive force limits the wheel slip <While machine is turning>
limit on the slipping side, the excess of the drive The differential gears in the limited slip differential
force is transmitted through the brake on the back operate similarly to those in the ordinary differential.
side of the side gear and the case to the brake on Accordingly, a difference in rotation speed between
the opposite side (locked side) and given to the the outer and inner tires necessary for turning is
locked wheel. generated smoothly.
Only when the excessive drive force exceeds the
braking force, the differential starts working.
WA500-6R 21
22 WA500-6R
Unit: mm
Clearance in side bearing outer size Shaft Hole clearance limit
1
race of differential gear assembly –0.000 +0.012 –0.013 –
200 —
–0.015 –0.013 0.027
Clearance in side bearing inner +0.090 –0.000 –0.065 –
2 130 —
race of differential gear assembly +0.065 –0.025 –0.115
Clearance in outer race of bevel –0.000 –0.050 –0.020 –
3 215 —
pinion shaft bearing –0.030 –0.079 –0.079
4 100 —
pinion shaft bearing 0.023 –0.020 –0.065
Clearance in outer race of bevel +0.21 +0.063 –0.037 –
5 165 —
6 75 —
Clearance between differential –0.018 +0.057 0.018 –
7 320 —
carrier and cage –0.075 –0.000 0.132
8 Backlash of bevel gear 0.30 – 0.45
9 Backlash of differential gear 0.36 – 0.51
Replace
10 End play of bevel pinion gear Max. 0.64
Free rotational torque of bevel
11 Max. 8.34 Nm {0.85 kgm}
gear
12 Rear runout of bevel gear 0.1
13 Clearance between bolt and cap 0.08 – 0.13
14 Thickness of plate 3.4
±0.02 3.6
3.5
15 Thickness of disc 3.2 ±0.07 3.915
Clearance between disc and plate
16 0.2 – 0.8
(end play)
3.75
17 Thickness of washer
4.0 ±0.05 3.8
4.25
Wear of coupling seal sliding sur- 0
18 105 —
face –0.087
WA500-6R 23
Final drive 1
1. Axle shaft
2. Sun gear (Number of teeth: 17)
3. Ring gear (Number of teeth: 70)
4. Planetary carrier
5. Planetary gear (Number of teeth: 26)
6. Wheel
24 WA500-6R
WA500-6R 25
Unit: mm
Clearance between planetary size Shaft Hole clearance limit
1
shaft and bearing +0.029 +0.013 –0.003 –
50.8 —
+0.016 +0.000 –0.029
Clearance between ring gear hub +0.063 +0.025 –0.009 –
2 220.662 —
and bearing +0.034 +0.000 –0.063
Thickness of ring gear mounting Standard size Tolerance Repair limit
3
retainer 22 ±0.1 21.6
Backlash of planetary gear and
4 0.19
sun gear
Backlash of planetary gear and Replace
5 0.20
ring gear
Standard shim thickness of wheel
6 2.3
hub
Clearance between wheel hub size Shaft Hole clearance limit
7
and bearing +0.051 –0.036 –0.036 –
314.325 —
+0.000 –0.068 –0.119
Clearance between tube and –0.045 +0.072 0.045 –
8 190 —
bearing –0.074 +0.000 0.146
Clearance between wheel hub +0.000 –0.063 –0.059 –
9 260 —
and bearing –0.004 –0.095 –0.095
26 WA500-6R
Outline
q Final drive is reduced by the planetary gear
unit in order to gain increased force, and then
drive force is transmitted to the tires.
Operation
q Power transmitted from the differential mecha-
nism to sun gear (2) through axle shaft (1) is
transmitted to planetary gear (5). The plane-
tary gear rotates inside fixed ring gear (3) to
transmit reduced rotation to planetary carrier
(4) and the power is transmitted to wheel (6)
mounted onto the planetary carrier.
WA500-6R 27
SEN02890-00

© 2007 KOMATSU
All Rights Reserved
28
SEN02891-01
WA500-6R

WA500-6R 60001 and up

Steering system
Steering piping diagram .................................................................................................................................. 2
Steering column .............................................................................................................................................. 3
Steering control valve...................................................................................................................................... 4
Steering valve ............................................................................................................................................... 15
Stop valve ..................................................................................................................................................... 19
Joystick steering lever linkage (if equipped) ................................................................................................. 20
Steering cylinder ........................................................................................................................................... 21
Emergency steering piping diagram (if equipped) ........................................................................................ 24
Diverter valve ................................................................................................................................................ 25
WA500-6R 1
Steering piping diagram 1
1. Steering cylinder (right) 6. Steering pump

2. Steering valve 7. EPC and brake pump
3. Stop valve (right) 8. Steering control valve
4. Work equipment pump 9. Stop valve (left)
5. Hydraulic tank 10. Steering cylinder (left)
2 WA500-6R
Steering column 1
1. Steering wheel
2. Steering column
3. Joint
4. Steering valve
Unit: mm
Clearance between steering size Shaft Hole clearance limit
5 Replace
shaft and column bearing –0.00 +0.15
19 0.05 – 0.23 0.4
–0.08 –0.05
WA500-6R 3
Steering control valve 1
1. Relief valve A: To steering cylinder

2. Relief valve B: To steering cylinder
3. Relief valve Pa: From steering valve
4. Unload spool Pb: From steering valve
5. Main spool P: From steering pump
PR: From steering pump (LS line)
T1: Return
T2: Drain
4 WA500-6R
Unit: mm
Installed Installed Allowable
1 Steering spool return spring length load load
56.9N 45.1N
37.2 32.0 —
{5.8kg} {4.6kg}
2.9N 2.5N Replace
2 Load check valve spring 20.9 18.3 —
{0.30kg} {0.25kg}
147.1N 120.6N
3 Unload spool return spring 69.7 68.5 —
{15.0kg} {12.3kg}
182.4N 145.1N
4 Relief valve spring 24.0 22.19 —
{18.6kg} {14.8kg}
WA500-6R 5
Operation of steering control valve

When steering spool is at neutral position
q The oil from the steering pump is conducted to

port (A).
q When the steering spool is at neutral, pres-
sure-receiving chamber (II) is connected the
drain circuit through orifice (b) and notch (c) is
closed.
q Closed notch (c) increases pressure of oil in
port (A). This increased pressure is then led
through orifice (a) to pressure-receiving cham-
ber (I) to drive demand spool (1) leftward.
q As pressure of pressure-receiving chamber (I)
reaches a specific level (this level is set from
spring (3)), notch (f) opens to conduct oil from
the steering pump to the drain circuit. Notch (g)
also opens at this time to lead oil from the
steering pump to low-pressure relief valve (4).
q The pressure generated at low-pressure relief
valve (4) is input to the steering pump as the
pilot pressure (LS pressure) to be used for
controlling the steering pump flow rate.
6 WA500-6R
When steering spool is in operation
q Operating the steering conducts oil from the

steering valve to steering spool (2), pushing
steering spool (2) to the right. And, as pres-
sure-receiving chamber (II) and drain circuit
are disconnected, notch (c) opens.
q Above operation increases pressure in pres-
sure-receiving chamber (II), thereby moving
demand spool (1) to the right.
q The oil being conducted through notches (c)
and (d) pushes load check valve (5) and then
flows to the cylinder. Return oil from the cylin-
der flows to the drain circuit through notch (e).
q At this time, the pressure of oil before passing
through notch (c) is conducted to pressure-
receiving chamber (I) and the pressure after
passing through notch (c) is led to pressure-
receiving chamber (II). And demand spool (1)
operates in such that the difference in pres-
sures before and after passing through notch
(c) may be maintained at constant level. Thus
the flow rate to the cylinder port depends on
opening of notch (c). These differences in the
pressure are set from spring (3).
WA500-6R 7
Operation of steering control valve

Neutral
q Since the steering wheel is not operated,

steering spool (2) does not move.
q The oil from the steering pump flows in port
(A).
q Demand spool (1) moves to the left as the
pressure in port (A) increases and part of the
oil from the steering pump is drained through
port (B) of the spool and the other is conducted
to the low-pressure relief valve through port
(C).
8 WA500-6R
Turning right
q Turning the steering wheel to the right acti-

vates the steering valve, moving steering (2) to
the left.
The oil from the steering pump enters port (A)
and then enters steering spool (2) through
demand spool (1). This flow pushes open load
check valve (6) of the spool and the oil is con-
ducted to the bottom side of the left cylinder
and the rod side of the right cylinder to turn the
machine to the right.
q The oil returned from the left and right cylin-
ders is drained through the passage inside the
steering spool.
WA500-6R 9
Turning left
q Turning the steering wheel to the left activates

the steering valve, moving steering (2) to the
right. The oil from the steering pump enters
port (A) and then enters steering spool (2)
through demand spool (1). This flow pushes
open load check valve (5) of the spool and the
oil is conducted to the rod side of the left cylin-
der and the bottom side of the right cylinder to
turn the machine to the left.
q The oil returned from the left and right cylin-
ders is drained through the passage inside the
steering spool.
10 WA500-6R
Steering relief valve
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
q The steering relief valve is contained in the
steering valve. This valve is used to set the
maximum pressure of the steering circuit for
the steering valve in operation. If the pressure
of the steering circuit increases beyond the
relief valve-specified level while the steering
valve is in operation, oil is relieved from this
valve. Above relief activates the spool of the
demand valve, draining the oil to the steering
circuit.
WA500-6R 11
Operation of steering relief valve
q As the pressure of the circuit increases and

reaches the level being set from adjustment
screw (1) and spring (2), pilot poppet (3) opens
to drain the oil.
q Above breaks down the balance between pres-
sure-receiving chambers (I) and (II) and, as the
result, demand spool (4) is driven leftward.
q Move of demand spool (4) drains oil in the
steering pump, preventing the steering circuit
pressure from increasing beyond the set value.
12 WA500-6R
Safety-suction valve q As the pressure of port (A) reaches the level

being specified from safety valve, pilot poppet
(4) opens. The oil flows around pilot poppet (4)
and then flows to port (B) through hole.
1. Poppet
2. Safety valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring q Opening of pilot poppet (4) decreases pres-
sure on the backside of poppet (1), starting
Function move of poppet (1). By this move, pilot poppet
q The safety valve installed on the steering valve (4) is seated in its place.
has two functions. One is the safety valve func-
tion that is used to protect the steering cylinder
or hydraulic piping from damages when an
abnormal pressure is generated due to some
sort of impacts applied to the steering cylinder
while the steering valve is at neutral. In such
case, abnormal pressure is relieved from this
valve. The other is the suction valve function.
This function prevents vacuum state to emerge
in the circuit when negative pressure is gener-
ated on the steering cylinder side.
Operation
Operation of safety valve
q Port (A) and port (B) are connected to the cyl- q Since the inside pressure is lower than that of
inder circuit and drain circuit, respectively. port (A), safety valve poppet (2) opens. As the
After being conducted through poppet (1) hole, result, the oil is conducted from port (A) to port
the oil works on the different areas of diameter (B) and abnormally high pressure is prevented
(d1) and (d2). Check valve poppet (3) and from being generated.
safety valve poppet (2) are securely seated.
WA500-6R 13
Operation of suction valve

q As negative pressure is generated on port (A),
check valve poppet (3) opens due to the differ-
ence in areas between diameter (d1) and (d3).
As the result, the oil is conducted from port (B)
to port (A), preventing vacuum to emerge.
14 WA500-6R
Steering valve 1
1. Needle bearing 7. Center pin

2. Centering spring 8. Sleeve
3. Drive shaft 9. Spool
4. Valve body 10. Stator
5. Rotor 11. Lower cover
6. Cover
WA500-6R 15
Outline Structure
q The steering valve is directly connected to the q Spool (9) is directly connected to the drive
shaft of the steering wheel. The steering wheel shaft of the steering wheel. It is also connected
operation activates the steering valve using the to sleeve (8) through center pin (7) (it is
oil from PPC pump as the pilot pressure. The detached from the spool when the steering
oil from the steering valve is conducted, wheel is at “neutral“) and centering spring.
through the steering valve, to either of the left q The top of drive shaft (3) is engaged with cen-
and right steering cylinders to determine the ter pin (7) and thus combined with sleeve (8).
machine travelling direction. And the bottom is engaged with the spline of
q The steering valve is roughly divided into spool rotor (5) of Gerotor set.
(9) and sleeve (8) which has the rotary select- q Valve body (4) has 4 ports. These ports are
ing function. This valve is used being config- respectively connected to the pump circuit,
ured with Gerotor set (combination of rotor (5) tank circuit, steering cylinder head side and
and stator (10)). In the normal steering opera- bottom side. And the ports on the pump side
tion, this set functions as a hydraulic motor. and tank side are connected to the check valve
And if supply of oil is stopped due to a failure in the body. If the pump or engine fails, this
on the steering pump or engine, it functions as check valve allows to suction oil directly from
a hand pump to supply pilot pressure to the the tank.
steering valve.
16 WA500-6R
Connection of hand pump and sleeve
q The connections of suction and discharge

openings of the Gerotor and sleeve ports are
shown in the above figure.
q If the steering wheel is turned to the right, ports
(a), (c), (e), (g), (i), and (k) are connected to
the pump side by the vertical grooves of the
spool. Similarly, ports (b), (d), (f), (h), (j), and (l)
are connected to the steering cylinder head
side.
Under the condition in the upper left figure, the
ports (1), (2), and (3) are in the discharge state
of the Gerotor set and connected to ports (l),
(b), and (d) and the oil is sent to the steering
cylinder.
Ports (5), (6), and (7) are also connected and
the oil from the pump flows in them.
q The upper right figure shows the state after
turning the steering wheel 90° from above con-
dition. Here, ports (1), (2) and (3) are set to the
suction state and connected to ports (i), (k) and
(c). Ports (5), (6) and (7), on the other hand,
are set to the discharge state and connected to
ports (d), (f) and (h).
WA500-6R 17
q As shown above, the ports in the discharge Role of centering spring

state of the Gerotor are connected to the ports q Centering spring (2) is configured with 3 flat
which are connected to the steering cylinder. springs and 4 plate springs being laminated.
The ports in the suction state are connected to This spring is, as shown in the figure below,
the pump circuit. assembled between spool (9) and sleeve (8).
q Delivery adjustment tailored to the steering As the steering wheel is turned, the spool com-
angle of the steering wheel presses the spring, generating a difference in
The internal gear of the Gerotor advances by 1 rotation angle (angular displacement) between
tooth as the steering wheel rotates by 1/7 of a the spool and sleeve.
turn and discharges the oil from the pump Above connects the spool and the port of the
according to the steering angle of the steering sleeve and sends oil to the cylinder. As rotation
wheel. of the steering wheel is stopped, however,
Accordingly, the discharge amount varies in rotation of Gerotor is also stopped and flow of
proportion to the steering angle of the steering oil to the cylinder is stopped, too. Thus,
wheel. increase in the oil pressure results.
The center spring is used to avoid above trou-
ble. As rotation of the steering wheel is
stopped, the center spring turns the sleeve by
the difference in rotation angle (angular dis-
placement) between the sleeve and spool in
order to return the steering wheel to “neutral”
position.
18 WA500-6R
Stop valve 1
1. Boot
2. Wiper
3. Seal
4. Poppet
5. Spring
6. Spool
7. Spring
A: From steering valve

B: To steering demand valve
DR: Drain
WA500-6R 19
Joystick steering lever linkage (if equipped) 1

Joystick steering system
1. Joystick (steering lever)

2. HI/LOW selector switch
3. Console fore-aft adjustment lever
4. Joystick ON/OFF switch
5. Lock
6. Steering lock switch
7. Pad
8. Console tilt lever
9. Arm rest adjustment lever
10. Lock cable
20 WA500-6R
Steering cylinder 1
Unit: mm
Clearance between steering size clearance limit
Shaft Hole
1 cylinder rod, bushing at frame
connection and mounting pin –0.000 +0.174 0.100 –
65 —
–0.074 +0.100 0.248 Replace
Clearance between steering
cylinder bottom, bushing at –0.000 +0.174 0.100 –
2 65 —
frame connection and mount- –0.074 +0.100 0.248
ing pin
Standard
clearance
Steering cylinder and front Boss width Hinge width
3 (Clearance After shim adjust-
frame connection between a + b) ment
75 ± 1.2 79 ± 1 1.8 – 6.2 Max. 0.5
Steering cylinder and rear frame
4 75 ± 1.2 79 ± 1 1.8 – 6.2
connection
WA500-6R 21
Unit: mm
Clearance between pistion rod size Shaft Hole clearance limit Replace pin and
1
and bushing –0.030 +0.151 0.024 – bushing
60 0.527
–0.076 –0.006 0.227
Tightening torque of cylinder
2 785 ± 78.5 Nm {80 ± 8.0 kgm}
head
3 1,770 ± 180 Nm {180 ± 18.0 kgm} (Width across flat: 60 mm) Retighten
piston
4 9.8 - 12.74 Nm {1.0 - 1.3 kgm}
head port side plug
22 WA500-6R
WA500-6R 23
Emergency steering piping diagram (if equipped) 1
1. Diverter valve
2. Steering pump
3. Hydraulic tank
4. Emergency steering pump
5. Transmission
24 WA500-6R
Diverter valve 1
(for emergency steering)
1. Check valve A: From emergency steering pump

2. Check valve B: From emergency steering pump
3. Check valve L: Sensor mounting port
4. Check valve T: To hydraulic tank
5. Spool D: To steering demand valve
6. Valve body S: From hydraulic tank
P: From steering pump
WA500-6R 25
Function
q In a case where steering is disabled due to
engine stop or steering pump seizure during
machine traveling, this function enables opera-
tion of the steering wheel, utilizing rotations of
the transmission to operate emergency steer-
ing pump.
26 WA500-6R
Unit: mm
Clearance between body and size Shaft Hole clearance limit
1
spool –0.008 +0.015 0.017 –
26 —
–0.012 +0.009 0.027
Free length Free length Replace
2 Spool return spring length load load
91.2 N 86.3 N
92 64 90.5
{9.3 kg} {8.8 kg}
4.0 N 3.8 N
3 Check valve spring 54.4 38 37.4
{0.41 kg} {0.39 kg}
1.96 N 1.84 N
4 Check valve spring 54.5 46.5 53.6
{0.2 kg} {0.19 kg}
WA500-6R 27
Operation
q If the pump and engine are normal
q If the steering pump and engine are operating

normally, the steering pump is operated by the
engine, and oil can be sent to the steering
valve, which enables steering.
q The emergency steering pump is operated by
the transmission, and push-open check valve
(2) from port (A) of diverter valve (1) to direct
the flow toward port (B).
Spool (3) is pressed to the left as pressure oil
is flowing from the steering pump toward port
(D).
For that reason, oil at port (B) flows to port (C)
to be drained to the hydraulic tank.
28 WA500-6R
q If the machine is running and the pump or engine has failed
q In a case where the machine is running and

the pump or engine has failed, rotations from
the tires operate the emergency steering pump
through the transmission.
No pressure oil appears at port (D) because
the steering pump is not operating. For that
reason, spool (3) is pressed by spring (4) to
the right.
The oil from the emergency steering pump
goes through port (A) and port (B), and then
flows to the steering valve, enabling steering.
a The emergency steering pump is enabled for
normal and reverse rotations.
WA500-6R 29
SEN02891-01

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 08-10
30
SEN02892-02
WA500-6R

WA500-6R 60001 and up

Brake system
Brake piping diagram ...................................................................................................................................... 2
Brake valve ..................................................................................................................................................... 4
Slack adjuster ................................................................................................................................................. 9
Accumulator charge valve............................................................................................................................. 12
PPC relief valve ............................................................................................................................................ 16
Accumulator (for brake) ................................................................................................................................ 18
Brake............................................................................................................................................................. 20
Parking brake control .................................................................................................................................... 23
Parking brake................................................................................................................................................ 24
Parking brake solenoid valve ........................................................................................................................ 26
Emergency parking brake release valve ....................................................................................................... 28
WA500-6R 1
Brake piping diagram 1
1. Accumulator charge valve 11. Front brake (right)

2. Brake Valve 12. Front brake (left)
3. EPC and brake pump 13. Rear brake (right)
4. Slack adjuster (rear) 14. Rear brake (left)
5. Emergency parking brake cancel valve 15. Brake valve (right)
6. Slack adjuster (front) 16. Brake valve (left)
7. Transmission 17. Emergency brake switch (front)
8. Accumulator 18. Emergency brake switch (rear)
9. Accumulator (rear brake) 19. Hydraulic tank
10. Accumulator (front brake)
2 WA500-6R
WA500-6R 3
Brake valve 1
A: To front brake
B: To rear brake
PA: From accumulator charge valve ACC1 port
PB: From accumulator charge valve ACC2 port
TA: Drain port
TB: Drain port
1. Rod
2. Piston
3. Spool (for rear)
4. Spool (for front)
Unit: mm
No Check item Free Installed Free Installed Remedy
Installed load Installed load
length length length length
95.8 N
5 Return spring 71.7 58.6 66.1 — —
{9.77 kg}
22.8 N
6 Control spring 11 10 — — —
{2.32 kg}
41.1 N
7 Control spring 51.2 49.7 — — — Replace
{4.19 kg}
8 Control spring 31 — — — — —
9 Control spring 23.5 — — — — —
17.2 N
10 Return spring 40.1 27.5 — — —
{1.75 kg}
4 WA500-6R
Outline Operation
q The brake valve is installed in the lower front When brake operated
side of the operator's seat. Pressing the brake q Pedal (1) pressing effort is transmitted to spool
pedal conducts oil to the brake piston, operat- (4) through rod (2), piston (3) and spring (5).
ing the brake. q As spool (4) is pushed to the right, disconnect-
q The left side and right side brake pedals are ing between port (A) and port (T) and the oil
mechanically interlocked. Pressing one of the from the pump and accumulator is conducted
pedals operates another pedal at the same to port (A) through port (PA) to operate the
time. front brake cylinder.
q And working with the transmission cut-off q If pedal (1) is pressed, the pressing effort is
switch, they operate the transmission control transmitted through rod (2) and spring (5) to
valve electrically to set the transmission to the spool (4).
neutral position. q The pressing effort transmitted to spool (4) is
further transmitted through plunger (6) to spool
(5).
q As spool (6) is pushed to the right, cutting off
connection between port (B) and port (T). The
oil from the pump and accumulator is con-
ducted to port (B) through port (PB) to operate
the rear brake cylinder.
WA500-6R 5
When one side of brake alone is operated

(When the other brake failed)
q Even when only one of the brakes remained
operable due to leakage of oil in the front or
rear brake system, brake pedal (1) pressing
effort mechanically moves spool (4) and spool
(6) to the right.
Thus, the oil from the pump is normally sup-
plied to the normal brake piston, enabling it to
continue the operation. The brake, therefore, is
capable of stopping the machine as needed to
ensure the intended safety level.
6 WA500-6R
Balancing operation
q If the front brake cylinder is filled up with oil q Since port (B) is kept disconnected from port
and oil pressure between port (PA) and port (T), the brake is kept operated by the oil pres-
(A) becomes higher, the oil is conducted from sure applied to the brake cylinder.
orifice (e) of spool (4) to chamber (E). q The operating force of the front brake circuit
q The oil pushes spool (4) resisting against (port A side) is balanced against the pedal
spring (5), disconnecting ports (PA) and (A). pressing effort and the operating force of the
q Since port (A) is kept disconnected from port rear brake circuit (port B side) is balanced
(T), the brake is kept operated by the oil pres- against that of the front brake circuit (port A
sure applied to the brake cylinder. side).
q If ports (PA) and (A) of spool (4) are discon- q When spools (4) and (6) are moved to the
nected, the front brake cylinder is filled with the stroke end, ports (PA) and (A) connected com-
oil and the pressure in the line between ports pletely, and ports (PB) and (B) are also con-
(PB) and (B) rises simultaneously, and then the nected completely. As a result, the oil pressure
oil flows through orifice (f) of spool (6) to cham- in the front and rear brake cylinders is equal to
ber (F). the oil pressure from the pump.
q The oil pushes up spool (6) by the moving dis- q The braking force can be adjusted by adjusting
tance of spool (4) and disconnects port (PB) the pedal pressing effort until spools (4) and
from port (B). (6) are moved to the stroke end.
WA500-6R 7
As brake is released
q If pedal (1) is released, the operating pressure q At the same as spool (4) was pushed back,
being applied to spool (4) is reduced, and spool (6) is also pushed back by the back pres-
spool (4) is pushed back by the back pressure sure on the brake cylinder and the spool return
on the brake cylinder and the tension of the spring tension.
spool return spring. q Ports (B) and (T) are connected and the back
q Ports (A) and (T) are connected and the back pressure oil on the brake cylinder is drained
pressure oil on the brake cylinder is drained through port (T), thus the rear brake is
through port (T), thus the front brake is released.
released.
8 WA500-6R
Slack adjuster 1
1. Cylinder Function
2. Check valve q The slack adjuster is installed on the brake oil
3. Piston line leading to the brake piston from the brake
4. Spring valve, and functions to keep the time lag during
5. Bleeder brake operation at a fixed level.
A: Inlet port Specifications

B: Outlet port Hydraulic oil pressure of piston:
9.8 (+9.8/0) kPa {0.1 (+0.1/0) kg/cm2}
Check valve cracking pressure:
0.93 ± 0.05 MPa {9.5 ± 0.5 kg/cm2}
Check valve closing pressure:
0.59 ± 0.05 MPa {6.0 ± 0.5 kg/cm2}
WA500-6R 9
Unit: mm
Clearance between body and size Shaft Hole clearance limit
6
piston –0.030 +0.074 0.030 –
55 0.25
–0.076 +0.000 0.150
Installed Installed Allowable Replace
7 Slack adjuster spring length load load
39.2 N
198 60
{4.0 kg}
66.7 N
8 Spring 39.2 33
{6.8 kg}
10 WA500-6R
Operation q As the brake valve is kept pressed down fur-

1. When the brake pedal is pressed down ther, oil pressure from the brake valve exceeds
q Before the brake is pressed down, piston (4) is the specified to open check valve (3) and port
restored as much as the amount of stroke (S) (C) is imposed pressure to function as braking
(a full stroke). When the brake pedal is force.
pressed down, oil discharged from the brake Thus, the time lag when the brake is in opera-
valve branches into right and left cylinders (2) tion is maintained the same.
from port (P) of the slack adjuster to move pis-
ton (4) as much as the amount of stroke (S) to
the right and the left.
2. When the brake pedal is released

q When the brake is released, return spring (8)
q This move causes brake piston (7) to move as of the brake piston (7) as much as the amount
much as stroke (S). At this time, the relation- of oil of stroke (S) and the brake returns to its
ship between brake piston (7) and the disc is released state. In other words, return stroke
simply that the clearance is reduced to zero, (T) of brake piston (7) depends on the amount
and no braking force is generated. of oil of piston stroke (S) and the braking time
lag stays the same regardless of the amount of
wear of the brake disc.
WA500-6R 11
Accumulator charge valve 1
A1: To work equipment valve

A2: To Orbit-roll
ACC1: To brake valve PA
ACC2: To brake valve PB
PP: From pump
T: Drain
12 WA500-6R
1. Valve body Function

2. Main relief valve (R3) q The accumulator charge valve keeps the oil
3. Relief valve (R1) pressure from the pump to the set pressure
4. Relief valve (R2) and stores it in the accumulator.
5. Relief valve (H1) q If the oil pressure rises above the set pressure,
the oil from the pump is led to the drain circuit
to reduce the load on the pump.
WA500-6R 13
Operation 2. When oil is supplied to accumulator

1. When oil is not supplied to accumulator 1) Cut-in state
(Cut-out state) q If the pressure at port (B) drops below the
q Since the pressure at port (B) is higher set pressure of relief valve (R1), piston (2)
than the set pressure of relief valve (R1), is returned downward by the tension of
piston (2) is forced to move upward by the spring (8). This causes valve seat (9) to
hydraulic pressure of port (B). As this closely contact poppet (1) to disconnect
move opens poppet (1), port (C) and port port (C) from port (T).
(T) are shorted. q The right-hand side spring chamber of
q As the rightmost spring chamber of spool spool (6) also gets shuttered off from port
(6) leads to port (C) of relief valve (R1), (T) to increase pressure, leading to pres-
tank pressure prevails. sure at port (P) to rise as well.
q Oil from the pump enters port (P) and q When pressure at port (P) exceeds the
pushes spool (6) to the right with a low pressure at port (B) (accumulator pres-
pressure equivalent to the load of spring sure), oil supply to the accumulator starts.
(5) and then flows from port (A) to the This timing is determined by the area size
steering valve and the work equipment of orifice (7) and pressure differential
valve. before and after (equivalent to the load of
At the same time, it flows to the tank spring (5)). A fixed amount of oil is sup-
through orifices (7), (4) and (3). plied regardless of the engine speed, and
the remaining amount flows to port (A).
14 WA500-6R
2) When pressure reaches cut-out pressure 3. Safety relief valve (R3)

q When pressure at port (B) (accumulator q If the pressure at port (P) (pump pressure)
pressure) reaches the set pressure for rises above the set pressure for relief
relief valve (R1), poppet (1) leaves valve valve (R3), the oil from the pump resists
seat (9) to generate a flow of oil, creating spring (10) and pushes ball (11) upward to
relief operation. cause oil to flow into the tank circuit, thus
q The relief operation creates vertical pres- protecting the circuit by defining the maxi-
sure differential for piston (2). Thus, piston mum pressure for the brake circuit.
(2) moves upward to force poppet (1) to
open, shorting ports (C) and (T).
q As the rightmost spring chamber of spool
(6) leads to port (C) of relief valve (R1),
tank pressure prevails.
q Since the pressure at port (P) also drops
to the level equivalent to the load of spring
(5), oil supply to port (B) is stopped as
well.
WA500-6R 15
PPC relief valve 1
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
Function
q The PPC relief valves are located between the
EPC brake pump and the EPC valve and
between work equipment units. When the PPC
valve is not operating, or when any abnormal
pressure has occurred in the EPC circuit, oil
from the pump is relieved from this valve in
order to protect the pump and the circuit from
damage.
16 WA500-6R
Operation
q The relief valve is installed on the charge q When pressure at port (B) drops, the orifice of
valve. Port (A) is connected to the pump cir- main valve (1) functions so as to allow pres-
cuit, and port (C), to the drain circuit. sure differential to occur at ports (A) and (B),
Oil runs through the orifice of main valve (1) causing main valve (1) to open due to pressure
and fills port (B). from port (A) and oil in port (A) is drained to
Pilot poppet (4) is seated on valve seat (3). port (C) for relief.
q When pressure at ports (A) and (B) reaches
the set pressure, pilot poppet (4) opens and oil
pressure at port (B) is carried from port (D) to
port (C), causing pressure at port (B) to drop.
WA500-6R 17
Accumulator (for brake) 1

Specifications
Gas used : Nitrogen gas
Amount of gas : 3,750 cc
Charging pressure : 3.4 ± 0.1 MPa 
{35 ± 1.0 kg/cm2} (at 20°C)
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
q The accumulator is installed between the
charge valve and brake valve. The space
between cylinder (3) and free piston (4) is filled
with nitrogen gas. The nitrogen gas absorbs
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine stops by utilizing
its compressibility.
18 WA500-6R
WA500-6R 19
Brake 1
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear
6. Hub gear
7. Plate
8. Disc
20 WA500-6R
WA500-6R 21
Unit: mm
Installed Installed Allowable
9 Return spring length load hole load
452N 338N
104.8 96.5 102.7
{46kg} {35.0kg}
10 Plate thickness
2.4 — 2.15
11 Thickness of disc 5.1 — 4.6
Assembled thickness of plate
12 62.4 — 56.15
discs
–0.000
13 Wear of seal contact surface 430 — Replace
–0.155
Wear of piston seal contact sur- +0.097
14 420 —
face +0.000
Wear of piston seal contact sur- +0.097
15 455 —
face +0.000
Standard strain Repair limit
16 Strain of plate contact surface
0.5 0.7
17 Strain of disc contact surface 0.45 0.65
Backlash of outer gear and
18 0.179 – 0.713
plate
19 Backlash of inner gear and disc 0.165 – 0.522
Function
q All the 4 wheels are equipped with a main q When the brake pedal is released, back pres-
brake, which is a wet-type multi-disc brake. sure on brake piston (4) is released and force
q When the brake pedal is pressed down, pres- of return spring (2) moves the piston in the
sure oil from the slack adjuster moves brake direction shown by an arrow mark to release
piston (4) in the direction shown by an arrow the brake.
mark to press disc (8) to contact plate (7). This
generates friction force between the disc and
the plate. While the wheel is rotating with the
disc, this friction causes the machine to slow
down and stop.
22 WA500-6R
Parking brake control 1
1. Parking brake switch

2. Parking brake emergency release switch
3. Transmission control valve
5. Transmission (containing parking brake)
Outline
q The parking brake is installed at the output q The neutralizer relay cuts off current to the
shaft with the wet-type multi-disc brake being transmission solenoid valve as long as opera-
built in the transmission. Using the pressing tion of the parking brake is continued in order
force of the spring, it mechanically operates to to maintain the transmission at the neutral.
relieve the oil pressure. q Parking brake emergency release switch (2) is
q If parking brake switch (1) installed to the oper- provided to move a machine currently being
ator's cab is turned “ON”, parking brake sole- stopped due to an engine or drive system trou-
noid valve (4) installed to transmission control ble (parking brake of the machine is enabled).
valve (3) shuts off the oil pressure and the
parking brake is applied. If parking brake
switch (1) is turned “OFF”, the hydraulic force
in the cylinder releases the parking brake.
WA500-6R 23
Parking brake 1
1. Output shaft Outline

2. Spring (Outside) q The parking brake is a wet-type multi-disc
3. Spring (Inside) brake being operated mechanically with
4. Piston springs (2) and (3) to apply braking to output
5. Parking brake oil port shaft (1).
6. Plate q The tension of springs (2) and (3) presses disc
7. Disc (7) against plate (6) with piston (4) to stop out-
8. Wave spring put shaft (1).
q When releasing, the oil pressure from parking
brake oil port (5) operates piston (4) to release
the pressing force being applied to disc (7) and
plate (6).
24 WA500-6R
Unit: mm
9 Parking brake spring (outside) length load load
1,266 N 1,203 N
94 72.6 91.2
{129.2 kg} {122.7 kg}
662 N 630 N
10 Parking brake spring (inside) 94 72.6 91.2
{67.6 kg} {64.2 kg}
Standard size Tolerance Repair limit Replace
Thick- 4.0 ±0.05 3.9
11 Plate
ness 7.0 ±0.05 6.9
Strain — 0.05 0.6
Thick-
12 Disc 3.2 ±0.08 2.97
ness
Load of wave spring 626.4 N ±176.5 N 533 N
13
(testing height: 3.2 mm) {63.9 kg} {±18 kg} {54.3 kg}
WA500-6R 25
Parking brake solenoid valve 1
1. Coil (ON-OFF type)

2. Push pin
3. Spring
4. Spool
5. Block
6. Check valve
26 WA500-6R
Operation
When parking brake is applied  When parking brake is released 

(When solenoid is de-energized) (When solenoid is energized)
q As the parking brake switch is turned “ON”, the q If the parking brake switch is turned “OFF”, the
solenoid is turned “OFF”. As the result, spool solenoid is turned “ON” and spool (1) is moved
(1) is pushed back in the left direction by the to the right.
tension of spring (2). q The pressurized oil from the pump flows to the
q Pump port (P) is disconnected from parking parking brake through port (P), inside of spool
brake port (A), stopping flow of the pressurized (1) and port (A). At the same time, port (T) is
oil from the pump to the parking brake. At the closed and the oil is not drained.
same time, the oil that was working as back q As oil pressure is applied to the back side of
pressure of the parking brake is drained the piston, it compresses the spring, separat-
through ports (A) and port (T). ing the plate and disc from each other. As the
q As the back pressure of the piston is drained, result, the parking brake is released.
the piston being pushed back by the spring
contacts the plate and disc closely to enable
the parking brake.
WA500-6R 27
Emergency parking brake release valve 1

Operation
q When parking brake emergency release switch
(1) is turned to “ON”, solenoid valve (2) starts
operating and oil pressure from accumulator
(3) enters port (P). Then pilot pressure
switches the circuit, and the pressure moves to
the parking brake from port (A) to release the
parking brake.
1. Valve
2. Solenoid valve
A: To parking brake
B: From parking brake valve
C: From pilot circuit
T: Drain
P: From brake valve (accumulator circuit)
Function
q The emergency release solenoid valve is
installed between the transmission and trans-
mission control. It operates solenoid of the
parking brake release switch installed at the
operator's seat when oil pressure is not avail-
able from the power train pump due to engine
failure, etc. in order to supply accumulator
charge pressure in the brake circuit to the
parking brake.
28 WA500-6R
WA500-6R 29
SEN02892-02

© 2019 KOMATSU
All Rights Reserved
30
SEN02893-00
WA500-6R

WA500-6R 60001 and up

Undercarriage and frame
Axle mount ...................................................................................................................................................... 2
Center hinge pin.............................................................................................................................................. 7
WA500-6R 1
Axle mount 1
2 WA500-6R
1. Front axle Outline

2. Rear axle q Front axle (1) is directly fixed to front frame (4)
3. Rear frame with axle mount bolt (5) as it is directly sub-
4. Front frame jected to the working force.
5. Axle mount bolt q Rear axle (2) has swaying structure at the cen-
ter of rear axle to enable each tire to make
contact with the ground during travel on a soft
ground.
WA500-6R 3
4 WA500-6R
Unit: mm
Clearance between hole and size clearance limit
Shaft Hole
1 shaft on front support side (after
press-fitting of bushing) –0.056 +0.489 0.056 –
310 1.6
–0.137 +0.000 0.626
Clearance between hole and Replace
+2.300 +0.089 (Bushing is
2 shaft on front support side 320.2 — —
+0.800 +0.000 adhered to sup-
(before press-fitting of bushing)
port on both front
Clearance between hole and
–0.056 +0.481 0.048 – and rear.)
3 shaft on rear support side (after 260 1.6
–0.137 –0.008 0.618
press-fitting of bushing)
Clearance between hole and
+2.300 +0.089
4 shaft on rear support side 270.2 — —
+0.800 +0.000
(before press-fitting of bushing)
5 Thickness of thrust plate –0.10
22 —
–0.25
+0.1 Replace
6 Thickness of thrust washer 5 —
–0.3
7 Thickness of rear bushing 5 ±0.1 —
8 Thickness of front bushing 5 ±0.1 —
WA500-6R 5
6 WA500-6R
Center hinge pin 1
1. Front axle Outline

2. Front frame q Front frame (2) and rear frame (3) are coupled
3. Rear frame with each other through the bearings and cen-
4. Rear axle ter hinge pins (5) and (6).
5. Upper hinge pin The right and left steering cylinders connect
6. Lower hinge pin the front frame and rear frame and adjust the
articulating angle of the frame, or the turning
radius of the machine.
WA500-6R 7
8 WA500-6R
Unit: mm
Clearance between upper hinge size Shaft Hole clearance limit
1
pin and rear frame –0.036 +0.054 0.036 –
100 —
–0.058 +0.000 0.112
Clearance between upper hinge –0.036 +0.054 0.036 –
2 100 —
pin and spacer (small) –0.058 +0.000 0.112
Clearance between upper hinge –0.036 –0.000 0.016 –
3 100 —
pin and bearing –0.058 –0.020 0.058
Clearance between upper hinge –0.036 +0.054 0.036 –
4 100 —
pin and spacer (large) –0.058 +0.000 0.112
Clearance between rear frame –0.043 +0.063 0.043 –
5 130 —
and spacer (large) –0.106 +0.000 0.169
Clearance between front frame –0.000 –0.048 –0.023 –
6 155 —
and lower hinge bearing –0.025 –0.088 –0.088
Clearance between lower hinge –0.036 +0.054 0.036 –
7 100 —
pin and bushing –0.058 +0.000 0.112
Clearance between lower hinge –0.036 –0.000 0.016 –
8 100 —
pin and bearing –0.058 –0.020 0.058
Clearance between front frame –0.000 –0.050 –0.025 –
9 160 — Replace
and upper hinge bearing –0.025 –0.090 –0.090
Clearance between lower hinge –0.043 +0.063 0.043 –
10 125 —
rear frame and bushing –0.083 +0.000 0.146
Clearance in seal fitting part of +0.280 +0.054 –0.126 –
11 115 —
lower hinge +0.180 +0.000 –0.280
Clearance in seal fitting part of +0.310 +0.063 –0.147 –
12 135 —
upper hinge pin +0.210 +0.000 –0.310
Height of upper hinge pin Standard size Tolerance Repair limit
13
spacer (small) 35 ±0.1 —
Height of upper hinge pin
14 101.5 ±0.1 —
spacer (large)
Standard thickness of shim
15 between upper hinge and 2.3
retainer
16 between upper hinge and 1.6
retainer
17 between lower hinge and 1.6
retainer
WA500-6R 9
SEN02893-00

© 2007 KOMATSU
All Rights Reserved
10
SEN02894-00
WA500-6R

WA500-6R 60001 and up

Hydraulic system, Part 1
Hydraulic piping diagram ................................................................................................................................ 2
Work equipment control lever linkage ............................................................................................................. 4
Hydraulic tank ................................................................................................................................................. 5
Cooling fan motor............................................................................................................................................ 7
Cooling fan pump.......................................................................................................................................... 14
Steering pump............................................................................................................................................... 21
Work equipment hydraulic pump .................................................................................................................. 32
WA500-6R 1
Hydraulic piping diagram 1
1. Hydraulic tank 8. Steering cylinder

2. Work equipment pump 9. Bucket cylinder
3. Cooling fan pump 10. Work equipment valve
4. Hydraulic cooling pump 11. Lift cylinder
5. Steering pump 12. Charge valve (Built-in EPC relief valve)
6. Tandem pump (Power train + EPC and brake) 13. Accumulator
7. Steering demand valve 14. Hydraulic oil cooler
2 WA500-6R
WA500-6R 3
Work equipment control lever linkage 1
1. Lift arm control lever

2. Bucket control lever
3. Hold switch
4. Subtotal switch (Load meter specifications)
5. Work equipment lock lever
6. R.H. console forward-reverse slide lever
7. Armrest adjustment lever
8. Kickdown switch
9. Cancel switch (Load meter specifications)
10. Armrest
11. Work equipment EPC valve
4 WA500-6R
Hydraulic tank 1
1. Hydraulic tank A: EPC return port

2. Oil level sight gauge B: Main return port
3. Breather C: Hydraulic oil cooler return port
4. Oil filler port D: Steering and loader pump suction port
5. Filter bypass valve E: Emergency steering suction port
6. Oil filter F: Emergency steering return port
7. Strainer G: EPC pump suction port
8. Drain valve H: Steering return port
J: Steering drain port
K: Brake valve return port
L: Cooling fan pump and hydraulic cooling pump
suction port
M: Pump case drain port
WA500-6R 5
Operation of oil filter bypass valve Breather

q In the case the filter is clogged
Bypass valve (1) opens, and oil returns to the
tank bypassing the filter.
Bypass valve set pressure:
0.15 MPa {1.5 kg/cm2}
q In the case the return circuit turns negative
pressure
Whole valve (2) is held up to serve as the
check valve.
Check valve set pressure:
23.6 kPa {0.24 kg/cm2}
1. Body
2. Filter element
3. Poppet
4. Sleeve
Function
q Prevention of negative pressure in tank
Since the tank is pressurized and enclosed, if
the oil level in it lowers, negative pressure is
generated. At this time, poppet (3) is opened
by the differential pressure between the tank
pressure and the atmosphere pressure to pre-
vent generation of the negative pressure.
q Prevention of pressure rise in tank
If the pressure rises to above a specified level
while the circuit is in operation by an increase
or decrease of oil level and the temperature
rise, sleeve (4) is operated to relieve pressure
in the hydraulic tank.
6 WA500-6R
Cooling fan motor 1

Type: LMF40
P: From fan pump

T: From cooler to tank
TC: To tank
Specifications
Type : LMF40
Capacity : 40 cc/rev
Rated speed : 1,190 rpm
Rated flow : 47.6 l/min
Check valve cracking pressure: 44.1 kPa {0.45 kg/cm2}
WA500-6R 7
1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Reversible valve spool
6. Valve plate 12. Safety valve
Unit: mm
Free length
Installed Installed Free Installed
x Outside
13 Spool return spring length load length load If damaged or
diameter
deformed,
58.8 N 47.1 N replace spring
44.8 x 12.0 33.0 —
{6.0 kg} {4.8 kg}
1.96 N 1.57 N
14 Check valve spring 13.0 x 6.5 9.5 —
{0.2 kg} {0.16 kg}
8 WA500-6R
1. Hydraulic motor
Function
q This motor is called a swash plate-type axial
piston motor. It converts the energy of the
pressurized oil sent from the pump into rotary
motion.
Principle of operation
q The oil sent from the pump flows through valve
plate (7) into cylinder block (5).
q This oil can flow on only one side of the (Y–Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses pistons (4) (2 or 3 pieces) and gener-
ates force (F1).
q A single piston force F1 [F1 (kg) = P (kg/cm2) x
xD2/4 (cm2)]
q This force is applied to thrust plate (2).
q Since thrust plate (2) is fixed to a certain angle
(a) to output shaft (1), the force is divided into
components (F2) and (F3).
q Radial component (F3) generates torque [T =
F3 x ri] against the (Y – Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = s(F3 x ri)] rotates
cylinder block (5) through piston (4).
q This cylinder block (5) is coupled to output
shaft (1) with the spline.
q Output shaft (1) rotates and torque is transmit-
ted.
WA500-6R 9
2. Suction valve
Function 2) When the pump is stopped

q When the pump stops rotating, hydraulic oil q When the engine stops, the pump input revolu-
does not flow into the motor. tion becomes 0 rpm.
q Since the motor is revolved by the force of q Hydraulic oil from the pump is not supplied to
inertia, the pressure rises on the outlet side of port (P).
the motor. q As the hydraulic oil does not flow to (MA) side
q When the oil stops flowing in from inlet port (P), of the motor, the motor speed decreases grad-
suction valve (1) sucks in the oil on the outlet ually to stop.
side and supplies it to port (MA) where there is q If the motor shaft is revolved by the force of
not sufficient oil. Cavitation is prevented from inertia while the oil flow to port (P) decreases,
being generated accordingly. the oil in port (T) on the outlet side is sent by
suction valve (1) to (MA) side. Cavitation is
Operation prevented from being generated accordingly.
1) When pump is started
q When the hydraulic oil from the pump is sup-
plied to port (P) and the pressure on (MA) side
rises.
q When starting torque is generated in the motor,
the motor starts revolution.
q The oil on outlet (MB) side of the motor returns
through port (T) to the tank.
10 WA500-6R
3. Operation of reversible valve
1) When ON/OFF solenoid is de-energized 2) When ON/OFF solenoid is energized

q When ON/OFF solenoid (1) is “de-energized”, q When ON/OFF solenoid (1) is “energized”,
hydraulic oil from the pump is cut off by valve valve (2) switches.
(2). q Hydraulic oil from the pump flows through port
q Port (C) is connected to the tank circuit. (C) into spool chamber (D).
q Accordingly, spool (3) is pressed by spring (4) q Hydraulic oil in chamber (D) compresses
to the right. spring (4).
q As a result, motor port (MA) opens and the q Spool (3) moves to the left.
hydraulic oil flows into the motor to revolve it in q As a result, motor port (MB) opens and the
normal direction (clockwise). hydraulic oil flows into the motor to revolve it in
reverse (counterclockwise).
WA500-6R 11
4. Safety valve
Function
q When the engine is started, the pressure in
port (P) of the motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q Accordingly, abnormally high pressure is pre-
vented from being generated in port (P).
12 WA500-6R
WA500-6R 13
Cooling fan pump 1

Type: LPV45
P1: Pump discharge port

PAEPC: EPC output pressure pickup plug
PEPC: EPC valve basic pressure input port
PS: Pump suction port
TO: Drain port
1. Servo valve
2. Air bleeder
14 WA500-6R
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
WA500-6R 15
Function Structure
q The pump converts the engine rotation torque q Cylinder block (7) is supported to shaft (1) by
transmitted to its shaft to oil pressure and spline (11).
delivers pressurized oil corresponding to the q Shaft (1) is supported with front and rear bear-
load. ings (12).
q It is possible to change the delivery by chang- q The end of piston (6) has a spherical hollow
ing the swash plate angle. and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Shoe (5) is kept pressed against flat surface
(A) of rocker cam (4) and slid circularly.
q Rocker cam (4) slides around ball (13).
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q Cylinder block (7) seals the pressurized oil to
valve plate (8) and carries out relative rotation.
q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylin-
der block (7) is suctioned and discharged
through valve plate (8).
16 WA500-6R
Operation of pump q With the condition of center line (X) of rocker

q Cylinder block (7) rotates together with shaft cam (4) has swash plate angle (a) to axial
(1), and shoe (5) slides on flat surface (A). direction of cylinder block (7), flat surface (A)
q Rocker cam (4) slants around ball (13). As a functions as cam against shoe (5).
result, angle (a) between center line (X) of q Piston (6) slides on the inside of cylinder block
rocker cam (4) and the axis of cylinder block (7), so a difference between volumes (E) and
(7) changes. (F) is created inside cylinder block (7).
q Angle (a) is called the swash plate angle. q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q The volume of chamber (F) grows larger and,
in this process, the oil is suctioned.
WA500-6R 17
q As center line (X) of rocker cam (4) matches Control of delivery

the axial direction of cylinder block (7) [swash q If the swash plate angle (a) becomes larger,
plate angle (a) = 0], the difference between vol- the difference between volumes (E) and (F)
umes (E) and (F) inside cylinder block (7) be c o me s la r g er a nd pu m p d el i v er y ( Q )
becomes 0. increases.
q Suction and discharge of pressurized oil is not q Swash plate angle (a) is changed with servo
carried out in this state. Namely pumping piston (10).
action is not performed. (Actually, however, the q Servo piston (10) reciprocates straight accord-
swash plate angle is not set to 0) ing to the signal pressure of the servo valve.
q Swash plate angle (a) is in proportion to the q This straight motion is transmitted to rocker
pump delivery. cam (4).
q Rocker cam (4) supported with ball (13) slides
around ball (13).
18 WA500-6R
Servo valve
P: EPC valve basic pressure 1. Plug

PE: Control piston pressure 2. Lever
PH: Pump discharge pressure 3. Retainer
T: Drain port 4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring
WA500-6R 19
Function q Then, the land of the servo piston pressure

q The servo valve controls the current input to passage is connected to the pump discharge
the EPC valve and the pump delivery (Q) so passage by the notch of spool (5) and the dis-
that they will be related as shown in the dia- charge pressure is led to the servo piston.
gram. q When the rocker cam is pushed up by the
servo piston, a position feedback is applied
and lever (2) moves to compress spring (8).
q When spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
cut off.
q Pressure in the servo piston chamber drops
and the rocker cam returns in the direction of a
maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with spring (8) force.
q The greater the EPC output pressure, the
smaller the swash plate angle. Conversely, the
smaller the EPC output pressure, the greater
q The output pressure of the EPC valve flows in the swash plate angle.
the piston chamber to push piston (6).
q Piston (6) pushes spool (5) until it is balanced
with the spring.
20 WA500-6R
Steering pump 1
Type: LPV90
P1: Pump discharge port POP: External pilot pressure input port
P1L: Pump pressure input port PS: Pump suction port
PD: Drain port
PD2: Drain plug 1. Pump body
PD6: Drain port 2. Servo valve
PEN: Control pressure pickup plug 3. Air bleeder
PLS: Load pressure input port
WA500-6R 21
1. Pump unit
PA: Control basic pressure output port

PD4: Drain port
PD5: Drain port
PE: Control pressure input port
22 WA500-6R
1. Bearing
2. Shaft
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cover
10. Shoe retainer
11. Servo piston
12. Spring
13. Oil seal
14. Ball
WA500-6R 23
Function
q The pump converts the engine rotation torque
transmitted to its shaft to oil pressure and
delivers pressurized oil corresponding to the
load.
q It is possible to change the delivery by chang-
ing the swash plate angle.
Structure
q Cylinder block (6) is supported on shaft (1)
through spline (a). Shaft (1) is supported on
the front and rear bearings.
q The end of piston (5) has a spherical hollow
and is combined with shoe (4). Piston (5) and
shoe (4) form a spherical bearing.
q Rocker cam (3) is supported on case (2) and
ball (9) and has flat surface (A). Shoe (4) is
kept pressed against the plane of rocker cam
(3) and slid circularly. Shoe (4) leads high-
pressure oil to form a static pressure bearing
and slides.
q Piston (5) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (6).
valve plate (7) and carries out relative rotation.
q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylin-
der block (6) is suctioned and discharged
through valve plate (7).
24 WA500-6R
Operation
1) Operation of pump
q Cylinder block (6) rotates together with shaft q As center line (X) of rocker cam (3) matches
(1), and shoe (4) slides on flat surface (A). the axial direction of cylinder block (6) [swash
q Rocker cam (3) slants around ball (9). As a plate angle (a) = 0], the difference between vol-
result, angle (a) between center line (X) of umes (E) and (F) inside cylinder block (6)
rocker cam (3) and the axis of cylinder block becomes 0.
(6) changes. q Suction and discharge of pressurized oil is not
q Angle (a) is called the swash plate angle. carried out in this state. Namely pumping
action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q Swash plate angle (a) is in proportion to the
pump delivery.
q With the condition of center line (X) of rocker

cam (3) has swash plate angle (a) to axial
direction of cylinder block (6), flat surface (A)
functions as cam against shoe (4).
q Piston (5) slides on the inside of cylinder block
(6), so a difference between volumes (E) and
(F) is created inside cylinder block (6).
q A single piston (5) sucks and discharges the oil
oil is discharged.
WA500-6R 25
2) Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Swash plate angle (a) is changed with servo
piston (11).
q Servo piston (11) reciprocates straight accord-
ing to the signal pressure of the CO valve and
LS valve.
q This straight motion is transmitted to rocker
cam (3).
q Rocker cam (3) supported with ball (9) slides
around ball (9).
26 WA500-6R
2. Servo valve
P1: Pump discharge pressure port

PE: Control pressure output port
T: Drain port
WA500-6R 27
LS valve CO valve
PA: Pump pressure input PA: Pump pressure input
PE: Control piston pressure PPL: CO valve output pressure
PLS: LS pressure input T: Drain
PPL: CO valve output pressure
PPLS: LS pump pressure input
1. Nut 9. Piston
2. Plate 10. Seal
3. Plug 11. Piston
4. Spring 12. Sleeve
5. Seat 13. Spool
6. Plug 14. Seat
7. Spool 15. Retainer
8. Plug 16. Spring
28 WA500-6R
LS valve CO valve
Function Function
q The LS valve controls the pump delivery q When the pump pressure in the hydraulic cir-
according to the stroke of the control lever, or cuit reaches the maximum level, CO (Cut Off)
the demand flow for the actuator. valve minimizes the pump swash plate angle
q The LS valve detects the demand flow for the and protects the circuit by suppressing the rise
actuator from differential pressure (dPLS) of pressure.
between control valve inlet pressure (PPLS) q The minimum pump swash plate angle given
and control valve outlet pressure (PLS) and reduces the pump suction torque to improve
controls main pump delivery (Q). ((PPLS) is fuel economy.
called the LS pump pressure, (PLS) the LS
pressure, and (dPLS) is the LS differential
pressure.)
q In other words, the pressure loss caused by
flow of oil through the opening of the control
valve spool (= LS differential pressure dPLS) is
detected, and then pump delivery (Q) is con-
trolled to keep that pressure loss constant and
supply the pump delivery according to the
demand flow for the actuator.
q Main pump discharge pressure (PA), LS pump
pressure (PPLS), and LS pressure (PLS) are
led to the LS valve. The relationship between
LS differential pressure (dPLS) and pump
delivery (Q) changes as shown below. Operation
1. Function of spring
q The spring load of spring (2) on the CO valve is
determined by the pump discharge pressure
(PA).
2. When the load on the actuator is small and

pump discharge pressure (PA) is low
q The pressing force of spool (5) is decreased
and spool (3) is little to the right (Fig. 1). At this
time, ports (C) and (D) are connected to each
other and the pressure in the LS valve is drain
pressure (PT).
q At this time, ports (F) and (G) of LS valve are
connected each other. As a result, the pres-
sure in port (J) becomes drain pressure (PT)
and servo piston (6) moves to the left.
q Consequently, the pump delivery is increased.
3. When the load on the actuator is large and

pump discharge pressure (PA) reaches the
maximum pressure
q The pressing force of spool (5) is increased
and spool (3) is little to the left (Fig. 2). At this
time, ports (C) and (B) are connected to each
other and the pressure in the LS valve is pump
pressure (PA).
q At this time, ports (F) and (G) of LS valve are
connected each other. As a result, the pres-
sure in port (J) becomes pump pressure (PA)
and servo piston (6) moves to the right.
q Consequently, the pump delivery is decreased.
WA500-6R 29
When load is light

(Fig. 1)
When load is heavy

(Fig. 2)
30 WA500-6R
WA500-6R 31
Work equipment hydraulic pump 1

Type: HPV190
32 WA500-6R
Outline
q The pump unit is composed of the variable
capacity swash plate type piston pump, PC
valve, LS valve, and EPC valve.
IM: PC mode selector current

PA: Pump discharge port
PB: Pump pressure input port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PEPC: EPC basic pressure port
PEPCC: EPC basic pressure pickup port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
PS: Pump suction port
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve
WA500-6R 33
1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cover
10. Impeller
11. Servo piston
12. PC valve
34 WA500-6R
Function q Rocker cam (4) conducts high pressure oil to

q The pump converts the engine rotation torque cylinder surface (B) with cradle (2), which is
transmitted to its shaft to oil pressure and secured to the case, and forms a static pres-
delivers pressurized oil corresponding to the sure bearing when it slides.
load. q Piston (6) carries out relative movement in the
q It is possible to change the delivery by chang- axial direction inside each cylinder chamber of
ing the swash plate angle. cylinder block (7).
Structure valve plate (8) and carries out relative rotation.
q Cylinder block (7) is supported to shaft (1) by q This surface is designed so that the oil pres-
spline (14). sure balance is maintained at a suitable level.
q Shaft (1) is supported by front and rear bear- q The oil inside each cylinder chamber of cylin-
ings (15). der block (7) is suctioned and discharged
q The end of piston (6) has a spherical hollow through valve plate (8).
and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
WA500-6R 35
Operation of pump q As center line (X) of rocker cam (4) matches

q Cylinder block (7) rotates together with shaft the axial direction of cylinder block (7) [swash
(1), and shoe (5) slides on flat surface (A). plate angle (a) = 0], the difference between vol-
q Rocker cam (4) moves along cylindrical sur- umes (E) and (F) inside cylinder block (7)
face (B), so angle (a) between center line (X) becomes 0.
of rocker cam (4) and the axial direction of cyl- q Suction and discharge of pressurized oil is not
inder block (7) changes. carried out in this state. Namely pumping
q Angle (a) is called the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q Swash plate angle (a) is in proportion to the
pump delivery.
q With the condition of center line (X) of rocker

cam (4) has swash plate angle (a) to axial
direction of cylinder block (7), flat surface (A)
fuctions as cam against shoe (5).
q Piston (6) slides on the inside of cylinder block
(7), so a difference between volumes (E) and
(F) is created inside cylinder block (7).
q A single piston (6) sucks and discharges the oil
oil is discharged.
36 WA500-6R
Control of delivery
q If swash plate angle (a) becomes larger, the
difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
WA500-6R 37
1. LS valve
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Seat
PPL: Control pressure input port 6. Sleeve
PSIG: Drain port 7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load of
the actuator and controls the delivery.
q This valve controls pump delivery (Q) accord-
ing to differential pressure (dPLS)
[ = (PP) – (PLS)] (called LS differential pres-
sure) between pump discharge pressure (PP)
and control valve outlet port pressure (PLS).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.
38 WA500-6R
Operation
1) When the control valve is situated at neutral
q The LS valve is a 3-way selector valve, with q According to the difference in the areas on
pressure (PLS) (LS pressure) from the inlet servo piston (12), servo piston (12) moves in to
port of the control valve brought to spring the direction of minimizing the swash plate
chamber (B), and pump discharge pressure angle.
(PP) brought to port (H) of sleeve (8).
q Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the
pump discharge pressure (self pressure) (PP)
determine the position of spool (6).
q Before starting engine, servo piston (12) is
pressed to the left. (See the figure to the right)
q If the control lever is in neutral at start of the
engine, LS pressure (PLS) is set to 0 MPa {0
kg/cm2}. (It is connected with the drain circuit
through the control valve spool.)
q Spool (6) is pushed to the right, and port (C)
and port (D) will be connected.
q Shuttle valve output pressure (PPH) enters the
large diameter side of the piston from port (K).
q Pump pressure (PP) is present in port (J) on
the small diameter side of the piston.
WA500-6R 39
2) Action for the direction of maximizing the pump delivery
q When the difference between pump discharge

pressure (PP) and LS pressure (PLS), in other
wo r ds , L S d iff er e nti a l p re s s ur e ( dP L S)
becomes smaller [for example, when the area
of opening of the control valve becomes larger
and pump discharge pressure (PP) drops],
spool (6) is pushed to the left by the combined
force of LS pressure (PLS) and the force of
spring (4).
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the left side. Therefore, servo pis-
ton (12) is moved in the direction to make the
delivery larger.
40 WA500-6R
3) Action for the direction of minimizing the pump delivery
q If LS differential pressure (dPLS) becomes

larger (for example, when the area of control
valve opening becomes smaller and the pump
pressure (PP) increases), spool (6) is pressed
to the right by the force of pump pressure (PP).
q As a result of the movement of spool (6), shut-
tle valve output pressure (PPH) flows from port
(C) to port (D), then from port (K) to the large
diameter side of the piston.
q While main pump pressure (PP) is present in
port (J) of the smaller diameter side of the pis-
ton, servo piston (12) is pressed to the right by
its area difference between the larger and the
smaller diameter sides. As the result, servo
piston (12) moves in the direction to minimize
the swash plate angle.
WA500-6R 41
4) When servo piston is balanced
q Let us take the area receiving the pressure at q The force of spring (4) is adjusted to determine
the large diameter end of the piston as (A1), the balanced stop position of this spool (6) at
the area receiving the pressure at the small the center of the standard when (PP) – (PLS) =
diameter end as (A0), and the pressure flowing 1.4 MPa {14 kg/cm2}.
into the large diameter end of the piston as
(PEN).
q If the main pump pressure (PP) of the LS valve
and the combined force of spring (4) and LS
pressure (PLS) are balanced, and the relation-
ship is (A0) x (PP) = (A1) x (PEN), servo piston
(12) will stop in that position.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q The formula (A0) : (A1) = 3 : 5 represents the
relation of pressure receiving areas across the
end of servo piston (12). And (PP) : (PEN) C 5 :
3 represents the pressure applied across the
piston when balanced.
42 WA500-6R
2. PC valve
PA: Pump port 1. Plug

PA2: Pump pressure pilot port 2. Servo piston assembly
PDP: Drain port 3. Pin
PM: Mode selector pressure pilot port 4. Spool
PPL: Control pressure output port (to LS valve) 5. Retainer
6. Seat
7. Cover
8. Wiring
Function
q PC valve controls the flow to a certain rate cor-
responding to the discharge pressure irrespec-
tive of how much the control valve stroke is
increased, when pump discharge pressure
(PP1) (self pressure) and (PP2) (other pump
pressure) are high.
q Uprise in the pump discharge pressure due to
increased load during work results in reducing
the pump delivery.
q If the pump discharge pressure drops, it
increases the delivery from the pump.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and pump delivery (Q) will
become as shown in the right figure if the rela-
tion is represented as the parameter of the cur-
rent value (X) to be given to PC-EPC valve
solenoid.
q The controller continues counting the actual
engine speed.
q During low speed, command current flows
from the controller to PC-EPC valve solenoid
according to the engine speed to reduce the
pump delivery.
WA500-6R 43
Operation
1) When the actuator load is small and pump pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1) a Other pump pressure denotes the pressure of
q Command current (X) is being sent to PC-EPC the pump situated on the opposite side.
valve solenoid (1) from the pump controller. For the front pump pressure, the other pump
q This command current (X) works on PC-EPC pressure is that of the rear pump.
valve and output the signal pressure to change And for the rear pump pressure, the other
the force of pushing piston (2). pump pressure is that of the front pump.
q Spool (3) stops at a position where the com-
bined force pressing spool (3) becomes bal-
anced between a set force of spring (4) and
pump pressure (PP1) (self pressure) and
(PP2) (other pump pressure).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
44 WA500-6R
Action of spring q If port (E) and port (G) of the LS valve are con-
q The load of spring (4) at the PC valve is deter- nected, the pressure entering the large diame-
mined by the position of the swash plate. ter end of the piston from port (J) becomes
q Spring load changes as servo piston (9) makes drain pressure (PT), and servo piston (9)
spring (4) elongate or contract. moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Spring (4) extends as servo piston (9) moves
q The load of spring (4) also changes according and weakens the spring force.
to the PC-EPC valve solenoid command cur- q As the spring force is weakened, spool (3)
rent (X). moves to the right, the connection between
q Port (C) of the PC valve is connected to port port (C) and port (D) is shut off and the pump
(E) of the LS valve. discharge pressure ports (B) and (C) are con-
q Self pressure (PP1) enters port (B) and the nected.
small diameter end of servo piston (9), and q The pressure on port (C) rises and the pres-
other pump pressure (PP2) enters port (A). sure on the large diameter end of the piston
q When pump pressures (PP1) and (PP2) are also rises. Thus, the leftward move of servo
small, spool (3) will be positioned in the left piston (9) is stopped.
side. q Stop position of servo piston (9) (= pump deliv-
q Ports (C) and (D) are connected, and the pres- ery) is determined by a position where press
sure entering the LS valve becomes drain force generated by pressures (PP1) and (PP2)
pressure (PT). on spool (3) and other press force by PC-EPC
valve solenoid are balanced with the force of
spring (4).
WA500-6R 45
2) When the actuator load is large, and the pump discharge pressure is high
Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressures (PP1) and (PP2) are high, the force connected, this pressure from port (J) enters
pushing spool (3) to the right becomes larger the large diameter end of servo piston (9),
and spool (3) will be moved to the position stopping servo piston (9).
shown in above figure. q If main pump pressure (PP2) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the right, main
(C) to LS valve flows from port (B) to ports (C) pump pressure (PP1) flows to port (C) and acts
and (D) through LS valve. At the end of this to make the pump delivery the minimum.
flow, level of this pressure becomes approxi- q When servo piston (9) moves to the right,
mately half of main pump pressure (PP2). springs (4) and (6) are compressed and push
back spool (3).
q When spool (3) moves to the left, the openings
of port (C) and port (D) become larger.
q The pressure on port (C) (= J) is decreased
and the rightward move of servo piston (9) is
stopped.
q The position in which servo piston (9) stops at
this time is further to the right than the position
when pump pressures (PP1) and (PP2) are
low.
46 WA500-6R
q The relationship between the average pump

pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.
q If command voltage (X) sent to PC-EPC valve

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
q Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to spool
(3), so the relationship between the average
pump pressure (PP1 + PP2)/2 and pump deliv-
ery (Q) moves from (A) to (B) as command
current (X) is increased.
WA500-6R 47
3. PC-EPC valve
C: To PC valve
P: From pilot pump
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
48 WA500-6R
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0
tion. (Coil is de-energized)
q On receiving signal current (i) from the control- q When there is no signal current flowing from
ler, the EPC valve generates EPC output pres- the controller to coil (2), coil (2) is de-ener-
sure in proportion to the signal current and gized.
outputs it to the PC valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) is closed and the oil from the pilot
pump does not flow to the PC valve.
q The oil from the PC valve is drained through
ports (C) and (T) to the tank.
WA500-6R 49
2) When signal current is very small 3) When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressure on port (C) increases and the force to q Spool (5) is pushed toward the right side by rod
act on spool (5) surface and the spring load on (6).
spring (4) become larger than the propulsion q Hydraulic oil from port (P) flows to port (C) with
force of plunger (7). maximum flow rate. As the result, the circuit
q Spool (5) is pushed to the left, and port (P) is pressure between the EPC and PC valves
shut off from port (C). becomes maximum.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves so that the propulsion force of not flow to the tank.
plunger (7) may be in balance with pressure of
port (C) + spring load of spring (4).
q Circuit pressure between the EPC valve and
PC valve is controlled in proportion to the size
of the signal current.
50 WA500-6R
WA500-6R 51
SEN02894-00

© 2007 KOMATSU
All Rights Reserved
52
SEN02895-00
WA500-6R

WA500-6R 60001 and up

Hydraulic system, Part 2
Control valve ................................................................................................................................................... 2
CLSS............................................................................................................................................................. 16
Each function and operation of each valve ................................................................................................... 21
Accumulator (for PPC circuit)........................................................................................................................ 32
Work equipment electric lever....................................................................................................................... 33
WA500-6R 1
Control valve 1
Outline
As for outside views and sectional views, only the 4-spool valve (with ECSS control valve) is shown.
A1: To bucket cylinder head

A2: To lift arm cylinder bottom
A3: To lift arm cylinder bottom
ACC: To ECSS accumulator
B1: To bucket cylinder bottom
B2: To lift arm cylinder head
B3: To bucket cylinder bottom
CP: Pressure sensor installation port
CR: Pressure pickup port
P1: From front work equipment hydraulic pump
P2: From rear work equipment hydraulic pump
PA1: From bucket dump controller
PA2: From lift arm raise controller
PACC: From ECSS controller
PB1: From bucket tilt controller
PB2: From lift arm lower controller
PLS: To work equipment hydraulic pump LS port
PP: From pilot pump
PPS: To work equipment hydraulic pump
T: To tank
TS: To tank
1. Bucket valve
2. Lift arm valve
3. ECSS control valve
4. Lift arm Hi and bucket Hi valves
5. Cover 1
6. Cover 2
7. Lift arm suction valve
8. Accumulator charge valve
2 WA500-6R
Outside view
WA500-6R 3
Sectional view
(1/6)
4 WA500-6R
1. Load check valve (Bucket head)

2. Load check valve (Lift arm bottom)
3. Load check valve (Lift arm Hi) and (Lift arm bottom)
4. Load check valve (Bucket Hi) and (Bucket bottom)
5. Pressure compensation valve (Lift arm head)
6. Load check valve (Bucket bottom)
Unit: mm
Free length
Installed Installed Free Installed If damaged or
x Outside
7 Check valve spring length load length load deformed,
diameter
replace spring
29.4 N 23.5 N
38.9 x 11.5 30.0 —
{3.0 kg} {2.4 kg}
WA500-6R 5
(2/6)
6 WA500-6R
1. Spool (Lift arm Hi)

2. Spool (Bucket Hi)
3. Spool (ECSS control)
4. Spool (Lift arm)
5. Spool (Bucket)
Unit: mm
Free length
x Outside
6 Spool return spring length load length load
diameter
393 N 315 N
54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg}
417 N 333 N
7 Spool return spring 54.2 x 34.8 51.2 —
{42.5 kg} {34.0 kg}
If damaged or
351 N 280 N
8 Spool return spring 58.1 x 33.0 51.5 — deformed,
{35.8 kg} {28.6 kg}
replace spring
351 N 280 N
{35.8 kg} {28.6 kg}
251 N 201 N
{25.6 kg} {20.5 kg}
263 N 210 N
{26.8 kg} {21.4 kg}
274 N 219 N
{27.9 kg} {22.3 kg}
WA500-6R 7
(3/6)
8 WA500-6R
1. Suction safety valve (bucket head)

2. Suction valve (bucket Hi) and (bucket bottom)
3. Suction valve (lift arm head)
4. Suction safety valve (bucket bottom)
Unit: mm
Free length
Installed Installed Free Installed If damaged or
x Outside
5 Suction valve spring length load length load deformed,
diameter
replace spring
5.5 N 4.4 N
46.8 x 7.5 40.6 —
{0.56 kg} {0.45 kg}
WA500-6R 9
(4/6)
10 WA500-6R
1. Unload valve
Bucket valve
2. EPC valve (Tilt)
3. Load check valve (Dump)
4. Load check valve (Tilt)
5. EPC valve (Dump)
6. Suction safety valve (Tilt)
7. Spool
8. Suction safety valve (Dump)
WA500-6R 11
(5/6)
12 WA500-6R
Lift arm valve

1. EPC valve (Lower and float)
2. Load check valve (Lift)
3. LS shuttle valve
4. Pressure compensation valve (Lower)
5. EPC valve (Raise)
6. Suction valve (Lower and float)
7. Suction valve (Lower and float)
8. Spool
ECSS valve
9. Spool
10. EPC valve
Unit: mm
Free length
x Outside
12 Check valve spring length load length load
diameter
If damaged or
5.9 N 4.72 N
41.5 x 8.5 31.5 — deformed,
{0.6 kg} {0.48 kg}
replace spring
19.6 N 15.7 N
13 Valve spring 19.2 x 7.2 16.1 —
{2.0 kg} {1.6 kg}
3.04 N 2.43 N
14 Suction valve spring 62.5 x 20.0 39.0 —
{0.31 kg} {0.25 kg}
WA500-6R 13
(6/6)
14 WA500-6R
Lift arm Hi and bucket Hi valves

1. Load check valve (Lift arm Hi)
2. Spool (Lift arm Hi)
3. Load check valve (Bucket Hi)
4. Spool (Bucket Hi)
5. Suction valve (Bucket Hi)
6. Unload valve
7. Main relief valve
8. LS bypass valve
WA500-6R 15
CLSS 1
Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with a variable capacity
tem, and has the following features. piston pump, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
16 WA500-6R
Basic principle
1. Pump swash plate angle control q The pump swash plate angle shifts toward the
q The pump swash plate angle (pump delivery) maximum position if LS differential pressure
is so controlled that the LS differential pressure (dPLS) is lower than the set pressure of the LS
(dPLS), which is the differential pressure valve (when the actuator load pressure is
between the pump discharge pressure (PPS) high).
and LS pressure (PLS) (the actuator load pres- q If it becomes higher than the set pressure
sure) at the control valve outlet, will be con- (when the actuator load pressure is low), the
stant. pump swash plate angle shifts toward the mini-
q [LS differential pressure (dPLS) = Pump dis- mum position.
charge pressure (PPS) – LS pressure (PLS)]
LS differential pressure ( d PLS) and pump

swash plate angle
a For details of functions, see the “Hydraulic

pump” paragraph.
WA500-6R 17
2. Pressure compensation control
q The valve (pressure compensation valve) to q This prevents the bucket from becoming inop-
balance the load is installed to the lift arm head erable because of excessive oil flow to the lift
outlet side of the control valve. arm head due to the lowering of lift arm under
q When actuators are operated simultaneously, its own weight and compound operation of the
the pressure difference (dP) between the bucket.
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of openings
(S1) and (S2) of each valve.
18 WA500-6R
WA500-6R 19
1. Bucket valve
2. Lift arm valve
3. ECSS valve
4. Lift arm Hi valve
5. Bucket Hi valve
6. Bucket spool
7. Lift arm spool
8. ECSS spool
9. Lift arm spool
10. Bucket spool
11. Pressure compensation valve
12. Suction valve
13. Load check valve
15. Main relief valve
Set pressure:
34.3 ± 0.5 MPa {350 ± 5 kg/cm2}
16. Unload valve
Cracking pressure:
1.96 ± 0.2 MPa {20 ± 2 kg/cm2}
17. Suction safety valve
Set pressure:
36.2 ± 0.5 MPa {370 ± 5 kg/cm2}
20 WA500-6R
Each function and operation of each valve 1

Pressure compensation valve
(Installed on the cylinder head side of the lift arm valve)
1. When a high load is applied to the lift arm
1. Main pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
Function Operation
q High load pressure is generated during inde- q Actuator circuit pressure (B) becomes higher
pendent operation of the lift arm and com- than pump discharge pressure (PPS) and LS
pound operation with the bucket. pressure (PLS).
q When the lift arm load pressure becomes q Shuttle valve (3) of the pressure compensation
higher than the bucket, the pressure compen- valve moves to the right.
sation valve operates as a load check valve to q Actuator circuit pressure (B) and spring cham-
prevent reverse oil flow in the circuit. ber (C) are connected.
q Accordingly, piston (4) is pressed by spring (5)
to the left.
q Also valve (2) is pressed by piston (4) to the
left and pump outlet circuit (A) is closed. This
prevents reverse flow of oil from actuator cir-
cuit (B) to pump outlet circuit (A).
WA500-6R 21
2. Compound operation (Lift arm lower + bucket tilt)
Function Operation
q If the load pressure is lower than the bucket q If the load pressure on the bucket side rises
and the flow rate starts increasing during com- during compound operation, the flow rate of
pound operation, the pressure compensation actuator circuit pressure (B) starts to increase.
valve compensates the pressure. q As LS pressure (PLS) rises on the bucket side,
q On the bucket side, the load pressure is higher shuttle valve (3) of the pressure compensation
and the flow rate starts to decrease. valve is pressed to the left.
q Hydraulic oil flows through the internal pas-
sage of piston (4) to spring chamber (C).
q Piston (4) and valve (2) are pressed to the left
and the outlet side of pump circuit (PPS) is cut
off.
q Outlet pressure (A) (spool meter-in down-
stream pressure) becomes equal to the bucket
outlet pressure.
q Pump pressure (PPS) (spool meter-in
upstream pressure) becomes equal for all
actuators.
q Pump pressure (PPS) and outlet pressure (A)
becomes equal for all spools.
q Pump flow rate is distributed in proportion to
the opening area of respective spools.
22 WA500-6R
Shuttle valve in the pressure compensation valve
1. If holding pressure of port (B) > LS pressure in spring chamber (C)
1. Hydraulic pump
2. Valve
3. Shuttle valve
4. Piston
Function
q Shuttle valve (3) is pressed to the right by port
(B) pressure and ports (B) and (D) are cut off.
q Holding pressure of port (B) is led to spring
chamber (C) and piston (4) is pressed to the
left to prevent it from being separated from
valve (2).
WA500-6R 23
Area ratio of pressure compensation valve
Function
q The state of division changes according to the
area ratio of pressure compensation portions
(A1) and (A2). Area ratio = (A2)/(A1)
q Since the area ratio is less than 1, spool meter-
in downstream pressure < maximum load
pressure, and the oil flow is divided greater
than by the area ratio of the opening.
24 WA500-6R
Supply of LS pressure
(LS shuttle valve)
1. Hydraulic pump 5. Check valve

2. Main spool 6. LS circuit
3. Pressure compensation valve 7. LS shuttle valve
4. Valve
Function Operation
q The LS pressure (PLS) means the actuator q If main spool (2) is operated, pump discharge
load pressure on the outlet side of the control pressure (PPS) flows to actuator circuit (B).
valve. q Pump discharge pressure (PPS) is led through
q Pressure compensation valve (3) upstream orifice (a) of main spool (2) to LS circuit (PLS).
pressure (spool meter-in downstream pres- q When actuator circuit (B) rises to necessary
sure) is led through main spool (2) to LS shut- pressure level, pump discharge pressure
tle valve (7). (PPS) rises.
q Connected to actuator port (B) through valve q Check valve (5) in main spool (2) opens and
(4), and makes LS pressure C actuator load the high pressure in LS circuit (PLS) flows out
pressure. to actuator circuit (B).
q Orifice (a) inside main spool (2) has a small q Pressure in LS circuit (PLS) becomes approxi-
diameter concurrently serving as a throttle. mately equal to that of actuator circuit pressure
(B).
WA500-6R 25
LS bypass valve 1
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass valve
6. LS circuit
Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to
prevent a sudden change of hydraulic pres-
sure.
q Bypass flow from LS bypass valve (5) causes
a pressure loss to be generated due to the cir-
cuit resistance between throttle (c) of main
spool (2) and LS shuttle valve (4).
q Effective LS differential pressure drops to
improve a dynamic stability of the actuator.
26 WA500-6R
ECSS control valve
Function q If accumulator (ACC) is charged up to the set pres-

q The controller automatically turns on and off sure, check valve (5) is closed and the pressure in
the accumulator charged with high-pressure accumulator (ACC) does not rise any more.
gas according to the travel condition.
q The ECSS control valve gives elasticity to the Accumulator pressure relief valve
vertical movement of the work equipment and q If the pressure in accumulator (ACC) needs to
reduces rocking of the machine body during be relieved, loosen plug (3) and nut (4) to open
high-speed travel to improve the operator com- circuits (PR) and (TS).
fort and prevent spillage of material for higher
working efficiency.
Operation
q If the travel speed exceeds 5 km/h, the signal
is sent to solenoid valve (2) and the pressure is
applied to (a).
q Spool (1) moves to the right.
q As spool (1) moves, the line from (PR) to accu-
mulator (ACC) is closed and the lines from (A2)
to accumulator (ACC) and from (B2) to (T) are
opened. As a result, the ECSS is turned ON.
q While the travel speed is below 4 km/h, the sig-
nal is not sent to solenoid valve (2) and spool
(1) is in neutral. At this time, the line from (PR)
to accumulator (ACC) is opened and accumu-
lator (ACC) is charged.
WA500-6R 27
Accumulator charge valve
CR: Pressure pickup port 1. Screw

P: From main pump 2. Poppet (Safety valve)
PR: To accumulator through ECSS spool 3. Spring (Safety valve)
TS1: To tank 4. Spring (Main pressure reducing valve)
TS2: To tank 5. Pressure reducing valve spool
TS3: To tank 6. Poppet (Check valve)
7. Spring (Check valve)
28 WA500-6R
WA500-6R 29
1. When valve is in neutral and (P) is low
Function
q Discharge pressure (P) of the hydraulic pump
is reduced and the oil is supplied to the ECSS
accumulator.
Operation
q Poppet (2) is pressed by spring (3) against the
seat and the line from port (P1) to port (T) is
closed.
q Poppet (6) is pressed to the left and the line
from port (P1) to port (PR) is closed.
q Poppet (6) is moved to the right by pressure
(P1) and the line from (P1) to (PR) is opened. If
(P1) < (PR), poppet (6) is pressed to the left by
spring (7) and the line from (P1) to (PR) is
closed.
30 WA500-6R
2. When load pressure (P) is high
Operation
q If pressure (P) rises above the set pressure,
poppet (3) opens and the hydraulic oil flows
through port (P1), hole (a) in spool (5), opening
of poppet (2), and tank port (T).
q Accordingly, differential pressure is made
before and after hole (a) in spool (5) and spool
(5) moves to close the opening between ports
(P) and (P1). Pressure (P) is reduced to a cer-
tain pressure (the set pressure) by the open
area at this time and supplied as pressure
(P1).
WA500-6R 31
Accumulator (for PPC circuit) 1
Operation
q After engine is stopped, chamber (A) in the
bladder is compressed by oil pressure in
chamber (B).
q When work equipment EPC solenoid is tripped
by operating the work equipment EPC lever,
pressure inside nitrogen gas chamber (A)
expands the bladder, and the oil in chamber
(B) operates the work equipment valve as the
pilot pressure.
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas: Nitrogen gas
Amount of gas: 500 cc
Max. operating pressure: 3.92 MPa {40 kg/cm2}
Min. operating pressure: 0 MPa {0 kg/cm2}
Function
q Accumulator is installed between the charge
valve and work equipment valve. In the case
the engine is stopped with the lift arm lifted up,
compressed nitrogen gas pressure in the accu-
mulator feeds the pilot oil pressure to the work
equipment valve for operation. Thus the lift
arm and bucket are enabled to descend under
own weight.
32 WA500-6R
Work equipment electric lever 1
WA500-6R 33
1. Lever 11. Seat

2. Rod 12. Ball
3. Centering spring 13. Detent spring
4. Metering spring 14. Rod
5. Nut 15. Body
6. Rod 16. Solenoid
7. Detent spring 17. Bushing
8. Retainer 18. Body
9. Lever 19. Retainer
10. Potentiometer 20. Rod
34 WA500-6R
Function
q When lever (1) is operated, rod (20) moves up
and down and rotates potentiometer (10)
according to the operating distance of the
lever.
q The operating angle (stroke) of the control
lever is sensed with the potentiometer and out-
put as a signal voltage to the controller.
q A potentiometer is installed, and it outputs 2
signal voltages which are opposite to each
other as shown in “Lever stroke - voltage”
characteristics.
Operation
When work equipment control lever is operated

q Rod (20) is pushed up by spring (4) according
to the operating distance of lever (1).
q Lever (9) and rod (14) installed to the rotary
shaft of potentiometer (10) are connected to
each other.
q Potentiometer (10) outputs signal voltage
according to the vertical stroke of the rod.
When work equipment is operated to “lift arm

lower” (or to “lift arm raise” or “bucket tilt”)
q If rod (2) on the “lift arm lower” side is pushed
down by lever (1), ball (12) touches projection When “lift arm lower” operation of work equip-
(a) of rod (14) in the middle of the stroke
ment control lever is reset
(before electric detent operation starts).
q If rods (2) and (14) are pushed in further, ball q Lever (1) is returned from the “lift arm lower”
(12) pushes up retainer (8) supported on position by pushing down rod (20) with a force
detent spring (7) and escapes out to go over larger than the attractive force of the solenoid.
projection (a) of rod (14). The “lift arm lower” state also can be reset and
q At this time, rod (20) on the opposite side is lever (1) can be returned to the neutral position
pushed up by spring (4). by turning off the current in solenoid.
q If rod (20) is pushed up while the current is
flowing in solenoid (16), nut (5) is attracted by
bushing (17).
q Accordingly, rod (20) is kept pushed up and the
“lift arm lower” state is kept even if the lever is
released.
WA500-6R 35
SEN02895-00

© 2007 KOMATSU
All Rights Reserved
36
SEN02896-01
WA500-6R

WA500-6R 60001 and up

Work equipment
Work equipment linkage ................................................................................................................................. 2
Bucket ............................................................................................................................................................. 6
Bucket positioner and boom kick-out .............................................................................................................. 8
Work equipment lubrication ............................................................................................................................ 9
Work equipment cylinder ...............................................................................................................................11
WA500-6R 1
Work equipment linkage 1
1. Bucket 6. Bucket link

2. Bell crank 7. Bucket hinge pin
3. Bucket cylinder 8. Bucket hinge pin
4. Lift cylinder 9. Bell crank pin
5. Lift arm 10. Cord ring
2 WA500-6R
WA500-6R 3
4 WA500-6R
Unit: mm
Standard Standard
Tolerance Clear-
size clear-
Clearance between bushing and pin at each ance limit
1 Shaft Hole ance
end of bucket link
–0.036 +0.307 0.256 –
120 1.0
–0.090 +0.220 0.397
Clearance between bushing and pin con- –0.036 +0.307 0.256 –
2 120 1.0
necting lift arm and bucket –0.090 +0.220 0.397
3 140 1.0
necting lift arm and frame –0.106 +0.295 0.501 Replace
Clearance between bushing and pin con- –0.043 +0.395 0.338 – [Replace if pin
4 125 1.0 has scuff mark]
necting bucket cylinder bottom and frame –0.106 +0.295 0.501
5 125 1.0
necting bucket cylinder rod and bell crank –0.106 +0.295 0.501
6 160 1.0
necting bell crank and lift arm –0.106 +0.295 0.501
7 120 1.0
necting lift cylinder bottom and frame –0.090 +0.220 0.397
8 120 1.0
necting lift cylinder rod and lift arm –0.090 +0.220 0.397
Standard
Boss to boss clearance
Connecting part of bucket cylinder and Width of hinge
9 width (Clearance of
frame a+b)
153 150 3.0
10 Connecting part of lift arm and frame 183 180 3.0 Adjust
11 Connecting part of lift arm and bucket 183 180 3.0 [Insert shims to
12 Connection of bucket link and bucket 183 180 3.0 both sides so that
clearance will be
Connecting part of bell crank and bucket below 1.5 mm on
13 183 180 3.0
link each side]
14 Connecting part of lift cylinder and frame 153 150 3.0
15 Connecting part of bell crank and lift arm 316 313 3.0
Connecting part of bucket cylinder and bell
16 155 150 5.0
crank
17 Connecting part of lift arm and lift cylinder 153 150 3.0
WA500-6R 5
Bucket 1
3
Bucket 5.6 m (with Bolt-on cutting edge)
1. Bucket
2. Bolt-on cutting edge (BOC)
Unit: mm
3 Wear on edge Turn over or replace
38 15
6 WA500-6R
Bucket 5.2 m3 (with teeth and segment edge)
Unit: mm
1 Wear on bucket teeth Replace
38 23
Clearance in bucket tooth mount-
2 Max. 0.5 (Clearance between edge) Adjust or replace
ing parts
3 Wear on segment edge 38 15 Turn over or replace
WA500-6R 7
Bucket positioner and boom kick-out 1
Unit: mm
1 Clearance of bucket positioner switch 3–5
Clearance of lift arm position detection Adjust
2 0.5 – 1
switch
8 WA500-6R
Work equipment lubrication 1
1. Steering cylinder A: Lift cylinder pin left

2. Bell crank B: Lift cylinder pin right
3. Lift arm C: Bucket cylinder (bottom side)
4. Bucket cylinder D: Lift cylinder (bottom side) right
5. Front frame E: Lift cylinder (bottom side) left
6. Lift cylinder F: Steering cylinder (rod side) right
7. Rear frame G: Steering cylinder (rod side) left
H: Center support
WA500-6R 9
J: Rear axle (thrust plate)

K: Rear axle mount (rear)
L: Rear axle mount (front)
10 WA500-6R
Work equipment cylinder 1

Lift cylinder
Bucket cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance
1 between piston -0.036 +0.263 0.084 - Replace bushing
Lift 120 0.653
rod and bushing -0.090 +0.048 0.353
-0.036 +0.263 0.084 -
Bucket 120 0.653
-0.090 +0.048 0.353
Tightening torque Lift 529.7 ± 78.5 Nm {54.0 ± 8.0 kgm}
2
of cylinder head Bucket 892 ± 137 Nm {91.0 ± 14 kgm}
Tightening torque Lift 294 ± 29.4 Nm {30 ± 3.0 kgm}
3 Retighten
of cylinder piston Bucket 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque Lift 58.9 - 73.6 Nm {6.0 - 7.5 kgm}
4 of cylinder piston
lock screw Bucket 58.9 - 73.6 Nm {6.0 - 7.5 kgm}
WA500-6R 11
SEN02896-01

© 2010 KOMATSU
All Rights Reserved
12
SEN02897-00
WHEEL LOADER
1SHOP MANUAL
2SHOP MANUAL
WA500-6R

WA500-6R 60001 and up

Cab and its attachments
ROPS cab ....................................................................................................................................................... 2
Air conditioner ................................................................................................................................................. 4
WA500-6R 1
ROPS cab 1
1. Front glass
2. Front wiper
3. Door
4. Rear wiper
2 WA500-6R
WA500-6R 3
Air conditioner 1
Air conditioner piping diagram
1. Air outlet duct Specifications

2. Air conditioner unit
Refrigerant used R134a
3. Compressor
4. Receiver Refrigerant refilling volume (g) 1,250 ± 50
5. Condenser
6. Hot water take-out port
7. Hot water return port
4 WA500-6R
Cooling circuit diagram
WA500-6R 5
Air conditioner unit
A: Hot water outlet

B: Hot water inlet
C: Refrigerant inlet side
D: Refrigerant outlet side
6 WA500-6R
Condenser
1. Fin Function
2. Tube q It cools and liquefies the high-pressure and
high-temperature misty refrigerant from the
A: Refrigerant gas outlet port compressor.
B: Refrigerant gas inlet port
a If the fin crushes or is clogged with dusts, heat
exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.
Specifications
Fin pitch (mm) 1.5
2
Total heat dissipation surface (m ) 6.55
2
Max. pressure used (MPa {kg/cm }) 3.6 {36}
WA500-6R 7
Compressor
1. Case Function
2. Clutch q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
A: Suction service valve tor to high-pressure, high-temperature misty
B: Discharge service valve refrigerant so that it may be easily regenerated
(liquefied) at normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinders – Bore x Stroke
5 – 35 x 28.6
(mm)
Piston capacity
138
(cc/rev)
Allowable maximum speed
4,000
(rpm)
Refrigerant oil used Sanden: SP-20
Refrigerant oil refilling volume

175
(cc)
8 WA500-6R
Receiver 1
A : From condenser Function

B : To air conditioner unit q It is used to store liquefied high-pressure, high-
temperature misty refrigerant from the con-
1. Sight glass denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspecting flow of the
refrigerant.
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
WA500-6R 9
Air conditioner panel 1
Manual air conditioner specification
Display unit
Display Display
No. Displayed items Display range Display method Remarks
category color
Spurting out See above All segments below applicable level come on
1
temperature figure (8-step display)
Gauges
Air blasting See above All segments below applicable level come on
2
volume figure (4-step display)
Circulation of When circulating The display indicates which is currently taking Liquid
internal air and internal air and place – internal air circulation or external air Black
3 crystal
introduction of introducing introduction – responding to the operation of
Pilot external air external air the internal/external air changeover switch.
When air condi-
Turns “ON” air conditioner switch, this lamp
4 Air conditioner tioner switch is
lights up.
turned “ON”
Switch block
No. Type Function Operation
It is used for selecting the internal air circulation or external air
Internal air circulation
Internal/external air introduction
5 I O
changeover switch (The pilot indication on the display unit varies depending on the
External air introduction
given setting.)
It turns on or off the cooling and the dehumidifying heating func-
6 Air conditioner switch OFF i o ON
tion.
This switch turns on or off the main power of the air conditioner.
ON: Display unit indicates the setting being specified when
7 Main power switch OFF i o ON
power was turned “OFF”.
OFF: Turns off the display unit and stops the fan.
It controls volume of air sent from the fan.
8 Fan switch LO i o HI
(Adjusted in 4 steps [LO, M1, M2, HI])
Low temperature
Temperature adjusting It is used to control spurting out temperature.
9 I O
switch (8-step adjustment)
High temperature
10 WA500-6R
Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
Input and output signals

JAE IL-AG5-14P [CN-C48] JAE IL-AG5-22P [CN-C47]
Input and Input and
Pin No. Signal name output sig- Pin No. Signal name output sig-
nals nals
1 GND — 1 NC —
2 Sensor ground — 2 NC —
Internal/external air changeover damper 3 Blower motor relay Input
3 Input
actuator limiter
Internal/external air changeover damper
4 Output
4 External air temperature sensor Input actuator output 1
5 Evaporator temperature sensor Input Internal/external air changeover damper
5 Output
actuator output 2
6 Internal air temperature sensor Input
6 Mode selector actuator output 2 Output
7 Starting switch (ON) Input
7 Mode selector actuator output 1 Output
8 Night lamp signal Input
8 Air mix damper actuator output 2 Output
9 NC —
10 NC — 9 Air mix damper actuator output 1 Output
11 NC — Actuator potentiometer power supply

10 —
(5 V)
12 NC —
11 NC —
13 Day light sensor 2 Input
12 NC —
14 Day light sensor 1 Output
13 NC —
14 NC —
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
18 Air mix damper actuator potentiometer Input
19 Mode selector actuator potentiometer Input
20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground —
WA500-6R 11
SEN02897-00

© 2007 KOMATSU
All Rights Reserved
12
SEN02898-02
WA500-6R

WA500-6R 60001 and up

Electrical system, Part 1
Machine monitor system ................................................................................................................................. 2
Machine monitor ........................................................................................................................................... 10
WA500-6R 1
Machine monitor system 1

Outline
q In the machine monitor system, each monitor 4. In addition to the above, the following can be
on the network monitors and controls the displayed, set, and adjusted by using the char-
machine condition with the sensors installed to acter display and the machine monitor mode
various parts of the machine, and then sends selector switch which is the operation switch of
the result as network information to the the character display.
machine monitor, which displays the informa-
tion to notify the operator of the machine condi- 1) Load meter (If equipped)
tion. q Loaded/no loaded calibration
q Reset of calibration
q The machine monitor displays the information q Display/non-display of load meter
in the normal mode or service mode. q Printer output format (printer (if equip-
ped))
q The normal mode is used to display the infor- 2) Display of odometer
mation to the operator normally. The major 3) Reset of filter oil replacement time
items displayed in this mode are as follows. 4) Input of telephone number
5) Selection of language
1. Items always displayed 6) Adjustment of brightness of the night light-
q Meters (Speedometer or engine tachome- ing for the machine monitor
ter) 7) Adjustment of time of clock (Load meter (if
q Gauges (Engine coolant temperature equipped))
gauge, torque converter oil temperature 8) Selection of travel speed and engine
gauge, hydraulic oil temperature gauge, speed display
and fuel level gauge) 9) Function to display/non-display of travel
q Pilot indicators speed and engine speed on the character
q Service meter display
The following is displayed according to setting

condition of optional device.
q Load meter calculated weight
q Hours
q Display of travel speed/engine speed on
the character display
2. Items displayed when abnormality is detected

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

character display displays that filter or oil.
(Maintenance monitoring function)
2 WA500-6R
q The service mode function is used for the ease 9. Function of selecting optional device
of troubleshooting for the controllers on the Information of the controller to be used and
network (including the machine monitor itself). optional device are selected.
The major functions used in the service mode
are as follows. 10. Input of machine serial number (No.)
Enter the machine serial number to specify the
1. Display of electrical system failure history machine.
The electrical system failures of each controller
saved in the machine monitor are displayed. 11. Model selection function
The information of those failures is deleted Enter the information of applicable model.
with this function, too.
12. Initialize
2. Display of mechanical system failure history This function is used to set the machine moni-
The mechanical system failures of each con- tor to the state set when delivered.
troller saved in the machine monitor are dis-
played.
3. Real-time monitor
The input and output values recognized by
each controller on the network are displayed in
real time.
4. Reduced-cylinder mode
This function is used to stop fuel injection by
cylinder and specify the cylinder having defec-
tive fuel by shutting off fuel injected from the
fuel injector.
5. No injection cranking
This function is used when lubricating the
engine with the engine stopped when restart-
ing it after a long time of non-operation.
6. Adjustment function
The installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
are corrected and adjusted, and control char-
acteristic data is changed upon request of the
user.
7. Maintenance monitor
The filter and oi l replacement period is
changed and its function is stopped.
8. Operating information display function

Fuel consumption per operating hours is dis-
played.
WA500-6R 3
Each circuit of machine monitor
Starting and lighting
4 WA500-6R
Load meter
WA500-6R 5
Sensing
6 WA500-6R
Power supply and network
WA500-6R 7
Machine monitor electrical circuit diagram
8 WA500-6R
WA500-6R 9
Machine monitor 1
1. Torque converter oil temperature gauge 28. Battery charge circuit caution lamp
2. Torque converter oil temperature caution lamp 29. Steering oil pressure caution lamp
3. Engine coolant temperature gauge 30. Emergency steering pilot lamp
4. Engine coolant temperature caution lamp 31. Output mode pilot lamp (Power mode)
5. Speedometer or engine tachometer 32. Preheater pilot lamp
6. Display of the unit of speedometer or engine 33. Semi auto digging pilot lamp
tachometer 34. Auto-grease pilot lamp (If equipped)
7. Turn signal pilot lamp (Left) 35. Joystick pilot lamp (If equipped)
8. Head lamp high beam pilot lamp 36. Directional selector pilot lamp (Not used)
9. Turn signal pilot lamp (Right) 37. ECSS pilot lamp
10. Hydraulic oil temperature gauge 38. Economy operation indicator lamp
11. Hydraulic oil temperature caution lamp 39. Shift position pilot lamp (Forward/reverse)
12. Fuel level gauge 40. Shift position pilot lamp (Gear speed)
13. Fuel level caution lamp 41. Shift indicator
14. Central warning lamp 42. Auto-shift pilot lamp
15. Brake oil pressure caution lamp 43. Lockup pilot lamp
16. Engine oil pressure caution lamp 44. Shift hold pilot lamp
17. Water separator caution lamp (Not used) 45. Display of bucket loading (If equipped)
18. Engine oil level caution lamp 46. Addition mode: Total loading display/Reduction
19. Radiator coolant level caution lamp mode: Display of level (If equipped)
20. Parking brake pilot lamp 47. Working object display (If equipped)
21. Air cleaner clogging caution lamp 48. Addition/reduction mode display (If equipped)
22. Transmission oil filter clogging caution lamp 49. Character display
23. Axle oil temperature caution lamp
24. Modulation clutch temperature caution lamp
(Not used)
25. Cooling fan reverse rotation pilot lamp
26. Maintenance caution lamp
27. Battery electrolyte level caution lamp
(If equipped)
10 WA500-6R
1. Load meter display selector switch (if equipped)

q Total mass display
2. Load meter mode selector switch (if equipped)
q Material selection
q Addition/reduction selection
3. Character display mode selector switch
4. Character display item selector switch
WA500-6R 11
List of items displayed on monitor

During starting the engine, the monitor checks if:
1. Starting motor switch ON has been recorded.
2. Charge level is min. the specified value or more.
3. Engine speed is the specified value (500 rpm) or more
At least two items above are satisfied, or CAN communication error (transmission controller:
DAQRKR) or (engine controller: DB2RKR) and charge level are the specified values or more.
Q: Lighting
w: Flashing (1.6 sec., 50% duty)
A: Intermittent (Period: 240 msec., “ON“: 80 msec., “OFF“: 160 msec.)
E: As per separate setting condition
Operating condition: Engine operating
condition included, error detection time Operating state
counted (As indicated at right)
Signal detection controller

Detec-
tion time Engine: Stopped Engine is running
Display color
(SEC)
Category
No. Item Device Remarks
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Lights when error (E03, E02)
Central warning lamp
occurs on each controller and at
Red
When error is made E E E E E E E E E
the same time displays mes-
sage.
14 Central warning lamp LED
Other than above, see “Oper-
ating condition – Central
— — — — — — — —
warning lamp” column of rele-
vant items.
For night Back light:
White
Back light
Back
light
— lighting of When small lamp is turned — — — — — — Monitor

(various back lights)
LED ON
Indicates “0” if error is made
Switchable to speedmeter
in communication other than
The first digit is fixed at 0.
Engine speed Fixed LCD when engine speed is — — — — — — — Engine
Number of display digits (4-dig-
selected or tilt positioner set
its): 0 – 3990
angle is displayed.
Other than when engine Switchable to tachometer
speed is not selected and tilt Number of display digits (4-dig-
Travel speed Fixed LCD — — — — — — — TM
positioner set angle is dis- its): 0 – 99 (middle 2 out of 4
played digits are used.)
Switching between speedome-
ter/tachometer
Displayed just 3 seconds when
instruction is given from work
When tilt positioner set angle
equipment controller.
is displayed.
Number of display digits is 1-
Gauges and meters
Tilt positioner set position

Fixed LCD — — — — — — — BBC digit (–5 to 5) (middle 2 out of 4-
display Lamp does not light up when
digits are used, unit is not dis-
error is made in communica-
played).
5 tion.
Operation completion sound
(short beep) and cancel sound
(long beep sound) are given
simultaneously.
Alarm is issued when infor-
mation of “Overrun preven-
Overrun prevention
tion (in lockup release o
Remarks
Remarks
(when lockup release o

Fixed LCD torque converter mode) alarm w Q w Q — TM
w
torque converter mode)

notice” is obtained from
alarm notice
transmission controller, and is
kept at least 3 minutes.
Note)
Alarm is issued when infor-
mation of “Overrun preven-
Overrun prevention
tion (in lockup release o
Remarks
Remarks
(in lockup release o

Fixed LCD torque converter mode) alarm w Q w Q — TM
w
torque converter mode)

detecting” is obtained from
alarm
transmission controller, and is
continued at least 3 minutes.
When engine speed is
— — — r/min — — r/min — —
selected
When speed [km/H] is
— — — km/h — — km/h — — Monitor
selected
Unit
6 Unit display LCD

When speed [MPH] is
— — — MPH — — MPH — —
selected
When tilt positioner set angle
— — — — — — — BBC
is displayed
Note 1)
Central
Main part
warning Buzzer Message
(*1)
lamp
Overrun notice Q w w (flashing) —
Overrun Q w w (flashing) Overrun prevention
(*1) When the engine speed is displayed on the center LCD, the display flashes.
When the travel speed is displayed, it is switched to the engine speed and
the display flashes.
12 WA500-6R
Operating condition: Engine operating

condition included, error detection time Operating state
counted (As indicated at right)

Detec-
Engine: Engine is run-
tion time
Display color
Stopped ning
(SEC)
Category
No. Item Device Remarks
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Torque converter Pointer:
1 — — — — — — — — —
oil temperature Movement MAX position: 135°C
Red zone start point: 120°C
DGT1KX B@CENS (b@CENS)
DGT1KX B@CENS (b@CENS)

Alarm: Min. 120°C and [No Level: 110°C
Red
abnormality is detected 10 1 — Q — — Q — 1/4 of full scale: 80°C
(See figures
(DGT1KX is not generated)] Min. position 50°C
below.)
When sensor is grounded: Max.
Torque converter Monitor of gauge
Indicator: Alarm: Min. 130°C and [No
2 oil temperature When sensor is disconnected or
Red
LED abnormality is detected 10 1 w Q Q w Q Q
caution lamp hot shorted: Min. of gauge
(DGT1KX is not generated)]
When abnormality is
Red
20 5 — — — — — — b@CENS does not display character message.
detected
Engine coolant Pointer:

3 — — — — — — — — —
temperature Movement
Alarm: Min. 102°C and [No
abnormality is detected
Red
3 — Q — — — Q — —
(CA144 and CA145 are not
generated)]
MAX position: 135°C
Operation of gauges and meters
CA145 CA144 B@BCNS
CA145 CA144 B@BCNS

Engine (See figures Level: 85°C
Red
Engine coolant
Indicator: Alarm: Min. 105°C w Q Q w Q Q monitor below.) 1/4 of full scale: 65°C
4 temperature cau- Min. position: 50°C
LED
tion lamp
When abnormality is
— — — — — —
detected
When abnormality is
— — — — — —
detected
Hydraulic oil tem- Pointer: Max. position: 125°C
10 — — — — — — — — —
perature Movement Red zone start point: 100°C
Level: 85°C (green graduations
DGH2KX B@HANS
DGH2KX B@HANS
Alarm: Min. 100°C and [No only)

Red
abnormality is detected 10 1 w Q Q w Q Q 1/4 of full scale: 65°C

(DGH2KX is not generated)] (See figures
Hydraulic oil tem- Monitor (green graduations only)
Indicator: below.)
11 perature caution Min. position: 50°C
LED When sensor is grounded: Max.
lamp
When abnormality is of gauge
20 5 — — — — — — —
detected When sensor is disconnected or
hot shorted: Min. of gauge
Pointer: MAX position: 100%: 10z
12 Fuel level — — — — — — —
Movement 3/4 of full scale: 75%:
Level: 50%: 32z
1/4 of full scale: 25%: 49.5z
Red zone start point:
(See figures See specified LED lighting per-
Monitor
Fuel level caution Indicator: below.) cent or resistance.
Red
13 Min. 61.3 z 10 1 — Q — — Q — Min. position: 0%: 85z

lamp LED
When sensor is disconnected or
hot shorted: Gauge EMPTY
When sensor is grounded:
Gauge FULL
WA500-6R 13
Operating condition: Engine operating condition

included, error detection time counted (As indi- Operating state

cated at right)
Detec-
Engine: Engine is
tion time
Display color
(SEC) Stopped running
Category
Device
Display of message
Display of message
No. Item Remarks
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
[When F is selected] and [Engine is
1 0 A Q Q — — — Green
stopped]
[When R is selected] and [Engine is
1 0 A Q Q — — — Green
stopped]
When F is selected 0 0 — Q — — Q — Green
When N is selected 0 0 — Q — — Q — Green
39 Shift position When R is selected 0 0 — Q — — Q — Green Monitor
LED
40 pilot lamp TM
When 4th gear speed is selected 0 0 — Q — — Q — Green
When 3rd gear speed is selected 0 0 — Q — — Q — Green
When 2nd gear speed is selected 0 0 — Q — — Q — Green
When 1st gear speed is selected 0 0 — Q — — Q — Green
Actual gear speed
If error is made in communication, display

— — — — — — —
is held until key is turned OFF.
Displayed on right of [Gear speed display].
Upper line: F, N, R
Interlocked with shift valve. In neutral, how-
9-segment Lower line: 1, 2, 3, 4
41 Shift indicator 0 0 — — — — — — — TM ever, gear speed is not displayed.
LCD If error is made in communication, display
Displayed on left of [FNR display].
N when F or R solenoid valve is OFF.
When auto-shift is selected 0 0 — Q — — Q — Green
Auto-shift
42 LED If error is made in communication, display
pilot lamp — — — — — — Green
When auto-shift and shift hold are
0 0 — Q — — Q — Green
Shift hold selected
44 LED
pilot lamp If error is made in communication, display
— — — — — — —
When lockup functions 0 0 — — — — Q — Green
Lockup pilot
43 LED If error is made in communication, display
lamp — — — — — — —
Functions when key is OFF to provide haz-
7 Turn signal When turn signal switch is input
LED 0 0 — Q — — Q — Green Monitor ard function interlocking with turn signal
9 pilot lamp (including when key is OFF)
switch.
Head lamp
When high beam is functioning: Head
8 high beam LED 0 0 — Q — — Q — Blue Monitor
lamp ON and High beam ON
pilot lamp
Normal oil pressure (CLOSED) — — — — — — —
2G43ZG 2G42ZG
Below specified value (F) (OPEN)

(detection time is continued) and in 45 5 1 — Q — w Q Q Red Front
seconds after engine is started
Below specified value (R) (OPEN)
(detection time is continued) and in 45
5 1 — Q — w Q Q Red Rear
seconds after engine is started
(No detection time)
Below specified pressure (F) (OPEN)
Brake oil (detection time is continued) and 45 sec-
15 pressure cau- LED onds after engine is started Monitor
tion lamp (No detection time) 1 1 — Q — w Q Q Red Front
* When engine is stopped, condition of
“45 seconds after engine is started” is not
applied.
Others
Below specified pressure (R) (OPEN)

(detection time is continued) and 45 sec-
onds after engine is started
(No detection time) 1 1 — Q — w Q Q Red Rear
* When engine is stopped, condition of
“45 seconds after engine is started” is not
applied.
At normal operation — — — — — — — —
Engine oil
B@BAZG
B@BAZG
16 pressure cau- LED Engine oil pressure reduction error is Engine

tion lamp w Q Q w Q Q Red
received
Normal oil level (CLOSED) — — — — — — —

If alarm is detected when key is turned ON,
Engine oil Low oil level (OPEN) continues 2 sec-
B@BAZK
first information is kept until engine oil

18 level caution LED onds. Monitor
lamp 2 1 — Q — — — — Red reaches normal oil level even if engine is
For 300 seconds after engine is stopped, started.
however, no error is detected.
Normal coolant level (CLOSED) — — — — — — —
Radiator
B@BCZK
B@BCZK
19 coolant level LED Monitor

caution lamp Low coolant level (OPEN) 30 1 — Q — — Q — Red
14 WA500-6R


cated at right)
Detec-
Engine: Engine is
tion time
Display color
Category
Device
Display of message
Display of message
No. Item Remarks
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
When parking brake is applied (OPEN) — Q — — Q — Red
When parking brake is not applied
Parking — — — — — — —
(CLOSED)
20 brake pilot LED Monitor
lamp Other than when parking brake is applied
and gear shift lever is at “N” position, and 0 0 A Q Q Red
during starting engine
Normal (CLOSED) — — — — — — —
Air cleaner
AA1ANX
21 clogging cau- LED Monitor
Sensor detects clogging (OPEN) 2 1 — — — — Q — Red
Others
tion lamp
Normal (CLOSED) — — — — — — —
15BONX
Clogging (OPEN) and torque converter
Transmis- 2 1 — — — — Q — Red
oil temperature > 50°C If abnormality is detected while engine is
sion oil filter
22 LED Monitor stopped, alarm is continued even after
clogging cau-
DHT2L6
engine is started.
tion lamp OFF
When abnormality is detected 3 — — — — — — —
— — — — — — Red
Other than below — — — — — — — — —
Temperature increase (Min. 120°C)
5 5 — Q — — — Q — — Red
(notice alarm)
Temperature increase (1 or 2 below)
1. Oil temperature is above 130°C for 5
seconds.
B@C7NS
B@C7NS
2. When travel speed is above 35 km/h
while brake oil temperature, 125°C and 5 5 w Q Q w Q Q Red
Axle oil tem- above, is detected continuously for 5 sec-
23 perature cau- LED onds. It is released when oil temperature, Monitor
tion lamp 125°C and below, is detected continu-
ously for 5 seconds.
DGR2KX DGR2KA
DGR2KX DGR2KA
When abnormality is detected — — — — — — —
When abnormality is detected — — — — — — —
Cooling fan forward drive 0 0 — — — — — — — —

As indicated at right
As indicated at right
Cooling fan reverse rotation state is dis-

Cooling fan
played.
reverse rota- Trans-
25 LED Cooling fan reverse rotation 0 0 — Q — — Q — Orange While fan is reversed, message is dis-
tion pilot mission
played on character display.
lamp
COOLING FAN REVERSE ROTATION
Others
Fan switch and solenoid disagree. 0 0 — w — — — w — — Orange

Simultaneously displays contents on mes-
Ordinary — — — — — — —
Maintenance sage display.
26 LED Monitor
caution lamp 30 h or less before maintenance or main-
— Q — E — Q — E Red
tenance time
Normal — — — — — — —
B@GAZK
B@GAZK
Battery elec-
27 trolyte level LED Sensors: Less than 2 V 10 1 — Q — — — Red Monitor
caution lamp
Option is not applied — — — — — — If abnormality is detected while engine is

Normal voltage (hysteresis on the right stopped, alarm is continued even after
— — — — — — —
figure) engine is started.
Insufficient alternator voltage See figures on alternator terminal R volt-
AB00MA
Battery age.
(Hysteresis on the right figure), no start-
charge cir- 30 1 — — — w Q Q Red
28 LED ing motor C signal input, and during run- Monitor
cuit caution ning of engine
lamp
AB00L6
When abnormality is detected 3 1 w Q Q — — — Red
Not in operation — — — — — — — — — —
Steering oil In operation (CN3-3 = OPEN) — — Q — — Q — Red Implemented only when “Emergency steer-
DDE5MA
DDE5MA
29 pressure cau- LED Monitor ing enabled” is specified on optional setting

tion lamp When abnormality is detected — — — — — — — on monitor panel.
WA500-6R 15


cated at right)
Detec-
Engine: Engine is
tion time
Display color
Category
Device
Display of message
Display of message
No. Item Remarks
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Normal operation
Emergency [Operation of divider
1 1 — Q — — Q — Green
30 steering pilot LED (= Below S/T pressure CN3-3=OPEN)] Monitor
lamp and [Travel speed, min. 1 km/h]
Holds in position — — — — — —
Output mode Power mode = P 0 0 — Q — — Q — Green
pilot lamp Trans-
31 LED Selection of power mode is displayed.
(power Power mode = Other than P — — — — — — — — mission
mode)
Preheating Other than below — — — — — — —
32 LED Engine
pilot lamp In preheating (with signal) 0 0 — Q — — Q — Red
Semi auto When auto digging switch is OFF — — — — — — —
33 digging pilot LED When auto digging switch is ON 0 0 — Q — — Q — Green BBC
lamp When error is made in communication — — — — — — —
Not in operation and not installed — — — — — — —
Operation 1 1 — Q — w 2 Hz w 1 Hz — Q — Green Status: Port A: Port B: Panel display
w 2 Hz w 1 Hz
Operation: 0 V: 24 V: Lighting
Auto grease Empty tank 3 1 — — — — Green Monitor Abnormality: 0 V: 0 V: Flashing, 2 Hz
34 LED
pilot lamp
Empty tank: 24 V: 0 V: Flashing, 1 Hz
Abnormality: 24 V: 24 V: OFF
Abnormal 3 1 — — — — Green
Option is not applied — — — — — — — — —

Operation of steering wheel — — — — — — — — Monitor —
Operation of joystick system only when Trans- CAN input signal from transmission con-
0 0 — Q — — — Q — — Green
joystick optional setting is made. mission troller
Joystick lever neutral lock (Output from CAN input signal from work equipment
0 0 A w Q — A w Q — Green BBC
work equipment controller) controller
Operation of FR prohibition function dur-
Trans- CAN input signal from transmission con-
Others
Joystick pilot ing locking of joystick steering only when 0 0 A w Q — A w Q — Green

35 LED mission troller
lamp joystick optional setting is made.
Key ON and transmission controller in
CAN input signal from work equipment
other than N (joystick) only when joystick 0 0 A w Q — A w Q — Green BBC
controller
optional setting is made.
FNR lever priority caution (only machine
equipped with steering wheel and joy- Trans- CAN input signal from transmission con-
1 0 A w Q A w Q — Green
stick) only when joystick optional setting mission troller
is made.
When error is made in communication — — — — — — —
If Option not equipped — — — — — — —
When column gear shift is used — — — — — — —
When right FNR switch is used (In see-
saw switch mode)
0 0 — Q — — Q — Green
(Only when right FNR switch optional set-
ting is made)
Directional
FNR lever priority caution Trans-
36 selector pilot LED
lamp (Only when right FNR switch optional set- 0 0 A w Q — A w Q — Green mission
ting is made)
Right FNR switch neutral caution
(DDK3KM)
0 0 A w Q — A w Q — Green
(Only when right FNR switch optional set-
ting is made)
Error is not made in communication. — — — — — — —
Economy Economy mode 0 0 — Q — — Q — Green
operation Trans-
38 LED
indicator Other than above 0 0 — — — — — — — mission
lamp
Not operated — — — — — — —
ECSS pilot Trans-
37 LED Operating 0 0 — Q — — Q — Green
lamp mission
When error is made in communication — — — — — — —
Priority of sounding of buzzer: Continual (w) > Intermittent (A) > Cancellation of operation > Check of acceptance of operation.
16 WA500-6R
Character display function
Using the character display function, you can change the display and settings on the machine monitor.
For usage of functions for the operator, see the Operation and Maintenance Manual.
The operator can operate the part “Operator disclosure function” below.
(*1) Once you pass on the ID input screen, you can directly move to the function selection screen without
displaying this screen until the starting switch is turned OFF.
WA500-6R 17
Operator mode self-check function
Self-check (0th layer) Normal screen (1st layer)

The self-check function operates 3 seconds after After the self-check, the following screen is auto-
the key is turned ON. matically displayed.
After the key ON, it automatically starts and ends Press the U switch to move to the 2nd layer.
the self-check function operation.
After 3 seconds, you are brought to the 2nd layer
automatically.
In self-check mode, the mode switch is disabled.
* The clock is displayed only for the load meter.
Select “Displayed” for “10. Engine speed or travel

speed display on character display and normal
screen” in the optional setting. Then, when the
travel speed is displayed on the LCD at the center
of the monitor, the engine speed is displayed on the
character display.
when the engine speed is displayed on the LCD,
the travel speed is displayed on the character dis-
play.
For machines of SI specification, the travel speed
unit is km/h and for ones of non-SI specification,
the optional setting is conformed to.
18 WA500-6R
Failure code screen (1st layer)

q Pressing the “>” switch when the Warning screen is on display changes display to the Failure code
screen.
q If multiple failure codes are present, each pressing of the “>” switch displays them from the item of
higher priority downward. If items have the same priority, the item that occurred most recently will be dis-
played first
Example of a failure code screen (Simultaneously occurring errors: D191KA, B@BCZK, CA431)
*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec-
onds in the Normal screen display.
*2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the fail-
ure code screen or if a new alarm is turned ON.
*3: Pressing the “>” switch in the Normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.
WA500-6R 19
Operator disclosure function
Function opened to the operator (2nd layer and lower)

q If any switch operation is not done at least 60 seconds on the 2nd layer or lower, you are brought to the
1st layer automatically.
q Optional items are not displayed if not selected.
q The language selected by the language selection function is displayed.
q For operation after selecting each menu, see the corresponding menu item.
(Select each menu using the U switch.)
Function opened to the operator (2nd layer and lower)
(*1) This display is not available when the load meter function was turned off through OPT selection of Ser-
vice Mode.
(*2) This menu is not available when the function to display the travel speed/rpm on the character display is
turned OFF through the option selection of service mode.
20 WA500-6R
Outline of service mode

The service mode function is used for the ease of troubleshooting for the controllers on the network (includ-
ing the machine monitor itself).
When making initial settings and optional settings for the sensors, enter the service mode of the machine
monitor.
Operating method of machine monitor

1. Entering the service mode
1) Operating method
1] Turn the starting switch of the machine ON to power the machine monitor.
2] When the normal service meter screen or alarm screen is on the character display of the
machine monitor, press the machine monitor mode selector switches 1 (t) and 2 (<) simulta-
neously for 5 seconds. Then, the INPUT ID screen is displayed.
Machine monitor display selector switch 1 and 2 2) How to input ID

1] Press the < or > switch. Then, the
value at the cursor position increases
or decreases at the cursor position.
Select a desired value using the U
switch.
2] Completing operations equivalent to 4
digits (1) brings you to the ELECTRIC
FAULT screen.
a If you input an incorrect value,
press t switch to return the cur-
sor to the highest-order digit, and
re-enter values from there.
a If you press the t switch while
the cursor is at the highest-order
INPUT ID screen
digit, the normal service meter
screen or alarm screen is
returned.
a If any switch operation is done at
least 60 seconds during the ID
input, the normal service meter
screen or alarm screen is
returned.
I D to e nt er th e s er v i c e mo de is
“6491”.
Remarks: If the starting switch is
turned OFF in the service mode, the
normal service meter screen or alarm
screen is returned at the next starting
switch ON.
WA500-6R 21
2. Service mode menu
a The service mode menu shows a different

screen by operating the < or >switch. Select a
target operation menu screen with the switch.
a If you press the U when the following screen
(selection screen) is displayed, the menu
screen/operation screen of each function
appears.
a If you press the t when the following screen
(selection screen) is displayed, the normal ser-
vice meter screen or alarm screen is returned
at the next starting switch ON.
Operation menu screen (character display)

1) ELECTRIC FAULT screen 2) MACHINE FAULT screen
[ ] field displays number of the failure history [ ] field displays number of the failure history
currently recorded (up to 20 cases). currently recorded (up to 20 cases).
Outline Outline
This function is used to check the electrical system This function is used to check the mechanical sys-
failure history of each controller saved in the tem failure history of each controller saved in the
machine monitor. For the failure codes displayed in machine monitor. For the failure codes displayed in
the electrical system failure history, see “Trouble- the mechanical system failure history, see “Trouble-
shooting”. After each failure is repaired and the nor- shooting”.
mal operation is confirmed, delete the failure
history.
22 WA500-6R
3) REAL-TIME MONITOR screen 5) NO INJECTION screen
Outline Outline
This function is used to check the input and output This function is used when lubricating the engine
signals, etc. recognized by each controller on the with the engine stopped when restarting it after a
network. long time of non-operation.
For the starting method of engine using this func-
4) CYLINDER CUT-OUT screen tion, see “Testing and adjusting: No injection crank-
ing operation of engine”.
6) TUNING screen
Outline
This function is used to stop fuel injection by cylin-
der and specify the cylinder having defective com-
bustion by shutting off fuel injected from the fuel Outline
injector. The installation errors and manufacturing disper-
For the method of checking using this function, see sion of the sensors, solenoid valves, etc. are cor-
“Testing and adjusting: Operating engine in reduce rected and adjusted, and control characteristic data
cylinder mode”. is changed upon request of the user. Use this func-
tion if you have changed or added sensors, valves
or controllers. For adjustment using this function,
see “Testing and adjusting: Adjustment performed
on the monitor”.
WA500-6R 23
7) MAINTENANCE MONITOR screen 9) OPTIONAL SELECT screen
Outline Outline
This function is explained in “Operation and Mainte- With this function, you can display installation of an
nance Manual, Operation, Character display, Dis- optional device and change the setting of that
play of replacement periods of filters and oils”. The device. Use this function after any optional device
set replacement periods of a filter and oil are is installed or removed. For the method of setting
changed and their functions are stopped. and changing this function, see “Testing and adjust-
ing: Adjustment performed on the monitor”.
8) OPERATION INFO screen
10) MACHINE No. SET screen
Outline
Fuel consumption per operating hours is displayed. Outline
This function is used to display and set the machine
serial Nos. to control the machines.
24 WA500-6R
11) MACHINE screen
a The lower column displays the currently

selected model.
Outline
This function is used to display or select the
machine model.
12) INITIALIZE screen
Outline
This function is used only in the factory. Do not use
it.
WA500-6R 25
Function of displaying electrical system failure history
1) Display of electrical system failure history and selection of clearing entirely the electrical system failure
history
The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the older ones to the newer ones.
After the oldest saved item, the “Electrical system failure history all clear selected” screen is displayed.
Pressing the t switch changes the screen to the “Electrical system failure history selected” screen.
Pressing the U switch changes the screen to the “Electrical system failure history individual cleared” screen
or the “Electrical system failure history all cleared” screen.
2) Selection of electrical system failure history (1st layer)

Pressing the < switch changes the screen to the “Select initialization” screen.
Pressing the > switch changes the screen to the “Select display of mechanical system failure history” screen.
Pressing the t switch changes the screen to the normal screen or alarm screen.
Pressing the U switch changes the screen to the “Display electrical system failure history” screen.
26 WA500-6R
3) Display of electrical system failure history and the electrical system failure history all clear selected (2nd
layer)
Pressing the t switch changes the screen to the “Display electrical system failure history” screen.
Pressing the U switch changes the screen to the “Display electrical system failure history” screen.
q If there is only 1 history, the current screen does not change to the “Electrical system failure history all
clear” screen (Only the “Electrical system failure history individual clear” screen is displayed).
4) Electrical system failure history individual clear and Electrical system failure history all clear (3rd layer)
Select “YES” or “NO” with the < or > switch.
The cursor “_” blinks on the selected item. If “YES” is selected and the t switch is pressed, clearing is exe-
cuted. If “NO” is selected and the t switch is pressed, clearing is cancelled and the display changes as
shown below.
q If clearing is cancelled (NO), the current screen returns to the “Display electrical system failure history”
screen of the corresponding failure.
(Returns to the screen before the “Electrical system failure history individual clear” (Electrical system
failure history all clear) screen).)
q If clearing is executed (YES), the current screen returns to the “Display electrical system failure history”
screen of the corresponding next failure.
After all the failure histories are cleared, the current screen returns to the “Select electrical system fail-
ure history” screen.
By default, the cursor is on NO (cancel) to prevent resetting by an error.
You cannot delete a failure which has not been reset. At this time, the operation cancel peep (for 1 sec) is
heard.
If any failure history is cleared, the operation acceptance peeps (“ON” for 0.1 sec, “OFF” for 0.1 sec, “ON” for
0.1 sec) are heard.
When clearing of all the histories is selected, if there is any history to be cleared, clearing is assumed to be
completed.
WA500-6R 27
Function of displaying mechanical system failure history
1) Display of mechanical system failure history

Pressing the t switch changes the screen to the “Mechanical system failure history selected” screen.
2) Selection of mechanical system failure history (1st layer)

Pressing the > switch changes the screen to the “Select real-time monitor” screen.
Pressing the < switch changes the screen to the “Select display of electrical system failure history” screen.
Pressing the t switch changes the screen to the normal screen or alarm screen.
Pressing the U switch changes the screen to the “Mechanical system failure history selected” screen.
28 WA500-6R
3) Display of mechanical system failure history (2nd layer)

Pressing the t switch changes the screen to the “Mechanical system failure history selected” screen.
WA500-6R 29
Function of real-time monitor
The real-time monitor function displays the information saved in the controllers mounted on the machine in
real time.
This function is used for testing, adjusting, or troubleshooting the machine.
This function classifies the items and data by the controllers having them, and then displays the results. It
has 2 display modes of the normal display mode and the 2-item display mode for displaying 2 data simulta-
neously.
Operating procedure
1. Hold the t switch and < switch simultaneously for at least 5 seconds to change the screen to the ID
inputting screen.
2. Input the ID with the < and > switches, and then press the U switch to enter the screen for the service
person.
3. Using the < and > switches, display “Real-time monitor selection” screen, and then press the U switch.
30 WA500-6R
4. Press the U switch to display the “Monitor information display/selection” screen.

Pressing the < and > switches selects transmission controller information, engine controller information,
work equipment controller information, and 2 items display function in order.
WA500-6R 31
5. Press the U switch while each selection In display of 2 items mode, input the ID of infor-
screen is displayed, and then the “Display 1 mation to display 2 items simultaneously.
item” screen or “Select 2 items display infor- The ID displayed is the same as the ID number
mation” screen appears. displayed on the “Display 1 item” screen.
6. Items displayed on the “Display 1 item” screen

change in order by pressing < and > switches,
displaying information held by the controller.
***: tem name

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

change in order by pressing < and > switches,
displaying information held by the controller.
How to input ID
“00000” is displayed during screen transition.
Input a value between 0 and 9 at the cursor (_)
position.
First, the cursor appears at the highest-order
digit. Each time the > or < switch is pressed,
the digit changes by 1 between 0 and 9.
Select a desired digit and press the U switch.
The cursor moves to the 2nd position. Select
the digits for the all positions in the same man-
ner as the previous steps.
Input a value at the lowest-order digit and
press the U switch to move to the screen to
select the display of 2nd item.
If you press the t switch during the process-
ing, the screen returns to the “Select 2 items
display information” screen.
32 WA500-6R
WA500-6R 33
List of display contents of the real-time monitor

The state of the controller input and output signals can be checked using the real-time monitor function of the
monitor.
The following table shows the display items and display contents in normal operation of the real-time monitor
in relation to the machine monitor:
No. Item ID No. Display of item Contents of display data Display contents in normal operation Remarks
Monitor software part Part No. of software is dis-
1 20200 VERSION Depends on the software part number
No. played
Application version number is
2 Application version 20221 VERSION (APP) Depends on application version number
displayed
Data version number is dis-
3 Data version 20222 VERSION (DATA) Depends on data version
played
Li: 800 ± 25 rpm
Hi: 2000 ± 50 rpm (P-mode)
4 Engine Speed 01001 ENG SPEED Engine speed is displayed 1900 ± 50 rpm (E-mode)
T/C stall: 1800 ± 100 rpm (P-mode)
1730 ± 100 rpm (E-mode)
F1/R1: 6.7/7.3 km/h ± 5% (P-mode, T/C)
F2/R2: 11.7/12.8 km/h ± 5% (P-mode, T/C)
5 Travel speed 40000 SPEED Travel speed is displayed
F3/R3: 20.3/22.0 km/h ± 5% (P-mode, T/C)
F4/R4: 33.8/37.0 km/h ± 5%(P-mode, T/C)
6 Fuel level 04202 FUEL SENSOR Fuel level is displayed 0 – 100%
Gauge FULL (100%,10 z): 0.32 V When sensor is disconnected or hot
Gauge 1/2 (50%, 32 z): 0.88 V shorted: gauge EMPTY
7 Fuel level 04207 FUEL SENSOR Fuel level is displayed
Caution (61.3 z): 1.45 V When sensor is grounded: gauge
Gauge EMPTY (0%, 85 z): 1.81 V FULL
Coolant temperature, max. 100°C
Engine coolant temper- Coolant temperature is dis-
8 04103 COOLANT TEMP Depends on machine status (°C) Data is obtained from engine con-
ature played
troller.
Torque converter oil Torque converter oil tempera-
9 40100 TC OIL TEMP Depends on machine status (°C) Overheat: 120°C
temperature ture is displayed
When sensor is disconnected or hot
Torque converter oil Torque converter oil tempera- Gauge red zone start point (120°C): 1.62 V shorted: Min. of gauge
10 40101 TC OIL TEMP
temperature ture is displayed (80°C): 2.91 V When sensor is grounded: Max. of
gauge
Hydraulic oil tempera- Hydraulic oil temperature is Hydraulic tank oil temperature: Max.
11 04401 HYD TEMP Depends on machine status (°C)
ture displayed 100°C
When sensor is disconnected or hot
Hydraulic oil tempera- Hydraulic oil temperature is Gauge red zone start point (120°C): 1.62 V shorted: Min. of gauge
12 04404 HYD TEMP
ture displayed (80°C): 2.91 V When sensor is grounded: Max. of
gauge
Brake oil temperature is dis-
13 Brake oil temperature 30202 R BRAKE OIL Depends on machine status (°C)
played
Brake oil temperature is dis- (120°C): 1.62 V
14 Brake oil temperature 30205 R BRAKE OIL
played (80°C) : 2.91 V
15 Charge level 04302 ALTERNATOR R Charge level is displayed Depends on machine status (0.0 – 30 V)
Small lamp voltage is dis-
16 Small lamp voltage 40200 SMALL LAMP Depends on machine status (0.0 – 30 V)
played
Battery electrolyte level Battery electrolyte level is
17 40300 BATTERY A Min. 2 V Only when optional setting is made
A displayed
Battery electrolyte level
18 40301 BATTERY B — — Not used.
B
Standard lift arm
Lift arm top: 46.8 ± 2.0deg
Calculation results of lift arm Lift arm bottom: –42.3 ± 3.0deg
19 Lift arm angle 06001 BOOM ANG
angle is displayed Hi lift arm
Lift arm top: 49.3 ± 2.0deg
Lift arm bottom: –40.5 ± 3.0deg
Standard lift arm
Lift arm top: 3.80 ± 0.3 V
Input voltage value to lift arm
Lift arm bottom: 1.33 ± 0.5 V
20 Lift arm angle 06003 BOOM ANG angle sensor potentiometer is
Hi lift arm
displayed
Lift arm top: 3.87 ± 0.3 V
Lift arm bottom: 1.38 ± 0.5 V
(When arm is placed horizontally at
Lift arm bottom pres- BOOM BTM Lift arm bottom pressure is
21 40400 Depends on status rated loading and Hi lift arm opera-
sure PRESS displayed
tion lever at FULL): Approx. 18 MPa
(0MPa) : 0.5V
Lift arm bottom pres- BOOM BTM Lift arm bottom pressure is (10MPa): 1.3V
22 40402
sure PRESS displayed (20MPa): 2.1V
(50MPa): 4.5V
Only when optional setting is made
in load meter
BOOM HEAD Lift arm head pressure is dis-
23 Lift arm head pressure 40500 Depends on status (When arm is placed horizontally at
PRESS played
rated loading and Hi lift arm opera-
tion lever at FULL): Approx. 0.5 MPa
(0MPa) : 0.5V
BOOM HEAD Lift arm head pressure is dis- (10MPa): 1.3V Only when optional setting is made
24 Lift arm head pressure 40501
PRESS played (20MPa): 2.1V in load meter
(50MPa): 4.5V
Lift arm differential pressure
corresponding to no load
25 Calibration pressure 40600 CAL PRESS — Not used.
around level position at load
meter calibration
34 WA500-6R
No. Item ID No. Display of item Contents of display data Display contents in normal operation Remarks
Load meter calculated weight Only when optional setting is made
26 Classified weight 40800 MES LOAD Load weight [t]
is displayed in load meter
27 Position of rotary switch 30802 SW1, SW2, SW3 — — Not used.
28 Position of DIP switch 30904 SW5-1, SW5-2 — — Not used.
31 Position of DIP switch 30907 SW6-3. SW6-4 — — Not used.
D-IN-0: Head lamp
10000000 (Head lamp = on) D-IN-1: Not used
00000000 (Not used) D-IN-2: Starting motor C
00100000 (Starting motor C = on) D-IN-3: Not used
00000000 (Not used) D-IN-4: Auto grease A
The state of input signal is 00001000 (Auto grease: Empty) (Only when optional setting is made
32 Input signal D_IN_0-7 40900 D-IN--0------7
displayed 00000100 (Auto grease: Operation) in auto grease)
00000000 (Auto grease: Abnormal) D-IN-5: Auto grease B
00001100 (Auto grease: Abnormal) (Only when optional setting is made
00000000 (Not used) in auto grease)
00000000 (Not used) D-IN-6: Not used
D-IN-7: Not used
D-IN-8: Not used
D-IN-9: Not used
00000000 (Not used) D-IN-10: Load meter material selec-
00000000 (Not used) tor SW input
00100000 (Load meter material selector SW = (Only when optional setting is made
on) in load meter)
The state of input signal is 00010000 (Load meter addition/reduction selec- D-IN-11: Load meter addition/reduc-
33 Input signal D_IN_8-15 40901 D-IN- 8-----15
displayed tor SW = on) tion selector SW input
00001000 (Right winker on) (Only when optional setting is made
00000100 (Left winker on) in load meter)
00000010 (Monitor mode SW (U) = on) D-IN-12: Winker right
00000001 (Monitor mode SW (t) = on) D-IN-13: Winker left
D-IN-14: Monitor mode SW (U)
D-IN-15: Monitor mode SW (t)
10000000 (Front brake oil pressure SW = on = D-IN-16: Brake oil pressure (Front)
low level) D-IN-17: Brake oil pressure (Rear)
01000000 (Rear brake oil pressure SW = on = D-IN-18: Not used
low level) D-IN-19: Not used
00000000 (Not used) D-IN-20: Air cleaner clogging
Input signal D_IN_16- The state of input signal is 00000000 (Not used) D-IN-21: Not used
34 40902 D-IN-16-----23
23 displayed 00001000 (Air cleaner clogging SW = on) D-IN-22: Parking brake emergency
00000000 (Not used) release SW
00000010 (Parking brake emergency release SW D-IN-23: Load meter total weight
= on) display SW
00000001 (Load meter total weight display SW = (Only when optional setting is made
on) in load meter)
D-IN-24: T/M filter clogging
10000000 (T/M filter clogging SW = on)
(Only when optional setting is made)
00000000 (Not used)
D-IN-25: Not used
00100000 (Parking brake = on)
D-IN-26: Parking brake
00010000 (Coolant level SW = on = low level)
Input signal D_IN_24- The state of input signal is D-IN-27: Coolant level
35 40903 D-IN-24-----31 00000000 (Not used)
31 displayed D-IN-28: Not used
00000100 (Engine oil level SW = on = low level)
D-IN-29: Engine oil level
00000010 (Emergency steering operation SW =
D-IN-30: Emergency steering opera-
on)
tion (Low S/T pressure)
00000000 (Not used)
D-IN-31: Not used
D-IN-32: Subtotal SW
(Only when optional setting is made
10000000 (Subtotal SW = on) in auto grease)
01000000 (Cancel SW = on) D-IN-33: Cancel SW
00100000 (High beam = on) (Only when optional setting is made
Input signal D_IN_32- The state of input signal is 00000000 (Not used) in auto grease)
36 40904 D-IN-32-----39
39 displayed 00001000 (SW for servicing = on) D-IN-34: High beam
00000100 (Monitor mode SW (>) = on) D-IN-35: Not used
00000010 (Monitor mode SW (<) = on) D-IN-36: SW for servicing
00000000 (Not used) D-IN-37: Monitor mode SW (>)
D-IN-38: Monitor mode SW (<)
D-IN-39: Not used
1000 (Buzzer = on) D-OUT-0: Buzzer
Output signal The state of output signal is 0000 (Not used) D-OUT-1: Not used
37 40952 D-OUT-0--3
D_OUT_0-3 displayed 0000 (Not used) D-OUT-2: Not used
0000 (Not used) D-OUT-3: Not used
WA500-6R 35
Engine reduced-cylinder function

1. Using the < and > switches, display “Reduced
cylinder mode selection (CYLINDER CUT-
OUT)” screen, and then press the U switch.
2. Operating method of reduced-cylinder function

Every pressing the > switch moves the cursor to the right (select a cylinder to issue the reduced-cylinder
command).
Every pressing the < switch moves the cursor to the left (select a cylinder to issue the reduced-cylinder com-
mand).
Press the U switch to issue the monitor reduced-cylinder command. Every pressing this switch repeats out-
put/release of the command.
Press the t switch to return to the “Reduced cylinder mode selection (CYLINDER CUT-OUT)” screen and
the reduced-cylinder commands from the monitor are all released.
Operation example: When the 3rd cylinder stop command is issued
36 WA500-6R
No injection cranking
For the starting method of engine using this function, see “Testing and adjusting: No injection cranking oper-
ation of engine”.
This section describes only the operating method.
WA500-6R 37
Adjustment function
For adjustment using this function, see “Testing and
adjusting: Adjustment performed on the monitor”.
This section describes its outline only.
01: Reset of transmission initial learning

See “Testing and adjusting: Reset of transmis-
sion initial learning and implementation of trans-
mission initial learning”.
02: ECMV compensation

See “Testing and adjusting: Adjustment of
transmission ECMV current”.
04: Transmission shift point adjustment function

See “Testing and adjusting: Changing L mode
gear shift point”.
05: Adjustment of lift arm angle sensor (Raise)

(For EPC lever)
See “Testing and adjusting: Adjustment of work
equipment controller lift arm angle”.
06: Adjustment of lift arm raise lever and variations

in the dead zone of EPC
equipment EPC lever detent position”.
equipment EPC starting current”.
07: Adjustment of lift arm lower lever and variations

08: Adjustment of bucket tilt lever and variations in

the dead zone of EPC
09: Adjustment of bucket dump lever and variations

10: Adjustment of 3rd EPC cylinder extraction lever

and variations in the dead zone of EPC
38 WA500-6R
11: Adjustment of 3rd EPC cylinder retraction lever

and variations in the dead zone of EPC
12: Adjustment of joystick right lever and variations

in the starting point of EPC
Do not operate it.
13: Adjustment of joystick left lever and variations in

the starting point of EPC
Do not operate it.
14: Modification of lift arm lever pattern

See “Testing and adjusting: Changing the lift
arm table.”
15: Modification of bucket lever pattern

See “Testing and adjusting: Changing the
bucket table.”
16: Adjustment of lift arm lower stop modulation

See “Testing and adjusting: Changing lift arm
stop modulation”.
17: Adjustment of pump cut-off pressure in up move

of lift arm
See “Testing and adjusting: Adjusting pump cut-
off pressure.”
18: Adjustment of lift arm angle sensor (raise) (For

load meter)
See “Testing and adjusting: Adjustment of load
meter lift arm angle”.
19: Adjustment of lift arm angle sensor (lower) (For

load meter)
See “Testing and adjusting: Adjustment of load
meter lift arm angle”.
21: Modification of AJSS oil pressure command

table pattern
Do not operate it.
22: Adjustment of speed limit

See “Testing and adjusting: Changing the maxi-
mum speed limit”.
WA500-6R 39
Maintenance monitoring function

1. Selection of display of maintenance monitor function (1st layer)
For the destination you can go to using <, >, and t switches, see “Function 1 for the service person: 2nd
layer transition diagram”.
Pressing the U switch changes the screen to the “Item NO. 1 is displayed” screen.
40 WA500-6R
2. “Select maintenance item” screen

(1) Using the > switch, display items in ascending order of numbers in Table 5-2-3-2.
a When the last item is selected, the screen is changed to the “Default value is set” screen.
(2) Using the < switch, display items in descending order of numbers in Table 5-2-3-2.
a When the last item is selected, the screen is changed to the “All item timer stop/all item valid selector” screen.
a. Change of maintenance interval time

How to input interval
(1) Input a value between 0 and 9 at the cursor
position.
(2) The cursor is positioned at the highest-order
digit. Pressing the > or < switch increases or
decreases the value between 0 and 9.
(3) Input a desired value and press the U switch.
(4) The cursor moves to the 2nd position. Select
the digits for the all positions by performing
steps (2) and (3) above.
(5) After selecting the digit for the lowest position,
press the U switch.
a If the input interval time is acceptable, the
screen changes to the check screen.
a If the input interval time is not acceptable, the
time does not change.
(6) Return the cursor to the highest-order digit.
a The lower limit of set value is 50h.
(7) When you have entered a wrong value to a
position succeeding to the highest-order digit,
move to the highest-order digit using t switch
and repeat the procedure from the first.
a In this case, values that had been entered
remain as they are until modified.
(8) When the cursor is at the highest-order digit,
move to the higher layer using t switch.
q Select YES or NO with the < or > switch.
q The cursor (_) is blinking at the selected item. If
you have selected “YES”, press the t switch to
execute the change. If you have selected “NO”,
press it to return to the “Select maintenance
item” screen without executing the change.
a By default, the cursor is set to NO (cancel) to
prevent resetting error.
q When an interval time is changed, the remain-
ing timer time is changed as shown below.
(Interval time being set – Elapsed time from
the last replacement)
WA500-6R 41
b. Selection between enabling or disabling timer by 3. Setting of a default value

item
q Select YES or NO with the < or > switch.

q When “Timer by item” is enabled at present, q The cursor (_) blinks on the selected item. If
“ON o OFF” is displayed at the lower column. “YES” is selected with the t switch, the
q When “Timer by item” is disabled at present, change is executed. If “NO” is selected, the
“OFF o ON” is displayed at the lower column. change is cancelled and the “Select mainte-
a By default, it is “ON” and the timer function is nance item” screen is returned.
enabled. a By default, the cursor is set to NO (cancel) to
prevent resetting error.
q When you disable “Timer by item”, “OFF” is
displayed at the upper column. q If the default value is executed, all the currently
q When you enable “Timer by item”, “ON” is dis- changed interval times are returned to the
played at the upper column. default values. It is executed on every item
independent of whether or not the function is
q Select YES or NO with the < or > switch. enabled for a specific item.
q The cursor (_) blinks on the selected item. If
“YES” is selected with the t switch, the q Timer remaining time shall be Default value –
change is executed. If “NO” is selected, the Elapsed time since the last replacement.
change is cancelled and the “Select mainte- a The reset frequency is not incremented and
nance item” screen is returned. remains the same as before the resetting.
a By default, the cursor is set to NO (cancel) to a Set enable for enable or disable of individual
prevent resetting error. items.
q Specify disabling the timer or releasing the dis-

abling by maintenance item.
q If you cancel the timer disabled, interval time

before having been disabled is used as the set
value.
q The timer remaining time is reset.

a The reset frequency is not incremented and
remains the same as before the resetting.
42 WA500-6R
4. Selection between timer stop for all items and enable by item
*1 Press the U switch to go to the “ALL ITEMS OFF” screen.

*2 When “ALL ITEMS OFF” is selected
*3 When ALL ITEMS OFF is executed:
The timer function for all items is stopped and the “Select maintenance monitor” screen is restored.
Setting for individual items is also disabled.
When ALL ITEMS OFF is canceled:
The operation is cancelled and the MAINTENANCE MONITOR screen is restored.
*4 When “ALL ITEMS ON” is selected
*5 Select YES or NO with the < or > switch.
The cursor (_) is blinking at the selected item.
a By default, the cursor is set to NO (cancel) to prevent resetting error.
*6 When ALL ITEMS ON is executed:
Interval time being set for all items is disabled independent of whether or not it is enabled or dis-
abled for a specific item.
The timer remaining time is reset.
The reset frequency is not incremented and remains the same as before the resetting.
The “Select maintenance monitor” screen is restored. Setting for individual items is also enabled.
When ALL ITEMS OFF is canceled:
The operation is canceled and the “Select maintenance monitor” screen is restored.
WA500-6R 43
Operating information display function
Outline
q The value of fuel consumption is obtained by adding the target injection amount sent from the engine
controller.
q It is not measured but calculated fuel consumption. Use it as a rough standard.
*1 The upper column displays fuel consumption The lower column displays the travel distance
[L/km or L/mile] per 1 km (or 1 mile) from the [km or mile] from the last resetting.
last resetting. The unit km or mile shall be selected depend-
It is calculated from the fuel consumption and ing on that used on the odometer.
travel distance above. The counting is stopped at 9999999.9, the
The unit km or mile shall be selected depend- upper limit.
ing on that used on the odometer.
The counting is stopped at 99999.9, the upper *3 The upper column displays the cumulative fuel
limit. consumption [L] from the last resetting.
The lower column displays the average fuel The counting is stopped at 9999999.9, the
consumption [L/h] from the last resetting. upper limit.
The counting is stopped at 99999.9, the upper The lower column displays the elapsed time [h]
limit. from the last resetting.
The counting is stopped at 9999999.9, the
*2 The upper column displays the cumulative fuel upper limit.
consumption [L] from the last resetting.
The counting is stopped at 9999999.9, the
upper limit.
44 WA500-6R
*4 Calculation of (*4) is executed when the load 8) If t switch is pressed before finishing
meter is installed. (The screen is not available entering, the cursor moves to the sign
when the load meter is not installed.) position. In this case, the value remains
The upper column displays the loaded volume unchanged. Using the t switch, return to
[ton] from the last resetting. the previous screen.
The counting is stopped at 199999999.9, the 9) If the value confirmed for the lowest-order
upper limit. digit is outside the range from –50.0 to
Short ton or metric ton depends on optional +50.0, the cursor moves to the sign posi-
setting. tion with the value unchanged as with
The lower column displays the loading fre- when the t switch is pressed.
quency from the last resetting.
The counting is stopped at 65000, the upper Processing on the monitor panel:
limit. q Default value: 0.0%
(*1 – *4) q This setting allows correcting the cumulative
Calculation is done only for the duration in fuel consumption (L) in the range of –50.0 to
which the engine is run. +50.0%.
*5 Using the U switch, clear data of (*1), (*2),

(*3), and (*4) to return to the previous screen.
Using the t switch, return to the previous
screen without resetting.
Note: Other than the reset operation above,
you can reset data by initializing the monitor
panel or specifying optional setting to OFF.
Acquisition of fuel consumption (L)

q The monitor panel calculates the cumulative
fuel consumption (L) based on the momentary
fuel consumption (L/h) from the engine control-
ler.
*6 Setting gain correction

1) When the screen appears, the current set
value is displayed and the cursor is placed
on the sign (+/–).
2) When the cursor is placed on the sign,
every pressing the > or < switch displays
“+” io “–” in order.
3) Press the U switch to confirm the sign.
o Cursor moves to the highest-order digit.
4) First, the cursor appears at the highest-
order digit. Each time the > or < switch is
pressed, the value at the digit increases or
decreases between 0 and 9. (The highest-
order digit is between 0 and 2.)
5) Input a desired value and press the U
switch to confirm the entry.
6) The cursor moves to the lowest-order
digit. Select a value in the same manner
as step 4).
7) Input a value at the lowest-order digit and
press the U switch. (The screen returns
to the previous one when the entry is con-
firmed.)
WA500-6R 45
Function of selecting optional device

For setting using this function, see “Testing and
Input of machine serial number (No.)

Model selection function

46 WA500-6R
Load meter function

(if equipped)
1. Outline 2. Weight calculation

q The load meter displays the remaining amount The load meter calculates weight (W) by
of total or target loaded volume by classifying detecting the lift arm operating pressure (P) by
working objects into five types and measuring the pressure sensor (A) installed at the lift arm
the bucket-loaded volume. cylinder bottom and pressure sensor (B)
q It is provided with the functions to switch installed at its head and calculating the center
between reduction mode and addition mode, of gravity by the lift arm angle sensor (C).
and between working objects, and the function
to display and clear total loaded volume. To
operate these functions, use the load meter
mode selector switch and monitor panel mode
selector switch.
q It is also equipped with calibration mode, cali-
bration clear mode, and load meter calculation
stop mode. To operate these modes, use the
monitor panel mode selector switch.
q Installing a printer (if equipped) allows printing
of measured data.
q For usage of the functions, see Operation and
Maintenance Manual.
Weight calculation is done based on the differ-
ential pressure (C) between the reference
value (A) where the lift arm pressure with no
load is saved (corrected by calibration) and the
calculated lift arm pressure (B) with load.
In addition, to improve its precision, the detec-
tion function calculates weight during lift arm
raise operation.
WA500-6R 47
Operation of tires and work equipment gener-

ates spring effect on the machine, however,
the measured lift arm pressure (D) is provided
with the characteristic shown in the figure
below.
The value (D) measured by lift arm raise oper-

ation is calculated based on the value obtained
as the calculated value (B) according to the fol-
lowing calculation criteria.
q For 0.5 seconds after lift arm raise operation

start (E), the lift arm state changes from the
static state to operating state and the pressure
largely fluctuates and is not stable. Therefore,
it is not used for calculation of the calculated
value (B).
q The spring effect of the machine is generated
at interval of approx. 1 second. Therefore, the
calculated value (B) is obtained based on the
mean every 1 second during the period
between the lift arm raise operation start and
the operation end.
48 WA500-6R
Determination of lift arm raise operation start

The load meter determines that the lift arm starts moving and starts weight calculation when all the following
conditions are satisfied.
The lift arm angle is between –10 and –30°.
Condition 1
(The range between the horizontal position and position immediately before it contacts the ground)
The lift arm angle changes at least 0.1° for 0.1 second.
Condition 2
(The lift arm starts moving with min. specified speed in raising direction.)
Determination of lift arm raise operation stop

The load meter determines that the lift arm stops moving and ends weight calculation when one of the follow-
ing conditions is satisfied.
The lift arm angle changes to under 0.5° for 0.5 second.
Condition 1
(The lift arm speed in raise direction is reduced below the specified speed.)
The lift arm angle changes to lowering direction.
Condition 2
(When the lift arm is lowered, weight calculation finishes.)
The lift arm angle changes to above +20°.
Condition 3
(At a high position, weight calculation stops.)
The lift arm raise speed suddenly changed.
Condition 4
(The current angular velocity is decreased 70% or more of the previous one.)
Condition 5 Weight calculation was performed 7 times.
Display of calculated weight

The average of calculated weight values are displayed.
Number of Calculation time
Weight calculation and display method
calculations (sec)
Displays weight based on a single calculation result.
Only 1 time 1.5 – 2.5 In this case, however, the weight display blinks to inform the operator that the preci-
sion is unstable due to short calculation time.
2 times 2.5 – 3.5 Displays weight based on the mean value of 2 calculation results.
Min. 3 times 3.5 – 0.0 Displays weight based on the mean value of latest 3 calculation results.
WA500-6R 49
3. Reduction/addition mode
Monitor display in addition mode Monitor display in reduction mode

This is the mode to display the bucket-loaded vol- This is the mode to display the bucket-loaded vol-
ume every time. ume every time based on the pre-set target weight.
Use this mode for grasping the work rate. Use this mode for constant loading work.
q When addition mode is selected, “TOTAL q When reduction mode is selected, “REMAIN-
LOADED” is displayed at the display of addi- ING TARGET” is displayed at the display of
tion mode (1), which indicates the value reduction mode (1), which indicates the value
obtained by adding the value at the display of obtained by reducing the value at the display of
calculated bucket-loaded volume (3) to the calculated bucket-loaded volume (3) from the
value at the total loaded volume (2). value specified at the display of total loaded
q Weight calculation can be displayed by cumu- volume (2).
lating up to any 5 working objects indepen- q Weight calculation can be displayed by cumu-
dently. lating up to any 5 working objects indepen-
Working objects can be selected from types A dently.
to E at the working object display (4) in mode Working objects can be selected from types A
selection. to E at the working object display (4) in mode
q The display of total loaded volume (2) indi- selection.
cates up to 9,999 t unless data is cleared by
the load meter subtotal switch. a For the display and calculation method when
The display indicates a value to one decimal the value at the display of bucket-loaded vol-
place (in 100 kg) in the case of max. 999.9 t. ume (3) exceeds the value at the display of
When it exceeds 1000 t, the decimal point dis- remaining volume (2), see Operation and
play disappears and switches to the display in Maintenance Manual “Handling the load
1 t. meter”.
a For details of the display of remaining volume,
a For details of the display of total loaded vol- see “Display of total loaded volume and dis-
ume, see “Display of total loaded volume and play of remaining volume”.
display of remaining volume”.
50 WA500-6R
Display of total loaded volume and display of Load meter subtotal switch
remaining volume
Display of
Actual total loaded
total loaded Remarks
weight (t)
volume
– –99.5 –99.9 Display of decimal point
Display of decimal point
–99.4 – –0.1 –**.* (the second decimal
place is rounded off.)
Display of decimal point
0 – 999.4 ***.* (the second decimal
Display of integer
999.5 – 9999.4 **** (the second decimal
q To clear the display of total loaded volume (in
9999.5 – 9999 Display of integer
addition mode) or display of remaining volume
Unit of calculated weight (in reduction mode), continuously press the
q Calculated weight values are all displayed in SI switch (1) at least 2 seconds.
(metric ton).
If “MPH” has been selected for speed display Specifications Operation after operating switch
in monitor setting, however, it can be switched Printer not Clears the display of total loaded volume (dis-
to short ton (US ton) in service mode optional installed play of remaining volume).
setting. Printer Outputs saved subtotal data on the printer.
If you switch it to short ton, weight display is installed After the output, the subtotal data is cleared.
also output in short ton (US to) on the printer.
k In countries where SI unit is adopted, the Subtotal data

speed display unit and weight display unit q The following data when calculated weight is
must not be changed to non-SI unit. confirmed is saved as a set.
q Type of working object
q Weight of loading in one bucket
Load meter cancel switch q Total number of loading
q Total loaded volume
Memory capacity: Min. 500 times of loading
q When the switch (1) is pressed during the hold-

ing time of calculated weight (15 seconds after
completion of calculation), the value at the dis-
play of bucket-loaded volume is canceled, and
the calculated weight is abandoned.)
In this case, the display of total loaded volume
(display of remaining volume) newly added
(reduced) is also canceled, and the previous
display value is returned.
WA500-6R 51
Auto subtotal function 4. Cumulative data display function

1) When the printer (if equipped) is connected. Display of data
The 501st weight calculation is executed, q Total loaded volume and total number of load-
and after 15 minutes, data is stored in ing in addition mode or reduction mode are dis-
RAM and up to the 500th data is printed played.
out on the printer at the same time. q Press the load meter mode selector switch to
After the output on the printer, the subtotal display “TOTAL DATA” on the character dis-
data is cleared. play.
The character display displays “LOAD
DATA FULL” and “CLEAR DATA” after
saving the 500th data, and continues
measurement.
2) When the printer (if equipped) is not con-

nected
The 501st weigh calculation is executed,
and after 15 minutes, data is stored in
RAM and up to the 500th weight data by
bucket is abandoned to secure store data
area.
The character display displays “LOAD a The lower column ( - h) dis-
DATA FULL” and “CLEAR DATA” after plays cumulative hours according to the hour
saving the 500th data, and continues meter criteria.
measurement. Example) In the case of display of 12300-
12450h, the cumulative data of 150 hours
Display on character display after 500th data is between 12300 and 12450 hours is displayed
stored in the character display.
q Press the monitor panel mode selector switch

2 (>) or (<) to select “By the item (A) to (E)” or
“All ON” at working object display (1).
In the former case, cumulative weight by type
(2) and the number of loading (3) are dis-
played.
In the latter case, total loaded volume (2) of all
objects from (A) to (E) and the total number of
loading (3) are displayed.
52 WA500-6R
Reset of data
q Cumulative data by the item (A) to (E) or of all objects are reset.
q Display “TOTAL DATA” on the character display. Press the load meter selector switch (A/B) to specify
either “By the item (A) to (E) or “All ON” at the working object display. Press the load meter mode selec-
tor switch (A/B) at least 4 seconds.
5. Printer output (if equipped)

a This function works only when the printer specified in optional setting is installed.
The output format of load meter can be selected from 3 types (A, B, C) of output mode.
The output format of each mode is as follows.
a For selection of output mode and output method, see Operation and Maintenance Manual “Han-
dling the load meter”.
A-mode B-mode C-mode
(Total printer output) (Subtotal printer output) (Operation record printer output)
• Model, serial number • Model, serial number • Model, serial number
• Date and time of printing • Date and time of printing • Date and time of starting record, service
• Subtotal loading data • Loading data meter
(Type/number of loading/loaded volume) (Loaded volume) • Date and time of ending record (printing),
• Total loading data • Subtotal loading data service meter
(Total number of loading/Total loaded vol- (Type/number of loading/loaded volume) • Subtotal loading data
ume) • Total loading data (Type/number of loading/loaded volume)
(Total number of loading/Total loaded vol- • Total loading data
ume) (Total number of loading/Total loaded vol-
ume)
• Maintenance time
(Maintenance item/remaining time)
WA500-6R 53
6. Calibration 2) Load calibration

q No load calibration and load calibration q This function compensates the reference
are provided: the former measures the pressure with the bucket loaded. It makes
pressure with the bucket empty and the compensation (B) of the error between the
latter measures the pressure with known actual pressure and the reference value
weight loaded. (A) in the vicinity of the position where
q The lift arm is raised with the bucket full load calibration is executed (C) as shown
tilting. In this condition, the lift arm working in the figure below.
pressure with no load (0 kg) or known
weight loaded is saved.
q If the center of gravity of load is deviated
from the factory-set position due to modifi-
cation of the lift arm or bucket, no load or
load calibration must be executed to oper-
ate the machine with high precision.
a The saved calibration data is not cleared
even after the battery has been removed
for a long time.
1) No load calibration
q This function cancels the individual differ-
ence of weight inherent to the machine,
a For the calibration execution method, see
e.g. the weight of working equipment. It
“Testing and adjusting: Testing and adjust-
makes compensation (B) by offsetting the
ing the load meter”.
error between the actual weight and the
reference value (A) as shown below.
7. Calculation stop
The calculation function of the load meter is
stopped.
During the calculation stop, the display of load
meter disappears, and speed display or engine
speed display appears. No data is added to the
total data in this mode.
To restart calculation, select the addition mode
or reduction mode.
a For the calculation stop method, see
“Operation and Maintenance Manual:
Handling the load meter”.
Function of troubleshooting
The machine monitors the input and output signals
constantly for troubleshooting for the system.
If any abnormality is detected by self-diagnosis, the
information on it is transmitted through the network
to the machine monitor. When abnormality occurs,
it can be confirmed on the machine monitor (display
of failure history).
54 WA500-6R
WA500-6R 55
Rear side of machine monitor
1. Spare rotary switch (SW1)

4. Spare DIP switch (SW5-1)
Do not change settings of spare rotary switches and spare DIP switches.
56 WA500-6R
WA500-6R 57
Signal table by connector
CN1 (070-20-pole) [CN-L51]

Pin No. Specifications I/O Group Form of use Signal name WA500-6 Remarks
1 — — — — —
Power supply of Power supply
2 I — — —
small lamp (+24 V)
Power supply of Power supply
3 I — — —
small lamp (+24 V)
NSW power supply Power supply NSW power supply NSW power supply
4 I —
(+24 V) (+24 V) (+24 V) (+24 V)
NSW power supply Power supply NSW power supply NSW power supply
5 I —
(+24 V) (+24 V) (+24 V) (+24 V)
SW power supply Power supply SW power supply SW power supply
6 I —
(+24 V) (+24 V) (+24 V) (+24 V)
SW power supply Power supply SW power supply SW power supply
7 I —
(+24 V) (+24 V) (+24 V) (+24 V)
8 — — — — — —
9 GND I — GND GND GND
D_OUT_3
11 O A D/O sink (Spare) —
(+24 V, sink 200 mA)
D_OUT_2 (Automatic preheater Executed by engine con-
12 O A D/O sink —
(+24 V, sink 200 mA) relay) troller.
For small models
D_OUT_1 (HST solenoid cutout
13 O A D/O sink — (Spare for medium and
(+24 V, sink 200 mA) relay)
large models)
D_OUT_0
14 O A D/O sink Buzzer (Monitor) Buzzer (Monitor)
(+24 V, sink 200 mA)
Sensor power supply Sensor power Lift arm pressure sen-
15 O — —
output (+24 V) supply sor power supply
Lift arm pressure and
Sensor power supply Sensor power Lift arm angle sensor
16 O — angle sensor power For load meter
output (+5 V) supply power supply
supply
58 WA500-6R
CN2 (070-18-pole + 12-pole) [CN-L52, CN-L53]

Form of
Pin No. Specifications I/O Group Signal name WA500-6 Remarks
use
D_IN_0 (Spare for WA800 or
1 I B D/I+24V Headlamp Headlamp
(+24 V, 5 mA) later)
2 D_IN_2 (24 V, 5 mA) I B D/I+24V Starting motor C Starting motor C
Auto grease A
3 D_IN_4 (24 V, 5 mA) I B D/I+24V Auto grease A If equipped
(If equipped)
For small models
4 D_IN_6 (24 V, 5 mA) I B D/I+24V (Direction F) — (Spare for medium and
large models)
For small models
5 D_IN_8 (24 V, 5 mA) I B D/I+24V (Direction R) — (Spare for medium and
large models)
Load meter material
6 D_IN_10 (24 V, 5 mA) I B D/I+24V (Spare)
selector switch input
D_IN_12
7 I C D/I+24V Winker right Winker right
(NSW 24 V, 5 mA)
D_IN_14 Monitor mode switch 1 Switch for monitor
8 I C D/I+24V U switch input
(NSW 24 V, 5 mA) U input operation
9 GND O — — SIGNAL GND SIGNAL GND
10 D_IN_1 (24 V, 5 mA) I B D/I+24V Starting motor ACC Starting motor ACC
Executed by engine
11 D_IN_3 (24 V, 5 mA) I B D/I+24V Preheat operation —
controller.
Auto grease B
12 D_IN_5 (24 V, 5 mA) I B D/I+24V Auto grease B If equipped
(If equipped)
For small models
13 D_IN_7 (24 V, 5 mA) I B D/I+24V (Direction N) — (Spare for medium and
large models)
14 D_IN_9 (24 V, 5 mA) I B D/I+24V (Spare) —
Load meter addition/
15 D_IN_11 (24 V, 5 mA) I B D/I+24V (Spare) reduction selector switch
input
D_IN_13
16 I C D/I+24V Winker left Winker left
(NSW 24 V, 5 mA)
D_IN_15 Monitor mode switch 1 t Switch for monitor
17 I C D/I+24V t switch input
(NSW 24 V, 5 mA) input operation
18 A_IN_0 (0 – 30 V) I H A/I Alternator R Alternator R
D_IN_16 Brake oil pressure Brake oil pressure
19 I D D/IGND
(24 V/GND, 5 mA) (Front) (Front)
D_IN_18 Brake oil level For WA1200
20 I D D/IGND —
(24 V/GND, 5 mA) (Front) (Spare for others)
D_IN_20
21 I D D/IGND Air cleaner clogging 1 Clogging of air cleaner
(24 V/GND, 5 mA)
Parking brake
D_IN_22
22 I D D/IGND (Spare) emergency release
(24 V/GND, 5 mA)
switch signal
D_IN_24 Transmission filter Transmission filter
23 I E D/IGND
(24 V/GND, 5 mA) clogging clogging
24 GND O — GND Sensor GND Sensor GND
D_IN_17 Brake oil pressure Brake oil pressure
25 I D D/IGND
(24 V/GND, 5 mA) (Rear) (Rear)
D_IN_19 Brake oil level For WA1200
26 I D D/IGND —
(24 V/GND, 5 mA) (Rear) (Spare for others)
D_IN_21 For WA800 later
27 I D D/IGND Air cleaner clogging 2 —
(24 V/GND, 5 mA) (Spare for others)
D_IN_23 Load meter total weight
28 I D D/IGND (Spare)
(24 V/GND, 5 mA) display switch input
Not schedule of instal-
D_IN_25 (Seat belt fastening
29 I E D/IGND — lation at present
(24 V/GND, 5 mA) warning)
(Spare)
30 A_IN_0 (0 – 30 V) I H A/I Small lamp switch Small lamp switch
WA500-6R 59
CN3 (070-18-pole + 12-pole) [CN-L54, CN-L55]

Form of
use
D_IN_26
1 I E D/IGND Parking brake Parking brake
(24 V/GND, 5 mA)
D_IN_28 Executed by engine
2 I E D/IGND Engine oil pressure —
(24 V/GND, 5 mA) controller.
D_IN_30 Normal emergency Normal emergency
3 I E D/IGND
(24 V/GND, 5 mA) steering steering
D_IN_32
4 I F D/IGND Subtotal switch Subtotal switch For load meter
(24 V/GND, 5 mA)
D_IN_34
5 I F D/IGND High beam switch High beam switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/IGND Service function 2 Service function 2
(24 V/GND, 5 mA)
D_IN_38 Monitor mode switch 2 < Switch for monitor
7 I G D/IGND < switch input
(24 V/GND, 5 mA) switch input operation
8 P_IN_0(0.5Vp-p) I M P/I (Spare) —
9 GND O — GND GND GND
D_IN_27
10 I E D/IGND Engine coolant level Engine coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/IGND Engine oil level Engine oil level
(24 V/GND, 5 mA)
12 N.C. I E D/IGND N.C. N.C.
D_IN_33
13 I F D/IGND Cancel switch Cancel switch For load meter
(24 V/GND, 5 mA)
D_IN_35
14 I F D/IGND (Spare) —
(24 V/GND, 5 mA)
D_IN_37 Monitor mode switch 2 >
15 I G D/IGND > switch input
(24 V/GND, 5 mA) input
D_IN_39
16 I G D/IGND Low steering oil pressure Spare
(24 V/GND, 5 mA)
17 P_IN_1(5Vp-p) I M P/I (Spare) —
18 N.C. — — N.C. N.C.
A_IN_2
19 I J A/I Fuel level sensor Fuel level sensor
(High-resistance input)
A_IN_4 Torque converter oil Torque converter oil
20 I J A/I
(High-resistance input) temperature sensor temperature sensor
Engine coolant
A_IN_6 temperature sensor Executed by engine
21 I K A/I —
(High-resistance input) (For automatic controller.
preheater)
Lift arm pressure sensor Lift arm pressure sensor
22 A_IN_8 (0 – 5 V) I L A/I For load meter
(Rod) (Head)
Battery electrolyte level Battery electrolyte level
23 A_IN_10 (0 – 14 V) — — If equipped
A (If equipped)
24 GND O — GND SIGNAL GND GND
A_IN_3 Hydraulic oil temperature Hydraulic oil temperature
25 I J A/I
(High-resistance input) sensor sensor
A_IN_5 Engine coolant tempera- Brake oil temperature Executed by engine
26 I J A/I
(High-resistance input) ture sensor sensor controller.
Lift arm pressure sensor Lift arm pressure sensor
27 A_IN_7 (0 – 5 V) I L A/I For load meter
(Bottom) (Bottom)
For load meter
28 A_IN_9 (0 – 5 V) I L A/I Lift arm angle sensor Lift arm angle sensor (Shared with work
equipment controller)
29 GND O — GND SIGNAL GND GND
Battery electrolyte level For WA800 later
30 A_IN_11 (0 – 14 V) — — —
B (Spare for others)
60 WA500-6R
CN4 (070 12-pole) [CN-L56]

Form of
use
Monitor – transmission
1 S_NET(+) I/O N S-NET work equipment —
controller
Monitor – transmission
2 S_NET(+) I/O N S-NET work equipment —
controller
Cummins engine con-
troller, VSM controller Communication
3 CAN+ I/O P
communication (CAN (+))
(CAN (+))
4 S_NET(–) O N S-NET S_NET GND —
5 S_NET(–) O N S-NET S_NET GND —
6 GND O — GND S_NET shield GND
7 GND O — GND CAN shield CAN: twisted only
Cummins engine con-
Communication
8 CAN- I/O P troller communication
(CAN (–))
(CAN (–))
9 (NC)
10 (NC)
11 (NC)
12 (NC)
CN5 (070-14-pole) [CN-L57]

Form of
use
1 (NC) — — —
RS232C serial
2 RS232C_1_RTS I/O Q —
communication
RS232C serial
3 RS232C_1_RD I Q RD —
communication
4 (NC) I R RD N.C. N.C.
5 (NC) I/O R N.C. N.C.
For load meter
BUSY input for load Printer BUSY
6 — — (Spare for medium
meter printer (if equipped)
and large models)
7 (NC) — — —
RS232C serial
8 RS232C_1_CTS I/O Q —
communication
RS232C serial Printer and personal
9 RS232C_1_TX O Q TX
communication computer TX
RS232C serial
10 RS232C_1_SG O Q —
communication
11 (NC) O R N.C. N.C.
12 (NC) O R TX N.C. N.C.
13 (NC) I/O R N.C. N.C.
14 (NC) — — N.C. N.C.
WA500-6R 61
CN6 (040 8-pole) [CN-L58]

Form of
use
1 RS232C_0_TXD O S — —
2 (NC) — — N.C. N.C.
3 RS232C_0_TXD O S — —
4 (NC) — — N.C. N.C.
5 RS232C_0_RXD I S — —
6 (NC) — — N.C. N.C.
7 RS232C_0_RXD I S — —
8 GND O — GND —
Setting switches (On circuit board)

Switch Form of
Specifications I/O Group Signal name WA500-6 Remarks
No. use
1 16 Posi rotary switch 1 I — Selection of model (Spare)
Selection of
2 16 Posi rotary switch 2 I — (Spare)
specification
Selection of
3 16 Posi rotary switch 3 I — (Spare)
specification
4 2 Posi DIP switch 1 I — Selection of options (Spare)
62 WA500-6R
WA500-6R 63
SEN02898-02

© 2009 KOMATSU
All Rights Reserved
64
SEN02899-00
WA500-6R

WA500-6R 60001 and up

Work equipment control system...................................................................................................................... 2
Transmission controller system..................................................................................................................... 36
WA500-6R 1
Work equipment control system 1

Work equipment controller 1
2 WA500-6R
WA500-6R 3
1. Work equipment control

1) Work equipment control input and output
4 WA500-6R
2) Work equipment control lever operation
Function
q The work equipment controller operates the work equipment by detecting the operating stroke
of raise/lower, tilt/dump from the signals of the work equipment lever potentiometer, and oper-
ating the main spool by operating each EPC valve attached to the main valve with current con-
trol.
WA500-6R 5
q The work equipment control lever is equipped with detent notches, and it is adjusted so that it
will operate at the maximum speed before each detent. The range beyond lower detent is the
“lift arm float” operation position, where the lift arm operates by external forces.
6 WA500-6R
3) Work equipment neutral lock
Function
q When the work equipment lock lever is operated to the lock position, the lock switch (baffle
lever switch) becomes OPEN, and the controller stops the operation of the work equipment by
turning ON the work equipment neutral lock valve, cutting EPC pilot basic pressure.
a While the work equipment is locked, the detent does not operate, and the lever is not held at
the detent position.
q The safety function, in which the work equipment is continued to be locked until the work
equipment control lever is temporarily returned to the neutral position, even if the work equip-
ment is unlocked, is incorporated.
Operation table
Operation by Operation of
Input of controller Work equipment control Output of controller
man machine
Work equipment lever Work equipment Oil
Baffle lever Baffle lever switch
potentiometer neutral lock valve pressure
Lower OFF ON
— Cut
(LOCK) (OPEN) (24V)
Lower to raise OFF Work equipment control lever being ON
Cut
(unlocking) (OPEN) operated (24V)
Lower to raise OFF After releasing, lever neutral of all OFF
Operating
(unlocking) (OPEN) work equipment detected once (OPEN)
Raise ON OFF
— Operating
(FREE) (CLOSE) (OPEN)
WA500-6R 7
4) Neutral position and work equipment speed
Function
q The work equipment control lever has neutral play of 5% in the lever stroke, and it is adjusted
so that the work equipment will start working from the position beyond the play.
q It also has a function to change the work equipment speed for the lever stroke through setting
of the controllers.
q The lift arm has five changeable tables, and the bucket has three.
a For the adjustment method and the characteristics of each table, refer to “Testing and adjust-
ing: changing the lift arm table or changing the bucket table.”
Lift arm lever stroke vs Speed table

Lever stroke -100 -90 -90 -85 -80 -70 -60 -50 -40 -30 -20 -10 -7 7 10 20 30 40 50 60 70 80 85 90 100
No.1 100 100 60 52 46 36 28 21 16 11 6 1 0 0 1 6 12 18 26 35 47 70 100 100 100
No.2 100 100 72 64 57 45 37 28 21 15 9 3 0 0 3 11 19 27 37 48 62 85 100 100 100
No.3 100 100 72 72 66 54 45 37 29 21 13 4 0 0 5 18 28 38 48 59 72 90 100 100 100
No.4 100 100 72 72 72 64 55 46 38 28 18 7 0 0 7 23 37 50 62 74 87 100 100 100 100
No.5 100 100 72 72 72 72 66 57 47 36 25 10 0 0 10 30 45 59 73 86 100 100 100 100 100
8 WA500-6R
Bucket lever stroke vs Speed table

Lever stroke -100 -95 -90 -85 -80 -70 -60 -50 -40 -30 -20 -10 -7 7 10 20 30 40 50 60 70 80 85 90 100
No.1 100 100 80 70 60 45 35 26 18 12 7 1 0 0 1 6 12 18 26 35 47 70 100 100 100
No.2 100 100 100 90 82 70 58 47 38 28 18 5 0 0 5 18 28 38 48 58 70 90 100 100 100
No.3 100 100 100 100 100 95 87 75 60 45 30 10 0 0 10 30 45 59 73 85 95 100 100 100 100
WA500-6R 9
5) Tilt priority control
Function
q Because CLSS is employed in this machine, although the bucket and the lift arm can be oper-
ated simultaneously, it has a function that prevents the lift arm from rising when the tilt operat-
ing stroke is large, for more efficient digging.
q It is realized by limiting the maximum speed of lift arm raise (table below) for the tilt speed.
a This function does not work in dump operation, which enables the simultaneous operation.
Bucket tilt speed 0% 20% 40% 60% 70% 100%
Maximum speed of lift arm raise 100% 80% 30% 0% 0% 0%
6) Lift arm stop modulation
Function
q The work equipment controller operates modulation, when the lift arm stop operation is per-
formed more suddenly than a certain speed by the operator, for easing stop shock of lift arm
raise/lower.
q The operation of this stop modulation function can be changed through setting.
a For the method to change and precautions, refer to “Testing and adjusting: changing the lift
arm stop modulation.”
Case A:
In the case of lever command flow rate < modulation command flow rate
q Outputs according to the lever command flow rate
Case B:
In the case of lever command flow rate > modulation command flow rate
q Outputs according to the modulation command flow rate
a: Modulation command flow rate

Deceleration flow rate: 0.75%/mS
100% ⇒ 0% 143 mS
b: Implements modulation from 30% flow rate command or under
10 WA500-6R
7) Speed reduction function in raising cargo lift arm
Function
q It implements the equivalent function as the cut-off function, performed with the cut-off valve in
the conventional machine (WA500-3).
q Lift arm above horizontal (Lift arm angle sensor signal)
q Bucket tilt end (Tilt end proximity switch signal)
q Lift arm bottom pressure minimum 20 MPa (Signal by network communication from the
monitor)
Only when the above conditions are simultaneously satisfied, the lift arm raise maximum speed
will be limited to 70%.
q When the lift arm raise maximum speed is changed between 70% and 100%, modulation is
equipped for reducing shocks, controlling so that the speed will not change suddenly.
q This function can change the condition value of the lift arm bottom pressure through controller
setting. By changing the set value of the lift arm bottom pressure, matching of the lift arm rising
speed and travel speed can be changed.
a For the method to change and procedure, refer to “Testing and adjusting: adjusting pump cut-
off pressure.”
8) Adjusting lever detent position and work equipment starting current
Function
q The work equipment controller has an adjusting function for correction dispersion.
q The detent position is adjusted so that the lever potentiometer voltage at the detent position
will be saved, ensuring control before and after the detent. When it is not adjusted, such phe-
nomena as “the positioner does not operate normally before and after the detent,” or “the lever
position of lift arm float is not normal” may occur.
q When the work equipment starting current is not adjusted, such phenomena as “the neutral
dead zone is large” or “dashing/stopping shock of the work equipment becomes large” may
occur.
a For the adjusting procedure, refer to “Testing and adjusting: adjusting the work equipment EPC
lever detent position/adjusting starting current.”
WA500-6R 11
2. Remote positioner
1) Bucket positioner
Function
q This is a function that the bucket will gently stop at any set position, when the tilt lever is set to
the detent position with the bucket level or lower.
1] Setting stop position

q The stop position of the bucket will change when the positioner is operated through the
operation of the bucket positioner position set switch.
Condition for
Bucket lever stroke: neutral and travel speed below 5 km/h
availability
(1) When setting it upward from the current stop position, press the bucket positioner +
position set switch position (upward). (Use the downward switch to change it down-
ward)
(2) Saves +1 to the current set position (memory), sounds a setting complete buzzer (pip)
and the monitor displays the numerical value for 3 seconds
Setting method
(Set position will be maintained when the key is turned off.)
* When the switch is operated exceeding ±5 of the set range, the monitor displays the
same value, and the setting cancel buzzer (pip) sounds.
(3) For further change, release the switch once, and then press it again.
(when *, the same as (2))
12 WA500-6R
2] Resetting tilt detent

q If the bucket horizontal proximity switch is operated when the bucket lever is at the tilt
detent position, the detent will be reset after the delay time, and the bucket will stop gently.
Delay time:
The bucket horizontal proximity switch is set at the position where the bucket is “down-
ward (–5).”
The flow rate to the tilt cylinder is calculated from the pump delivery, and, when the neces-
sary oil level for the set position is reached, the detent will be reset and it will stop gently.
3] Tilt stop (gentle)

q After resetting the detent, whether the bucket lever is maintained by the tilt detent will be
checked for 0.05 seconds, and if it is, stop operation will not be performed gently.
q If the bucket lever is operated when stopping (gently), the faster of the target speed with
the tilt lever operation and the target speed with the stop (gentle) function will be selected
and output.
q If the bucket lever is operated in the direction of dump for 60% or more during stop (gen-
tle) control, the stop (gentle) control will be stopped and dump will be output.
WA500-6R 13
3. Lift arm positioner
Function
a) Raise kick-out (when raise lamp is on)
Set the lift arm lever to “raise detent,” reset the lift arm raise detent when the lift arm rises before the
set position, and perform stop (gentle) control.
When the lift arm is at other positions than the “raise detent,” it is raised with operation by the oper-
ator.
When raise is not selected, only raise detent will operate.
When the detent is turned on, the remote positioner will not operate, and only the kick-out function
(stop at the top position of the lift arm) will operate.
b) Lower lift arm stop (when lower lamp is on)

Set the lift arm lever to the “float detent,” start decreasing the speed when the lift arm is 10° before
the set position, and reset the float detent when it is 4° before the set position, and perform stop
(gentle) control.
If the lift arm lever is kept as it is, the lift arm starts lowering again.
When lower is not selected, only float detent will operate.
When the detent is turned on with the lift arm angle level or lower, the remote positioner will not
operate, and only the float detent function (it will not stop automatically) will operate.
a The remote positioner of lower will not function as positioner, and will not stop, when the detent is
turned on with the lift arm angle level or lower, in order to distinguish it from float operation in grad-
ing operation.
14 WA500-6R
1] Setting stop position

q The stop position of the bucket will change when the positioner is operated through the
operation of the bucket positioner position set switch.
Setting and resetting raise stop position

Condition for
Lift arm lever stroke: neutral
availability
(1) Raise the lift arm to a desired set position.
(2) Press the remote positioner raise position set switch (less than a second).
(3) If the position where the switch is pressed is within the set range, save the lift arm
angle, the setting completion buzzer sounds (pip, pip), and the switch indicator lights
Method of up.
setting raise (4) If it is out of the range (lift arm angle less than 0°), and in sensor errors, it will not be
stop set again.
(The buzzer will not sound, the set position will not be changed.)
(5) When the set switch is operated less than a second, the set position is always
changed.
(The set position is maintained when the key is turned off.)
(1) Press and hold the remote positioner raise position set switch for a second or longer.
(2) If it is within the set range when the switch is pressed, the position is set temporarily.
If it is proceed for a second or longer in (3) above, the setting cancel buzzer (pip)
Method of
sounds when a second elapses, raise selection is reset, and the switch indicator goes
resetting
off.
raise stop
*After the setting is reset, the whole lift arm angle will be available.
(3) Remote positioner raise stop control is not performed. Only boom kick-out control will
be performed.
Setting and resetting lower stop position

Condition for
Lift arm lever stroke: neutral
setting
(1) Lower the lift arm to a desired set position.
(2) Press the remote positioner lower position set switch (less than a second).
(3) If the position where the switch is pressed is within the set range, save the lift arm
angle, the setting completion buzzer sounds (pip, pip), and the switch indicator lights
Method of up.
setting lower (4) If it is out of the range (other than lift arm angle of –37° to 0°), and in sensor errors, it
stop will not be set again.
(The buzzer will not sound, the set position will not be changed.)
(5) When the set switch is operated less than a second, the set position is always
changed.
(The set position is maintained when the key is turned off.)
(1) Press and hold the remote positioner lower position set switch for a second or longer.
(2) If it is within the set range when the switch is pressed, the position is set temporarily. If
it is proceed for a second or longer in (3) above, the setting cancel buzzer (pip)
Method of
sounds when a second elapses, lower selection is reset, and the switch indicator goes
resetting
off.
lower stop
*After the setting is reset, the whole lift arm angle will be available.
(3) Remote positioner lower stop control is not performed.
Only float detent control will be performed.
Settable range of remote positioner stop position

[Raise, lower stop position settable range]
Stop position “Raise“ “Lower“
Min. 0° 0 to – 37°
0°: Lift arm is level.
WA500-6R 15
2] Resetting lift arm raise detent

q Raise detent turns on when the lift arm lever stroke becomes 60% or more.
q When the remote positioner operates, the detent becomes off from 2° before stop angle to
1° past.
q When the lift arm raise detent becomes automatically off due to the operation of the stop
(gentle) function, the lift arm raise/lower detent stays off during a second after it is turned
off.
3] Lift arm raise stop (gentle)

q In the lift arm raise stop (gentle), the speed is decreased in accordance with the stop angle
from stop angle of 9° to 2° before, through lift arm angle feedback.
q After resetting the lift arm detent, check whether the lift arm lever is maintained by the
detent for 0.05 seconds, and if it is, (gentle) stop operation will not be performed. Acceler-
ate the raising rate of lift arm to reach maximum speed when the lift arm angle is 10°
above the stop position.
q Therefore, when operation exceeding the target stop angle is performed while the detent
is maintained with the lift arm raise remote positioner operated, the speed of the lift arm
raise temporarily decreases and then increases.
16 WA500-6R
4] Boom kick-out
q When the lift arm raise detent is set when the stop position of the remote positioner is not
set or above the stop position, the lift arm slowly stops before the stroke end as kick-out
operation, reducing stop shock due to stroke end.
q In kick-out operation, the detent becomes off from 2° before stop angle to above.
5] Resetting lift arm lower detent

q Lower detent turns on when the lift arm lever stroke becomes 60% or more.
q When the remote positioner operates, the detent becomes off from 2° before stop angle to
1° past.
q When the lift arm angle is less than –37°, the detent turns on for grading operation, regard-
less of operation of the remote positioner.
q When the lift arm lower detent becomes automatically off due to the operation of the stop
(gentle) function, the lift arm raise/lower detent stays off during a second after it is turned
off.
WA500-6R 17
6] Lift arm lower stop (gentle)

q In the lift arm lower stop (gentle), the speed is decreased in accordance with the stop
angle from stop angle of 9° to 2° before, through lift arm angle feedback.
q After resetting the lift arm lower detent, it is checked whether the lift arm lever is main-
tained by the detent for 0.05 seconds, and if it is, stop operation (gentle) will not be per-
formed.The lift arm lower is accelerated so that lift arm will be floating when the lift arm
angle is at 10° below the stop position.
q Therefore, when operation exceeding the target stop angle is performed while the detent
is maintained with the lift arm lower remote positioner operated, the speed of the lift arm
lower temporarily decreases and then increases.
q Even during acceleration, when the lift arm angle reaches –37°, acceleration ends and
float operation is set.
7] Detent operation during engine stop

q While the engine stops, the detent is constantly turned OFF. The lever is not held at detent
position during engine stop.
8] Adjustment of lift arm angle

q Work equipment controller has adjusting function for correcting the lift arm angle sensor
installation errors.
q It saves the lift arm angle sensor voltage at the lift arm top position and operates the kick-
out remote positioner function.
q When not implementing adjustment, such phenomena as the kick-out position is “too
early” and “no kick-out occurs and a shock is generated at the stroke end” may occur.
18 WA500-6R
4. Semi-automatic digging
Function
Control of semi-automatic digging
q Semi-automatic digging is a function, in which digging operation can easily be performed only with
the kick-down switch and lift arm raise operation, improving the working efficiency of less experi-
enced operators, and the two modes of LOOSE mode/ROCK mode are separately used due to the
characteristics of work objects.
q Select the bucket automatic operation pattern appropriate for work cycle/load
Mode selection No. Object Mode
1 Gravel/sand LOOSE mode
2 Quarry/blasted rock ROCK mode
WA500-6R 19
1) Conditions for starting semi-automatic digging

semi-automatic digging is ready with (1) to (4) below.
(1) The semi-automatic digging switch is either in “ROCK” or “LOOSE” mode.
(2) In forward (with F signal)
Condition 1 (3) Lift arm angle less than –30° (almost to the ground)
(4) Operate the kick-down switch.
* Even when working in 1st, semi-automatic digging will not start without operating
the kick-down switch.
Semi-automatic digging (automatic tilting) will start when the following conditions (1) and
(2) are satisfied.
Condition 2
(1) Perform lift arm raise operation after condition 1 is satisfied.
(2) Travel speed km/h <3.5 x ENG rpm/1,800>
2) Conditions for finishing semi-automatic digging

Automatic tilting is finished when any of the following conditions is satisfied.
(1) Forward finished (F signal: ON o OFF)
Conditions
(2) Lift arm angle level or higher
(3) Detect tilt end (becomes full tilt)
3) Tilt operation of digging mode

1] Operation of LOOSE mode
q Tilt operation will start 0.5 seconds after the conditions for starting semi-automatic digging
are satisfied.
q The speed is increased so that it becomes 100% 10 seconds after starting tilt, the maxi-
mum speed depends on engine speed.
20 WA500-6R
2] Operation of ROCK mode
q Tilt operation will start 0.6 seconds after the conditions for starting semi-automatic digging
are satisfied.
q Tilt repeats operation/stop, with different tilt time/cycle for each cycle, and the number of
tilts changes until loading is finished in accordance with loading object.
q The maximum speed depends on engine speed.
WA500-6R 21
5. Pump swash plate control
Function
In pump swash plate control, “horsepower loss decrease function in pump relief” and “pickup auxiliary
function when engine speed is low” are included, and based on calculation results of each function, data
with less pump delivery (larger pump EPC current) will be selected.
1) Horsepower loss decrease function in pump relief

q Horsepower loss is decreased by controlling pump delivery in relief, changing the command
value of the pump swash plate, when the work equipment pump is relieved.
q Output to pump EPC is changed with input signal of the loader pump pressure sensor.
22 WA500-6R
q The work equipment controller operates pump EPC in 200 mA until loader pump pressure reaches 32
MPa, and when it becomes 33 MPa or higher, the controller operates pump EPC in 700 mA.
q In this control, the delivery (pump EPC current) is changed over a second from 700 mA to 200 mA in
order to prevent sudden operation due to rapid increase of flow rate, when the delivery changes in
increasing direction (current decreasing direction).
Pump pressure Current value (A) Pump flow rate

33.3 MPa 0.2 100%
34.3 MPa 0.7 C 30%
WA500-6R 23
2) Pickup auxiliary function when engine speed is low

q When the engine speed is low and torque is low, acceleration of the engine in work equipment
operation is aided by limiting the pump delivery.
Engine speed is < 1,400 rpm

O
Pump flow rate restriction
24 WA500-6R
q The work equipment controller operates pump EPC in 200 mA until engine speed reaches 500
rpm, and when it becomes 950 rpm or higher, the controller operates pump EPC in 700 mA.
Engine Speed Current value (A) Pump flow rate
500 rpm 0.9 MIN
1,000 rpm 0.569 C 40%
1,400 rpm 0.2 100%
WA500-6R 25
6. Control of joystick steering
Function
1) Joystick Steering (J/S) system
q Joystick steering controls the turning speed according to the joystick lever operation angle.
q Standard steering system is added with a system for implementing Orbit-roll operation using
joystick solenoid valve.
q Therefore, even during a joystick steering operation, turning operation can be made using the
steering wheel.
q Transmission controller controls validity/invalidity of joystick steering system. When the
machine monitor joystick indicator is other than lit (turned out or flashing), turning operation
can not be made using the joystick lever.
2) Joystick neutral safety

q When starting engine with the joystick steering system being valid (J/S ON/OFF switch = ON
and J/S unlocked), if the joystick lever is set to other than neutral and the joystick knob FNR
switch is set to other than neutral, engine start signal is cut off to inhibit engine start by turning
the neutral safety relay ON to prevent the machine from turning and starting immediately after
engine start.
3) Joystick neutral interlock

q A safety function is incorporated to the system to disable turning operation using joystick lever
until it is returned to the neutral position even if joystick is turned valid with the joystick lever in
operation while the joystick steering is invalid (J/S ON/OFF switch = OFF or J/S is locked).
26 WA500-6R
4) Adjustment of starting current

q The work equipment controller has an adjusting function for correcting dispersion.
q The work equipment starting current usually does not require adjustment. However, if phenom-
ena such as “the neutral dead zone is large” or “dashing/stopping shock from J/S turning is
large” or “the time lag for turning operation start is large” should occur, they can be improved by
implementing an adjustment.
a For the adjusting procedure, refer to “Testing and adjusting: Adjusting the J/S starting cur-
rent.”
5) Joystick setting
q Since the joystick is an optional equipment, control will not be performed unless the option set-
ting for joystick is made valid in the optional setting of the machine monitor. It cannot be simul-
taneously installed with the right FNR switch.
a For the setting procedure of options, refer to “Testing and adjusting: Select optional equip-
ment.”
WA500-6R 27
1) List of display contents of the real-time monitor
In WA500-6, the state of the controller input and output signals can be checked using the real-time
monitor function of the monitor.
The following table shows the display items and display contents in normal operation of the real-
time monitor in relation to the work equipment controller:
Display of Contents of Display contents in
No. Check item ID No. Remarks
item name display data normal operation
Software part Part No. of software is dis- Depends on the software
1 20202 VERSION
number played number
Application Ver- Application version num- Depends on application
2 20225 VERSION APP
sion ber is displayed version number
Data version number is Depends on data version
3 Data Version 20226 VERSION DATA
displayed number
When work equipment is
Converted value of the in neutral
Loader pump
4 94700 PUMP PRESS loader pump oil pressure : 2.0±2.0 MPa
pressure
is displayed Work equipment relief
: 34.0±2.0 MPa
Input voltage value of in neutral
Loader pump
5 94701 PUMP PRESS loader pump oil pressure : 0.70±0.2 V
pressure
is displayed Work equipment relief
: 3.22±0.2 V
Li (800 rpm)
: 421±30 mA
Hi (above 950 rpm)
Loader pump Loader pump EPC OUT : 200±10 mA
6 EPC current 94500 PUMP EPC DIR command current value is Work equipment relief
(Command) displayed : 700±10 mA
Engine stop (below 500
rpm)
: 900±10 mA
in neutral:
Pump delivery Results of pump delivery
7 94600 PUMP FLOW 170 CC/R
flow rate calculation are displayed
Work equipment in relief:
23±10 CC/R
Standard lift arm
Lift arm top
: 47.0±2.0 deg
Lift arm bottom
Calculation results of lift : -43.0±3.0 deg
8 Lift arm angle 06002 BOOM ANG
arm angle is displayed Hi-lift lift arm
Lift arm top
: **.*±2.0 deg
Lift arm bottom
: -**.*±3.0 deg
STD lift arm
Lift arm top:
3.80±0.3 V
Lift arm bottom:
Input voltage value to lift
1.31±0.5 V
9 Lift arm angle 06005 BOOM ANG arm angle sensor potenti-
Hi-lift lift arm
ometer is displayed
Lift arm top:
**.*±0.3 V
Lift arm bottom:
**.*±0.5 V
Operation angle con- In WA500-6,
verted value of AJSS there is no cor-
10 Frame angle 94400 FRAME ANGLE —
frame potentiometer is responding
displayed functions
Number of lift Number of lift arm lever Display in accordance
11 arm lever opera- 42100 BOOM LVR operations is displayed in with the number of lever
tions the unit of thousand operations
28 WA500-6R

Neutral
2.50 V±0.10 V
Raise (before detent)
3.89 V±0.20 V
Lever potenti- Input voltage value to lift
Raise (detent position)
12 ometer voltage 42000 BOOM POT1 arm lever potentiometer 1
4.11 V±0.20 V
lift arm 1 is displayed
Lower (before detent)
1.11 V±0.20 V
Float (detent position)
0.89 V±0.20 V
Neutral
2.50 V±0.10 V
Raise (before detent)
1.11 V±0.20 V
Lever potenti- Input voltage value to lift
Raise (detent position)
13 ometer voltage 42001 BOOM POT2 arm lever potentiometer 2
0.89 V±0.20 V
lift arm 2 is displayed
Lower (before detent)
3.89 V±0.20 V
Float (detent position)
4.11 V±0.20 V
Bucket lever Number of bucket lever Display in accordance
14 operation fre- 42101 BUCKET LVR operations is displayed in with the number of lever
quency the unit of thousand operations
Neutral
2.50 V±0.10 V
Tilt (before detent)
Lever potenti- Input voltage value to
3.89 V±0.20 V
15 ometer voltage 42002 BUCKET POT1 bucket lever potentiome-
Tilt (detent position)
bucket 1 ter 1 is displayed
4.11 V±0.20 V
Full dump
0.89 V±0.20 V
Neutral
2.50 V±0.10 V
Tilt (before detent)
Lever potenti- Input voltage value to
1.11 V±0.20 V
16 ometer voltage 42003 BUCKET POT2 bucket lever potentiome-
Tilt (detent position)
bucket 2 ter 2 is displayed
0.89 V±0.20 V
Full dump
4.11 V±0.20 V
Neutral
Lift arm raise EPC output command
0±10 mA
17 EPC current 41900 RAISE EPC DIR current value to lift arm
Max.
(Command) raise is displayed
896±10 mA
Neutral
±10 mA
Lift arm lower EPC output command
LOWER EPC Before detent
18 EPC current 41901 current value to lift arm
DIR : 640±10 mA
(Command) lower is displayed
Float position
: 1,000±10 mA
Neutral
Bucket tilt EPC EPC output command
0±10 mA
19 current (Com- 41902 TILT EPC DIR current value to bucket tilt
Max.
mand) is displayed
930±10 mA
Neutral
Bucket dump EPC output command
0±10 mA
20 EPC current 41903 DUMP EPC DIR current value to bucket
Max.
(Command) dump is displayed
848±10 mA
In WA500-6,
EPC output command
J/S EPC cur- there is no cor-
21 41908 AJSS EPC DIR current value to AJSS is —
rent (command) responding
displayed
functions
* J/S = Joystick steering
WA500-6R 29

J/S right EPC EPC output command
22 current (com- 41904 J/S EPC DIR RH current value to J/S right Neutral
mand) is displayed 0±10 mA
J/S left EPC EPC output command Max.
23 current (com- 41905 J/S EPC DIR LH current value to J/S left is 850±10 mA
mand) displayed
Neutral
: 2.50 V±0.10 V
Lever potenti- Input voltage value to J/S
When fully turned right
24 ometer voltage 42004 J/S POTI1 lever potentiometer 1 is
: 1.34 V±0.20 V
J/S1 displayed
When fully turned left
: 3.66 V±0.20 V
Neutral
: 2.50 V±0.10 V
Lever potenti- Input voltage value to J/S
When fully turned right
25 ometer voltage 42005 J/S POTI2 lever potentiometer 2 is
: 1.34 V±0.20 V
J/S2 displayed
When fully turned left
: 3.66 V±0.20 V
3-spool valve 1, Neutral
EPC output command
ECMV and cur- 0±10 mA
26 41906 3RD EPC1 DIR current value to 3-spool
rent value Max.
valve 1 is displayed
(Command) 960±10 mA
3-spool valve 2,
EPC output command
ECMV and cur- Neutral: 0±10 mA
27 41907 3RD EPC2 DIR current value to 3-spool
rent value Max.: 960±10 mA
valve 2 is displayed
(Command)
Number of 3-spool valve
3-spool valve Display in accordance
lever operations is dis-
28 lever operation 42102 3RD LVR with the number of lever
played in the unit of thou-
frequency operations
sand
Lever potenti- Input voltage value to 3- Neutral: 2.50 V±0.10 V
29 ometer voltage 42006 3RD POT1 spool valve lever potenti- Retract: 4.11 V±0.20 V
3-spool valve 1 ometer 1 is displayed Extract: 0.89 V±0.20 V
Lever potenti- Input voltage value to 3- Neutral: 2.50 V±0.10 V
30 ometer voltage 42007 3RD POT2 spool valve lever potenti- Retract: 0.89 V±0.20 V
3-spool valve 2 ometer 2 is displayed Extract: 4.11 V±0.20 V
Operation angle con- In WA500-6,
AJSS lever verted value of AJSS there is no cor-
31 94300 AJSS LEVER —
operation angle lever potentiometer is dis- responding
played functions
In WA500-6,
AJSS lever Input voltage value of
there is no cor-
32 potentiometer 94301 AJSS LEVER AJSS lever potentiome- —
responding
voltage ter is displayed
functions
In WA500-6,
AJSS frame Input voltage value of
there is no cor-
33 potentiometer 94401 FRAME ANGLE AJSS frame potentiome- —
responding
voltage ter is displayed
functions
In WA500-6,
Deviation angle value of
AJSS S/T devi- S/T there is no cor-
34 94800 AJSS frame and lever is —
ation angle DEFLECTION responding
displayed
functions
During digging operation:
Digging-in- The state of digging flag
35 94900 WORK FLAG ON
progress flag is displayed
Other than above: OFF
30 WA500-6R

D-IN-0
00000000 : Semi auto
(Semi-auto switch = OFF) LOCK mode
10000000 switch
(Semi-auto switch = ON) D-IN-1
Input signal The state of input signal
36 40910 D-IN--0-----7 010000000 : Semi auto
D_IN_0-7 is displayed
(Semi-auto switch = ON) LOOSE mode
0010000000 switch
(J/S Hi-Lo selector D-IN-2
switch) : J/S Hi-Lo
selector switch
D-ON-8
11000000 : Tilt end prox-
(State of dump) imity switch
10000000 D-IN-9
(Bucket level) : Tilt level prox-
00000000 imity switch
Input signal The state of input signal (Full tilt) D-IN-10
37 40911 D-IN--8-----15
D_IN_8-15 is displayed 10100000 : Bucket posi-
(Bucket raise set switch = tioner raise set
ON) switch
10010000 D-IN-11
(Bucket lower set switch : Bucket posi-
= ON) tioner lower set
switch
D-IN-16
1000000
: Work equip-
(Work position)
ment N lock
Input signal The state of input signal 00000000
38 40912 D-IN-16-----23 switch
D_IN_16-23 is displayed (Lock position)
D-IN-17
01000000
: Starter C ter-
(While cranking)
minal signal
D-IN-28
0000000 :Lift arm posi-
00001000 tioner raise set
(Lift arm raise set SW = switch
Input signal The state of input signal
39 40913 D-IN-24-----31 ON) D-IN-29
D_IN_24-31 is displayed
0000010 : lift arm posi-
(Lift arm lower set SW = tioner lower set
ON) switch
Input signal
D_IN_32-39 There is no used items in
(No. 33-39 The state of input signal this data
40 40942 D-IN-32-----39
don't apply to is displayed 00000000 is constantly
work equipment displayed
controller.)
D-OUT-0
10000000 : Work equip-
(Lock position) ment N Lock
00000000 SOL
(Unlock neutral) D-OUT-1
ON/OFF output state of
01000000 : Lift arm raise
ON/OFF output SOL_OUT0 to 7
41 40952 D-OUT--0------7 (Raise detent SOL = ON) detent SOL
D_OUT_0--7 '0' is displayed when set-
00100000 D-OUT-2
ting current output
(Float detent SOL = ON) : lift arm float
0001000 detent SOL
(Tilt detent D-OUT-3
. SOL = ON) : Bucket tilt
detent SOL
WA500-6R 31

SOL_OUT8 to 13 and 00000000
ON/OFF output ON/OFF output state of (J/S cut relay: OFF) SOL-OUT-8
42 40953 D-OUT-8-----15
D_OUT_8--15 SIG_OUT0 and 1 10000000 : J/S cut relay
'0' is displayed when set- (J/S cut relay: ON)
ting current output
D-OUT-18
: Lift arm posi-
00001000
tioner raise set
(Operate safety relay)
SIG_OUT2 – 3 indicator ON
00010000
HSW_OUT0 – 1 D-OUT-19
ON/OFF output (Display lift arm positioner
43 40954 D-OUT-16----23 ON/OFF output state of : lift arm posi-
D_OUT_16--23 lower = ON)
BATT_RY_OUT is dis- tioner lower
00110000
played indicator ON
(Display lift arm positioner
D-OUT-20
raise/lower = ON)
: Operation
safety relay
32 WA500-6R
8. Diagnosis
1) Function of troubleshooting
The work equipment controller monitors the input and output signals constantly for troubleshooting
for the system.
If any abnormality is detected by self-diagnosis, the information on it is transmitted through the net-
work to the machine monitor. When abnormality occurs, it can be confirmed on the machine moni-
tor/KOMTRAX.
WA500-6R 33
9. Pin assignment
34 WA500-6R

DEUTSCH-24P [CN-L05]
Input and Input and
Pin No. Signal name Pin No. Signal name
output signals output signals
1 Bucket lever potentio B Input 13 Boom lever potentio B Input
2 Loader pump press. sensor Input 14 Third EPC lever B Input
3 J/S potentio B Input 15 NC Input
4 GND_SIG_D 16 NC Output
5 NC Input 17 Semiauto loading loose mode SW. Input
6 NC Input 18 NC Input
7 Bucket lever potentio A Input 19 Boom lever potentio A Input
8 Boom angle sensor Input 20 Third EPC lever A Input
9 J/S lever potentio A Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
11 J/S speed Hi/Lo select SW. Input 23 Semiauto loading lock mode SW. Input
DEUTSCH-40P(1) [CN-L06]
Input and Input and
1 NC Output 21 NC Input and output
2 NC Input 22 COMM_CAN_L_O Input and output
3 Remote positioner leveling set SW. Input 23 NC Input and output
4 NC Input 24 PWR_CTR_EXT Input
5 NC Input 25 Starting switch (IGN-C) Input
8 NC Output 28 NC Input
9 NC Output 29 NC
11 NC Output 31 NC
12 NC 32 COMM_CAN_H_O Input and output
13 Remote positioner lifting set SW. Input 33 NC Input and output
14 NC Output 34 NC
15 NC Input 35 Lever prohibiting equipment SW. Input
18 NC Output 38 NC Input
19 NC Output 39 NC
Input and out- Input and out-
put signals put signals
1 PWR_IN_BATT Input 21 GND_PWR
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 Safety relay Output 24 PWR_CTR_KEY Input
5 Bucket tilting EPC Output 25 Third EXT EPC Output
6 Boom lifting EPC Output 26 J/S solenoid cut relay Output
7 Work neutral lock solenoid Output 27 Magnetic detent of boom lever float Output
8 Remote positioner lifting indicator Output 28 J/S right EPC Output
10 Bucket cylinder tilt end SW. Input 30 Bucket positioner up set SW. Input
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 NC Output
15 Bucket dumping EPC Output 35 Third RET EPC Output
16 Boom lowering EPC Output 36 Loader pump EPC Output
17 Magnetic detent of boom lever lift Output 37 Magnetic detent of bucket lever tilt Output
18 Remote positioner lowering indicator Output 38 J/S left EPC Output
20 Bucket cylinder horizon SW. Input 40 Bucket positioner down set SW. Input
WA500-6R 35
Transmission controller system 1

1. Electrical circuit diagram
Transmission controller electrical circuit diagram (steering wheel specification)
With lockup (if equipped)
36 WA500-6R
WA500-6R 37
2. Transmission controller gear shifting control

1) Electronic modulation function
To reduce the shocks made when the gear speed is changed (when the clutch is engaged), the
modulation control is applied. The clutch oil pressure is controlled properly for the condition of the
hydraulic circuit, depending on the engine speed, transmission oil temperature, travel speed, and
gear shifting pattern and according to the transmission modulation data table saved in the transmis-
sion controller memory so that the transmission will be set in any gear speed (including the lockup
clutch) smoothly.
The modulation control is also performed for the clutch on the side to be turned off in order to
reduce lowering of the torque.
If an abnormal time lag is made in gear shifting, the learning function corrects the modulation auto-
matically.
2) Display of gearshift
The transmission controller displays the state of input signal related to gearshift by sending to the
machine monitor via network.
1] Directional indicators
The directional indicators of the machine monitor display the signal input state of the directional
lever, which is input to the transmission controller. Therefore, when the lever is in neutral posi-
tion, and there is no input signal to the transmission controller, the directional indicators totally
go out, and if two signals are input due to a problem, the two indicators may light up at the
same time.
If the directional lever is in “R” state, the backup lamp relay will be operated, and the back lamp
and back buzzer will be operated.
For the indication for the case where the machine is installed with right FNR switch (if
equipped) and the joystick steering (if equipped) with two systems of FNR signal, refer to the
items in the “Optional functions.”
2] Gear speed indicators

The gear speed indicators of the machine monitor display the signal input state of the gear
speed lever, which is input to the transmission controller. Therefore, when the lever is in neutral
position, and there is no input signal to the transmission controller, the gear speed indicators
totally go out, and if two signals are input due to a problem, an indicator different from the lever
position may light up, because priority is given to higher gear speed.
3] Display of actual gear speed

The actual gear speed display of the machine monitor shows the state of the gear speed and
travel direction, which is output from the transmission controller. When the directional lever is
in “N,” it will be “N” display, and when the directional lever is in “F” or “R,” it will be “F” or “R“+
gear speed display. This display will be always “N” since no gear speed is output while the
parking brake is ON.
38 WA500-6R
3) Automatic gear shifting function

In this function, auto shift, in which gear speed is automatically decided depending on travel speed,
and manual shift, in which the speed is decided as the gear speed of the gearshift lever, are
included. In auto shift, the auto shift indicator of the machine monitor lights up, and shifting up/down
and ON/OFF of the lockup clutch are changed with the engine power mode and selected shift
mode.
There are two modes, H/L, in auto shift, whose gearshift points are different depending on the
engine power mode.
In auto shift, shifting up/down are controlled in accordance with the directional lever, gearshift lever,
travel speed, accelerator pedal opening ratio, and data saved in the memory of the transmission
controller according to the engine speed. For the gearshift point of each mode, refer to “3: Auto-shift
points table.”
1] Gearshift lever in the 1st to 4th (when steering option is selected)

The maximum gear speed (gear shifting range) used in the automatic gear shifting operation is
limited.
In the automatic gear shifting operation, the vehicle usually starts in the 2nd gear speed.
Accordingly, if the gearshift lever is in 4th, the gear is shifted up and down between the 2nd
gear speed and 4th gear speeds, and the vehicle starts in the 1st gear speed only when the
kick-down function is used.
2] Directional lever in “N” position

The gear speed of transmission gearshift in neutral position is changed in accordance with
travel speed, but display will always be “N”.
4) Shift hold function

q The shift hold function will hold the current gear speed when the hold switch is pressed if the
auto-shift mode is selected, and will not shift up even when the travel speed is increased. Even
if the travel speed is decreased, the gear will not be shifted down.
q While the shift hold function is operating, the shift hold indicator of the machine monitor lights
up. When the shift hold switch is pressed again, the hold will be released, and the indicator will
go out.
q The hold will be released automatically also by the directional lever, gearshift lever, and kick-
down switch operation.
ON/OFF state of lockup will not be held.
5) Kickdown function
1] Kickdown in manual shift operation
q The kickdown switch operates only in the forward 2nd gear speed (F2), and the transmis-
sion is set in the forward 1st gear speed (F1). Operation of the kickdown switch is ignored
in any gear speed other than (F2).
q After the actual gear speed becomes (F1) due to kickdown switch operation, the kickdown
function will be released and the transmission will be set in the gear speed of the lever,
when the directional lever is operated to a position other than forward, or the gearshift
lever is operated to a position other than the 2nd gear speed.
WA500-6R 39
2] Kickdown in auto-shift operation

q The kickdown function will work regardless of the lever position, if the directional lever is in
a position other than N and the gearshift lever is in a position other than the 1st gear
speed.
q The gear speed selected by the operation of the kickdown switch depends on the travel
speed as shown in the following table.
q After the transmission gear is shifted because of the kickdown switch operation, ordinary
gear shift will be performed in accordance with the auto-shift points table, after the time
due to the no-shift time is passed or when the directional lever is operated.
<Reference>
Gear speed before Output shaft speed [rpm] Gear speed No-shift
Travel speed con-
shifting when kickdown switch = ON after shifting time
version
2nd All range 1st 5 sec
Below 824 12.5 km/h 1st 5 sec
3rd
Min. 824 12.5 km/h 2nd 4 sec
Below 824 12.5 km/h 1st 5 sec
4th
Min. 824 12.5 km/h 3rd 4 sec
2nd (lockup) All range 2nd *1
3rd (lockup) All range 3rd *1
4th (lockup) All range 4th *1
*1: When lockup is released due to kickdown switch operation, lockup will not be ON again
until the following conditions are satisfied.
a Perform temporary operation to turn the torque converter lockup switch OFF o ON.
a The travel speed changes from below to above lockup ON speed as listed in the Auto-shift
points table.
6) Torque converter lockup control function (if equipped)

q ON/OFF operation of the lockup is performed automatically due to ON operation of the torque
converter lockup switch.
q When the lockup clutch is ON, the lockup indicator of the machine monitor lights up.
q Even when the manual shift is selected, if the torque converter lockup switch is ON, ON/OFF of
the lockup is performed automatically by the transmission controller.
q The operation gear speed of lockup is shown in the following table.
Lockup operation gear speed (Lockup operates: Q)
Travel mode
F1 F2 F3 F4 R1 R2 R3 R4
MANUAL Q Q Q Q Q Q
Auto H Q Q Q Q Q Q
Auto L Q Q Q Q Q Q
1] Lockup rotation
For ON/OFF of lockup, refer to “3: Auto-shift points table.”
2] Lockup protection function

q Lockup ON only operates when the moving direction of the machine and the position of
the directional lever match.
Determination of moving direction of the machine
q The machine is thought to be stopping when the transmission controller is started (key
on), or the transmission output shaft speed is below 260 rpm.
q While the machine is thought to be stopping and the transmission output shaft speed
becomes 260 rpm or more, if the directional lever is in “F” position, it is thought to be mov-
ing forward, and if it is in “R” position, it is thought to be moving backward.
a The travel speed is approximately 4 km/h when the transmission output shaft speed is 260
rpm.
40 WA500-6R
7) Hunting prevention function

q The transmission controller prevents hunting by detecting hunting, which occurs between 2nd
and 3rd when auto shift is selected, with the controller.
q If gearshifts of 2nd to 3rd to 2nd to 3rd are performed within 6 seconds from the previous gear-
shift, hunting is thought to have occurred, and the gear speed is selected from 2nd or 3rd,
whose operation time is longer. When hunting prevention function operates, the shift point in
hunting prevention stated in “3. Auto-shift points table” will be selected for the next automatic
gear shifting operation.
q The operation of hunting prevention function ends when the next gear shift operation (including
FR, kickdown operation, etc.) is performed, and the gear will be set to the ordinary shift point of
the auto shift.
q When ON/OFF of 2nd lockup occurs consecutively within 5 seconds, the lockup will be turned
off, and the speed will be changed to lockup ON travel speed when the hunting prevention
function operates.
q The hunting prevention function operates when hunting occurs even in the manual shift.
8) Changing shift points

q The transmission controller has a function to adjust the gearshift points of L mode in auto shift.
q If hunting occurs due to the conditions in a job site, travel speed when shifted up/down can be
changed by adjusting the gearshift points.
a For the changing procedure, refer to “Testing and adjusting: L mode gearshift point adjust-
ment.”
9) 4th gear speed derating function

q The transmission controller has a function to limit the operation of the 4th gear speed by
changing the optional setting.
a For the changing procedure, refer to “Optional setting : Prohibition of 4th gear speed.”
10) Transmission initial learning and ECMV current adjustment

q The transmission controller has an adjusting function to correct dispersion between the trans-
mission unit and ECMV solenoid.
q If the adjustment is not performed, a gear shifting shock or a time lag may be made.
a For adjusting procedure, refer to “Testing and adjusting: Transmission initial learning and
ECMV current adjustment.”
WA500-6R 41
3. Auto-shift points table

q The relationship among transmission output shaft speed, engine mode, shift switch, and gear shift-
ing operation are shown below.
Unit: rpm
Engine mode and shift switch
Power mode Economy mode
Shift switch Shift switch Shift switch Shift switch
H L H L
F1oF2 395 395 362 362
F2oF2 (lockup) 560 – 660 560 – 660 540 – 632 540 – 632
F2oF2 (lockup)
692 – 824 692 – 824 659 – 744 659 – 744
when hunting is prevented
F2oF3 632 – 922 501 – 922 573 – 896 481 – 896
F2oF3
Gear shifting operation
698 – 903 698 – 903 639 – 876 639 – 876

F3oF3 (lockup) 942 – 1120 942 – 1120 909 – 1054 909 – 1054
F3oF4 1166 – 1502 1120 – 1502 1080 – 1430 1034 – 1430
F4oF4 (lockup) 1614 1614 1548 1548
F4 (lockup) oF4 1436 1436 1370 1370
F4oF3 1034 – 1436 988 – 1436 949 – 1370 903 – 1370
F3 (lockup) oF3 850 850 817 817
F3oF2 501 – 850 329 – 850 441 – 817 270 – 817
F3oF2
501 – 725 329 – 725 441 – 679 270 – 679
F2 (lockup) oF2 514 514 494 494
a The transmission output shaft speed of 1 rpm corresponds to 0.0145 km/h.

a The shifting down point of F4 o F2 and F3 o F2 will be 66 rpm, when the accelerator is idle.
42 WA500-6R
4. Transmission controller protection function

1) Protection function when changing FR
In order to protect the transmission, the controller limits changing F-R operation with the directional
lever during high-speed travel.
1] All range of auto modes (speed position switch at a position other than 1st gear speed) and
manual mode (2nd, 3rd, and 4th)
In auto-shift mode
Range I: F-R is changed and transmission is set in 2nd gear speed. (Ordinary range)
Range II: F-R is changed, transmission is set in 2nd gear speed, and the alarm is turned ON.
Range III: F-R is changed, and the alarm is turned ON. The gear speed of transmission gear-
shift depends on the travel speed.
Then, transmission is shifted down to 2nd gear speed with reduction of the travel
speed.
In manual-shift mode
Range I: Only F-R is changed. (Ordinary range)
Range II: F-R is changed, and the alarm is turned ON.
Range III: F-R is changed, and the alarm is turned ON. The gear speed of transmission gear-
shift depends on the travel speed.
Then, transmission is shifted down to the speed position with reduction of the travel
speed.
a Two seconds immediately after the F-R changing operation, shifting up/down and kick-
down switch operation will not be accepted, and if shifting up/down operation is performed
with the lever operation, gear shift will be performed in two seconds.
In auto-shift, shifting up will not be performed until 2nd gear speed is obtained by speed
reduction.
Transmission output shaft speed before gear shift (rpm)

A B C
856 922 1054
Remarks
13 km/h 14 km/h 16 km/h
(Travel speed conversion)
WA500-6R 43
2) Protection function in shift-down operation

q In order to protect the engine and pump, the transmission controller performs shift-down protec-
tion, in which operations are not accepted while shifting down, and the alarm is turned ON while
it is operating.
q The operation conditions of the shift-down protection is shown below, and the alarm goes ON until
the gear shift position of the shift lever and the actual output gear shift match. Therefore, even
when the travel speed does not decrease, performing the shift-up operation will stop the alarm.
Protection condition Condition for resetting protect
Target gear speed Transmission output Transmission output
Engine speed Engine speed
to shift down shaft speed shaft speed
To 3rd gear speed Min. 1,721 rpm — Below 1,549 rpm —
Min. 1,102 rpm — Below 861 rpm —
To 2nd gear speed
Min. 895 rpm Min. 1,620 rpm Below 964 rpm Below 1,440 rpm
To 1st gear speed Min. 895 rpm — Below 861 rpm —
q The shift-down protection is valid also in kickdown operation in auto-shift. If the machine is
traveling in travel speed above the protect condition when kickdown operation is performed,
the kickdown operation is not accepted, and the alarm goes ON for 3 seconds.
3) Protection function in lockup

q When the transmission output shaft speed becomes equivalent to the engine speed of 2,525 rpm
or above, the lockup is released automatically for preventing engine over run, and the alarm goes
off. For 5 seconds after it is released temporarily, the lockup stays OFF, but if after 5 seconds
pass and the transmission output shaft speed becomes equivalent to the engine speed of below
2,375 rpm, lockup will be on again. (Function of engine overrun prevention)
Lockup OFF travel speed by function of engine overrun prevention (reference)
Lockup operation OFF value (equivalent to engine speed of 2,525 rpm)
WA500-6R
Actual gear speed
Output shaft speed (rpm) Reference travel speed (km/h)
F2 1137 17.3
F3 1908 29.0
F4 3250 49.3
R2 1281 19.4
R3 2151 32.6
R4 3661 55.6
4) Protection function by shift-up

q When traveling in T/C, if the engine speed becomes 2,525 rpm or more, transmission is shifted
up and the alarm goes ON. After shifting up, it will not be shifted down for 3 seconds.
q After 3 seconds pass, when the engine speed becomes below 2,375 rpm, the alarm stops and
the shift control becomes the ordinary control.
q When traveling in 4th gear speed, shift-up is not performed, and only the alarm goes ON.
5) Function to warn operation of overrun prevention action warning

q When the engine speed becomes 2,425 rpm or more, the function to warn operation of overrun
prevention action warning operates.
q The alarm is released when the engine speed becomes below 2,325 rpm.
6) Neutralizer function
q When the parking brake switch is ON (while the parking brake switch is operating), transmis-
sion output is maintained in neutral regardless of the state of the gearshift lever, for parking
brake dragging prevention function.
q The parking brake switch circuit is a safety circuit, which will be not open when the key switch
is changed from OFF to ON. Therefore, while the key is on, transmission is always in neutral
regardless of the state of the lever.
44 WA500-6R
5. Engine control
1) Engine torque curve switching function

q The transmission controller selects engine power mode from signal input of engine power
mode changing switch, and while it sends torque curve information used in the engine control-
ler, it also sends engine power mode information of power/economy to the monitor panel.
2) Maximum travel speed limit

q For lower fuel consumption in load and carry, the maximum travel speed is limited by setting
the maximum travel speed (select from three levels), and setting the upper limit to throttle
value in F4 lockup state.
Throttle value
Setting information
upper limit
(1) (Default) 90%
(2) 100%
(3) 80%
3) Throttle lock
q For improving the working efficiency, the engine speed is maintained at an arbitrary speed.
q The engine speed is set with pressing the accelerator pedal, and RMP set idle up/down switch.
q When the right brake is pressed, throttle lock is temporarily released.
q For lower fuel consumption, in a setting with auto deceleration function, if the transmission
neutral continues for 4 seconds or the work equipment neutral state lasts for 4 seconds or
longer, if the throttle lock SET/ACCEL SW and throttle lock RESUME/DECEL SW are not oper-
ated, and if the travel speed is 5 km/h or less, the throttle lock function is temporarily released,
and transmission follows the signal of the accelerator pedal.
q In the state where the throttle lock is temporarily released, if the transmission is set to a posi-
tion other than neutral, or the work equipment is in a state other than N, the throttle control
state will be resumed automatically.
Right brake pedal oper-

Throttle lock
Compo- Throttle lock function Throttle lock SET/ ation (released) switch Throttle lock indica-
RESUME/DECEL
nent list switch ACCEL switch (Left brake tor lamp
switch
switch = OFF)
Switch
Alternate 3-position Momentary proximity
composi- Momentary seesaw switch Lamp
switch switch
tion
Brake operated (GND) ON
Switch ON(GND) ON(GND)
Brake not operated Performed through
theory OFF(OPEN) OFF(OPEN)
(OPEN) electrical circuit
When this switch is Function to set Resume function
pressed upward, throttle stroke While the throttle
“throttle lock auto Save the throttle lock function is
deceleration func- stroke when it is ON released with the
tion is disabled.” (lock accelerator right brake pedal
When this switch is opening ratio) operation (release),
pressed downward, Controls with input press this switch
“throttle lock auto signal edge and the throttle lock When the right brake
deceleration func- function is resumed. pedal is pressed for 0.5 Output is ON when
Function tion is enabled.” Controls with input sec. continually, the throttle lock ON/OFF
signal edge throttle lock function is switch is ON.
temporarily released.
When this switch is When acceleration When deceleration
pressed in the mid- function switch is function switch is
dle, the throttle lock pressed for 0.5 pressed for 0.5
function is OFF. sec.continually, set sec.continually, set
throttle stroke rises throttle stroke low-
by the time the ers by the time the
switch is pressed. switch is pressed.
WA500-6R 45
q For description of the throttle lock function, a sample time chart is shown below.
46 WA500-6R
6. Transmission cut-off
1) Transmission cut-off control

q A function to set the transmission in neutral by detecting the brake pilot oil pressure with the
pressure sensor when the left and right brake pedals are stepped on.
This function enables cut-off at an optional position by saving the brake pedal pressing position
where the transmission becomes neutral as the brake pilot oil pressure.
1] Contents of transmission cut-off control

When transmission cut-off switch “ON” and if pressure of left brake pressure
sensor signal exceeds set pressure, this switch sets the transmission in neu-
tral.
Outline (When the transmission cut-off operation condition is met)
Gear changes by cut-off return modulation provided the pressure drops
below the return pressure during cut-off or the condition for resetting trans-
mission cut-off is met and the left brake operation switch becomes “OFF”.
Operating condition at 1st and 2nd speed
Transmission When transmission cut-off switch is “ON” and brake pilot pressure
cut-off control becomes > cut-off IN pressure
Operating
condition Operating condition at 3rd and 4th speed
When transmission cut-off switch is “ON” and accelerator opening is less
than 30% (including 2nd speed low idle operating state), and the brake
pilot pressure becomes > cut-off IN pressure
{When transmission cut-off switch is “OFF“}
Condition for
or
resetting
{Transmission cut-off pressure is < cut-off OUT pressure}
Settable con-
Transmission cut-off switch is “ON”.
dition
(1) Press left brake pedal to the set position.
(Setting is enabled without stepping on the brake)
(2) Press the transmission cut-off switch.
(3) Transmission controller temporarily saves the pressure at the time the
switch is pressed if it is within the setting-enabled range.
If outside the range, the transmission controller temporarily saves the
Setting upper and lower limit pressure and transmits information for sounding the
method setting complete buzzer for 2 times (pip, pip) over the network to the
monitor.
Setting of trans-
(4) At this time, the built-in indicator in the transmission cut-off switch blinks
mission cut-off
for 2.5 seconds.
point
(5) After the indicator blinks for 2.5 seconds, the setting is saved. (end of set-
ting mode)
(Set condition is still held after the key is turned off.)
(1) During the 2.5 seconds in step (4) of the above setting method (while the
transmission cut-off switch built-in indicator is blinking), press the trans-
mission cut-off switch again.
Resetting (2) Indicator stops blinking and cut-off point is set to default left brake pres-
method sure. Transmit to the monitor information for sounding the setting cancel
buzzer over the network.
(3) Set (Default) value is saved. (end of setting mode)
(Set condition is still held after the key is turned off.)
WA500-6R 47
2] Outputting conditions for buzzer, indicator (main monitor), and indicator in transmission cut-off
switch
Indicator in trans- Buzzer command
Output conditions mission cut-off (Communication Cut-off point
switch output)
When transmission cut-off switch is Controlled with value
ON Not displayed
“ON“ saved last
2.5 seconds when transmission cut-
When set switch is Controls with previously
off switch is “ON” and transmission Blinking
pressed, set com- saved value
cut-off set switch is “ON” or resetting (2.6 sec or until
pletion buzzer Saves the pressure that
(while sensor being normal) and set- reset)
sounds pressed the set switch
ting method being (2) to (5).
When transmission cut-off switch is Not displayed No control is made
“ON” and pressure sensor is abnor- Remains turned out (Error buzzer Saved value is not
mal (see FMEA) sounds) changed
Controlled with value
When transmission cut-off switch is Not displayed
saved previous time
“ON” and set switch is abnormal (see ON (Monitor displays
Saved value is not
FMEA) error)
changed
When transmission cut-off switch is
“ON” and transmission cut-off set Set cancel buzzer Controls with previously
switch is “ON“ ON sounds when set saved value
switch is pressed Saves the default
Reset within 2.5 sec
When transmission cut-off switch is
OFF Not displayed Not controlled
“OFF“
a During cut-off, actual transmission gear speed will be indication as N (neutral). (FNR out-
put number will be “N“)
a During lockup, lockup will be cancelled to implement cut-off.
a If cut-off is made after reaching 1st speed with kickdown switch, gear should return to 1st
gear speed for both auto/manual shift.
3] Setting enabled range of transmission cut-off point

Setting enabled range: 0.49 MPa – 4.41 MPa
q Add hysteresis of 0.2 MPa to the cut-off IN (for neutral) pressure and OUT (reset) pres-
sure.
Example)
When cut-off point is set to position of 0.98 MPa of pressure sensor
Cut-off IN pressure = 0.98 MPa
Cut-off OUT pressure = 0.78 MPa
a If the pressure sensor is set for under 0.49 MPa, the set value is 0.49 MPa.
a If the pressure sensor is set for over 4.41 MPa, the set value is 4.41 MPa.
The default value is 1.47 MPa.
48 WA500-6R
7. ECSS
1) ECSS function
q It is a system in which the controller automatically turns on and off the accumulator charged
with high-pressure gas according to the travel condition, and the lift arm operation condition,
improving operator comfort and working efficiency by preventing spillage of material by absorb-
ing the vertical movement of the work equipment, when the vehicle travels at high speed.
WA500-6R ECSS system

1] ECSS system circuit
2] Operation of ECSS
q The operating condition of ECSS is as follows.
Since the ECSS is optional equipment, control will not be performed unless the option of
ECSS is enabled in the optional setting of the machine monitor.
ment.”
Output shaft
ECSS switch Gear speed ECSS output
speed
OFF All 0 to MAX OFF
1st 0 to MAX OFF
ON Condition A OFF
2nd to 4th
Condition B ON
q The transmission output shaft speed of 198

rpm corresponds to approximately 3 km/h.
q The transmission output shaft speed of 329
rpm corresponds to approximately 5 km/h.
WA500-6R 49
3] Operation of solenoid in ECSS ON/OFF

q Modulation control is performed for the ECSS solenoid with EPC output in switching ON/
OFF, reducing the lowering of the lift arm and occurrence of switching shocks.
q The constant current when the ECSS solenoid is ON is 800 mA.
8. Economy lamp
1) Control of economy lamp
q The transmission controller lights up the economy lamp indicator of the machine monitor when
operating in low fuel consumption, in order to prompt low fuel consumption operation to the
operator.
1] Lighting condition of economy lamp

q When the engine power mode is the economy mode, and the accelerator pedal opening
ratio is 80% or less, the economy lamp is lighted.
Accelerator Power Economy
opening ratio mode mode
Min. 80% OFF OFF
Max. 80% OFF Lighting
2] Turning off economy lamp

q The economy lamp can be constantly kept off with the optional setting of the monitor.
a For the setting procedure, refer to “Testing and adjusting: Select optional equipment.”
50 WA500-6R
9. Cooling fan control

1) Control of fan
q Employment of the hydraulically driven cooling fan as well as controlling its speed through con-
trol of the hydraulic pump swash plate allows reducing the horsepower loss and noises in low
temperature environment.
q Engine speed and coolant temperature received by the engine controller and hydraulic oil tem-
perature and torque converter oil temperature received by the machine monitor are sent to the
transmission controller via the network.
q Based on the received information, the transmission controller sends the signal current to the
swash plate angle control EPC valve on the cooling fan pump, so that the valve may control
the swash plate angle in order to set the fan speed to a level suitable for the given temperature
level and the engine speed.
WA500-6R 51
2) Fan speed in accordance with temperature

q As for the fan speed, the target fan speed is determined based on the data with highest tem-
perature among coolant temperature, hydraulic oil temperature, and torque converter oil tem-
perature.
q Fan speed
3) Protection function
q In order to prevent overrun of the cooling fan motor, this function minimizes the swash plate
angle of the cooling fan pump as the engine speed reached 2,300 rpm or above.
q If the transmission controller fails to recognize the engine speed and respective temperature
data due to a failure on the network communication, this function sends a specific command
current (677 mA) to the swash plate angle control EPC valve on the pump so that the pump
may work functionally – equivalent to a fixed pump.
52 WA500-6R
4) Control for starting engine

In fan control, a different control from the ordinary control with temperature when starting the
engine.
q When stopping the engine (key switch 1-stage on)
When the engine is stopped, the cooling fan pump EPC current of 677 mA is output, for it is the
same as a state where the engine speed cannot be recognized.
q While cranking
While cranking to start the engine, in order to improve engine start, the minimum swash plate is
used for the cooling fan pump by setting the fan EPC current to 850 mA, reducing the torque
necessary for starting the engine.
WA500-6R 53
5) Fan reverse rotation function

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

q It is a function to reverse the fan rotation arbitrarily by the operator. By pressing the fan
manual reverse switch, the turning direction of the fan is changed.
q Changing from forward to reverse, and reverse to forward is performed when the following
conditions are satisfied.
q The fan manual reverse switch is pressed
q The engine speed is 500 rpm or lower.
q The fan reverse indicator flashes when the state of the fan manual reverse switch and the
rotation direction of the fan do not match. While the fan is rotating in reverse direction, the
fan reverse indicator lights up.
Reverse SOL out- Forward/reverse
Reverse SOL Fan pump EPC Monitor indicator lighting
put before switch selector switch Engine speed
output output logic
operation operation
OFF From OFF to ON ON MIN speed From OFF to ON
OFF From ON to OFF OFF Ordinary From flashing to OFF
Below 500 rpm
ON From OFF to ON ON MIN speed From flashing to ON
ON From ON to OFF OFF Ordinary From ON to OFF
OFF From OFF to ON OFF Ordinary From OFF to flashing
OFF From ON to OFF OFF Ordinary From flashing to OFF
Min. 500 rpm
ON From OFF to ON ON MAX speed From flashing to ON
ON From ON to OFF ON MAX speed From ON to flashing
2] Fan reverse rotation function

q Not used.
3] Fan speed in reverse

q While it is operating in reverse, cleaning of the radiator core is facilitated by increasing air
flow by turning the fan at the maximum speed without outputting fan pump EPC current
(output 0 mA).
54 WA500-6R
10. Right FNR switch control (if equipped)
Right FNR switch control

q An optional equipment installed to the side of the work equipment lever separately from the stan-
dard FNR lever. It enables to change travel direction with the right hand by arranging the directional
selector switch.
1) Change of right FNR

q When using only the standard FNR lever, FNR lever input signal equals to FNR recognition.
When multiple switches are installed for the identical purpose of switching the travel direction,
however, the selector switch is provided to select operation.
a Switching of operation to the right FNR switch is made when the right FNR validity switch is
turned ON. The operational priority will be given to the FNR lever (standard FNR lever), how-
ever.
q Switching condition to the right FNR switch will be to turn the right FNR validity switch ON
when the standard FNR lever is at N (neutral) and the right FNR switch is at N (neutral). Only
then the switching of travel direction is enabled with the right FNR switch.
a When the travel direction is selectable with the right FNR switch, the right FNR indicator on the
machine monitor is lit.
a If either one of the switches is at other than N (neutral) and the right FNR validity switch ON-
OFF is operated, the buzzer will be actuated and right FNR indicator flashes on the machine
monitor.
q In addition, even if the right FNR switch is enabled, if the standard FNR lever is operated to
other than N (F or R), the standard FNR lever will have the priority. As the result, the standard
FNR lever will control the travel direction. Since the switching has not been made normally, the
warning will be actuated and the right FNR indicator on the machine monitor will start flashing.
a The alarm is actuated and the right FNR indicator started flashing, the alarm will not stop
unless and until both the standard and the right FNR switches are set to N (neutral), and the
right FNR switch will not function to effect forward-reverse travel.
The following table outlines the above contents.

Right FNR Monitor operation
Mode Condition FNR recognition
valid/invalid state (Reference)
Lever: [ F or N or R ]
Pilot lamp turns
<a> lever Right SW: [ N ] Follows the FNR OFF
OFF
(Normal) Right FNR lever (Invalid)
buzzer stop
validity SW: [ OFF ]
Lever: [ N ]
Pilot lamp turns
<b> seasaw SW Right SW: [ F or N or R ] Follow the right ON
ON
(Normally [right switch]) Right FNR FNR seasaw SW (Valid)
buzzer stop
validity SW: [ ON ]
Lever: [ F or R ]
Pilot lamp is
<c> lever has priority Right SW: [ F or N or R ] Follows the FNR OFF
FLASHING
(Emergency operation) Right FNR lever (Invalid)
buzzer sounding
validity SW: [ ON ]
Lever: [ F or N or R ] Follows the FNR
Pilot lamp is
<d> lever SW error Right SW: [ F or R ] lever OFF
FLASHING
(Operation error) Right FNR (Right SW is disre- (Invalid)
buzzer sounding
validity SW: [ OFF ] garded)
Lever: [ other than N ]
Pilot lamp is
<e> switching error Right SW: [ other than N ] Follows the FNR OFF
FLASHING
(Operation error) Right FNR lever (Invalid)
buzzer sounding
validity SW: [ OFF ⇔ ON operation ]
* SW = Switch
WA500-6R 55
2) Interlocking at starting engine (engine start inhibited)

To prevent the machine from starting travel suddenly immediately upon engine start, starting motor
C terminal signal is cut by actuating the neutral safety through the work equipment controller in the
case the right FNR validity switch is at ON position and the right FNR switch is at other than N (neu-
tral) position.
3) Setting of the right FNR switch

Since the right FNR switch is an optional device, it does not perform control unless the right FNR
optional setting is enabled with the option setting on the machine monitor. Also no simultaneous
installation with the joystick steering is enabled.
ment.”
11. Joystick
Control of joystick steering

q This is an optional device that enables turning machine (steering operation) and forward-reverse
travel, shift-up/-down by using the joystick lever provided to the left console.
Since turning of the machine is performed by the work equipment controller, refer to the section of
work equipment controller for turning operation by the joystick.
1) Switching to the joystick

q When using only the standard FNR lever, FNR lever input signal equals to FNR recognition.
When multiple switches are installed for the identical purpose of switching the travel direction,
however, the select switch is provided to select operation.
Switching of operation to the FNR switch on the joystick knob is made only when the joystick
validity switch is ON and the joystick lock lever is cancelled. The FNR lever (standard FNR
lever) will have complete priority for operation, however.
a Switching conditions of the joystick to the FNR switch (hereinafter referred to as the joystick
switch) are as follows:
Selection of the travel direction becomes enabled with the joystick switch by turning the joy-
stick validity switch ON and canceling the joystick lock lever while the “standard FNR lever is at
N (neutral)” and the “joystick switch is at N (neutral).”
When the travel direction is selectable with the joystick switch, the joystick indicator on the
machine monitor is lit.
If either one of the switches is at other than N (neutral) and the joystick validity switch ON/OFF
is operated, the alarm will be actuated and the joystick indicator flashes on the machine moni-
tor.
q In addition, even if the joystick switch is enabled, if the standard FNR lever is operated to other
than N (F or R), the standard FNR lever will have the priority. As the result, the standard FNR
lever will control the forward-reverse travel. Since the switching has not been made normally,
the alarm will be actuated and the joystick indicator on the machine monitor will start flashing.
Once the alarm is actuated and the joystick indicator started flashing, the alarm will not stop
unless and until both the standard FNR lever and the joystick switches are set to N (neutral),
and the joystick switch will not function to effect forward-reverse travel.
q In the case the joystick indicator is not lit, forward and reverse operation are disabled, simulta-
neously the turning operation by the joystick also being disabled.
56 WA500-6R
The following table outlines the above contents.

JS
FNR recog- Monitor operation
Mode Condition valid/invalid
nition (Reference)
state
Lever: [ F or N or R ] Pilot lamp turns
<a> lever Follows the OFF
JS SW: [ N ] OUT
(Normal) FNR lever (Invalid)
JS validity SW: [ OFF ] buzzer stop
Lever: [ N ] Pilot lamp turns
<b> JS SW Follow the ON
JS SW: [ F or N or R ] ON
(Normal [JS]) JS FNR SW (Valid)
JS validity SW: [ ON ] buzzer stop
<c> lever has priority Lever: [ F or R ] Pilot lamp is
Follows the OFF
(Emergency opera- JS SW: [ F or N or R ] FLASHING
FNR lever (Invalid)
tion) JS validity SW: [ ON ] buzzer sounding
Lever: [ F or N or R ] Follows the
Pilot lamp is
<d> lever SW error JS SW: [ F or R ] FNR lever OFF
FLASHING
(Operation error) JS validity SW: [ OFF ] (JS SW dis- (Invalid)
buzzer sounding
regarded)
Lever: [ other than N]
Pilot lamp is
<e> switching error Right SW: [ other than N] Follows the OFF
FLASHING
(Operation error) Right FNR FNR lever (Invalid)
buzzer sounding
JS validity SW: [ OFF ⇔ ON operation ]
a JS validity switch [ON] in the table indicates the state where JS validity switch [ON] and JS lock lever being
cancelled and [OFF] indicating the state where J/S validity switch [OFF] or JS lock lever locked
* JS refers to the joystick steering system. * SW = Switch
WA500-6R 57
2) Joystick shift-up and shift-down switch

q The joystick shift-up and shift-down switch performs shift-up and shift-down in the manual shift
mode in the gear speed below the gear speed of the gearshift lever. (Not set to a gear speed
above the gear speed lever position) If the “current gear speed should exceed the gear speed
lever position”, the switch performs shift-down to the gear speed of the gear speed lever posi-
tion same as the normal shift-down.
a However, when shifting down during high-speed travel, the shift-down protection function oper-
ates and shifting down will be performed after the travel speed has decreased.
q In the case the shift mode is in auto shift mode (both H and L), the shift-up and shift-down
switch of the joystick lever does not function and the range switch only by the gear speed lever.
1] Function of shift-up and shift-down switch

q When the shift-up and shift-down switch is operated at the same time, shift down is effec-
tive.
After pressing the switch once, the next shift-up and shift-down switch operation is not
accepted for intermittent 0.2 seconds.
3) Interlocking at starting engine (engine start inhibited)

q To prevent the machine from starting travel suddenly immediately upon engine start, starting
motor C terminal signal is cut by actuating the neutral safety relay through the work equipment
controller in the case the joystick validity switch is at ON position and the joystick lock lever is
in open state and the joystick FNR switch is at other than N (neutral) position.
(Starting motor signal is cut if the joystick indicator is in flashing state.)
q Also, in the case the joystick lever is operated when the joystick is in valid state, the work
equipment controller sends an engine start inhibit information to actuate the neutral safety
relay and cut the starting motor C terminal signal.
4) Joystick setting
q Since the joystick is an optional equipment, it makes no control unless the option setting for
joystick is made valid in the optional setting on the machine monitor.
q It cannot be simultaneously installed with the right FNR switch.
ment.”
58 WA500-6R

1) List of display contents of the real-time monitor
In WA500-6, the state of the controller input and output signals can be checked using the real-time
monitor function of the monitor.
The following table shows the display items and display contents in normal operation of the real-
time monitor in relation to the transmission controller:
Display of
No. Check item ID No. Contents of display data Data unit (and range) Remarks
item name
Software part Output mass production Depends on the software
1 20201 VERSION
number software part number part number
Output software version
Software appli- Depends on the software
2 20223 VERSION(APP) (software logic part ver-
cation version version
sion)
Software appli- Output software version
Depends on the software
3 cation data ver- 20224 VERSION(DATA) (software data part ver-
version
sion sion)
Output engine mode for
0: power mode
4 Engine mode 41600 ENGINE MODE controlling engine out-
2: economy mode
put
X1 [mA]
(0 – 1000 [mA])
When engine speed is
below 500 rpm
= 677 mA
ECMV output Output to FAN EPC out-
While cranking (C termi-
5 command value 41400 FAN EPC DIR put command current
nal operation)
(FAN pump) value
= 850 mA
Switching fan reverse
= 850 mA
Fan operating in reverse
= 0 mA
Fan reverse FAN REVERSE Output fan reverse SW 1: ON(CLOSE)
6 93400
switch input SW input state 0: OFF
Torque con-
T/C IN OIL Not used by this
7 verter inlet oil 41501 — —
TEMP machine
temperature
Torque con-
T/C IN OIL Not used by this
8 verter inlet oil 41502 — —
TEMP machine
temperature
Torque con-
Not used by this
9 verter input 93500 T/C SPEED: IN — —
machine
shaft speed
Torque con-
T/C TORQUE: Not used by this
10 verter output 93501 — —
OUT machine
shaft torque
Transmission Output transmission
X1 [min-1]
11 input shaft 31200 T/M SPEED: IN input shaft speed
(0 – 32,767 [min-1])
speed [PLS_AC_IN_0]
X1 [min-1]
(0 – 32,767 [min-1])
Transmission Output output shaft
T/M SPEED: 0 km/h = 0 rpm
12 output shaft 31400 speed
OUT 10 km/h = 788 rpm
speed [PLS_AC_IN_2]
20 km/h = 1,376 rpm
30 km/h = 2,063 rpm
40 km/h = 2,751 rpm
Transmission
T/M SPEED: Not used by this
13 output shaft 31404 — —
OUT2 machine
speed
WA500-6R 59
Display of
item name
Converted value of the
Displayed value
Transmission set oil pressure (IN oil
X1 [MPa] changes according
14 cut-off opera- 41203 T/M CUT SET pressure) to be trans-
(0.00 – 5.00 [MPa]) to the cut-off set
tion setting mission cut-off is dis-
operation
played
When the foot brake
is released:
0.00±0.1 MPa
Transmission
Converted value of the When foot brake is
cut-off X1 [MPa]
15 41201 T/M CUT OFF P brake oil pressure is dis- actuated:
(Left brake) (0.00 – 5.00 [MPa])
played Displayed value
pressure
changes according
to the brake-actuat-
ing operation
When the foot brake
is released:
1.00±0.1 V
Transmission
Input voltage value of When the foot brake
cut-off X1 [mV]
16 41202 T/M CUT OFF P brake oil pressure is dis- is actuated:
(Left brake) (0.00 – 5.00 [V])
played Displayed value
pressure
changes according
to the brake-actuat-
ing operation
Torque con-
TC SPEED Output torque converter X1 [%]
17 verter speed 93700
RATIO speed ratio (0 – 100 [%])
ratio
Transmission Output oil temperature
X1 [°C]
18 oil temperature 93600 T/M OIL TEMP value of transmission oil
(0 – 150 [°C])
input temperature (A_IN_1)
X1 [mV]
(0.00 – 5.00 [V])
Input voltage of Output input voltage 4.72 V = 0°C
19 transmission oil 93601 T/M OIL TEMP value of transmission oil 4.33 V = 30°C
temperature temperature (A_IN_1) 3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
MOD/C oil Not used by this
20 92400 MOD/C PRESS — —
pressure input machine
MOD/C oil
Not used by this
21 pressure input 92401 MOD/C PRESS — —
machine
voltage
MOD/C heat Not used by this
22 92500 MOD/C Q — —
release value machine
MOD/C heat Not used by this
23 92501 MOD/C q — —
ratio machine
Throttle lock
0:
switch (pressed
Output the state of input RPM set switch OFF
24 upward) 95500 THROT LOCK A
signal 1:
(RPM set
PRM set switch ON
switch)
Throttle lock
switch (pressed 0: RPM set auto deceler-
downward) Output the state of input ation switch OFF
25 95501 THROT LOCK B
(PRM set auto signal 1: RPM set auto deceler-
deceleration ation switch ON
switch)
Throttle correc- Output throttle correc-
THROTTLE X1 [%]
26 tion command 95400 tion command output
MOD (-100 – 100 [%])
output amount
Throttle open- Output throttle upper
THROT LIMIT X0.1 [%]
27 ing upper limit 44200 limit command output
UP (0.0 – 100.0 [%])
output amount
60 WA500-6R
Display of
item name
Throttle open- Output throttle lower
THROT LIMIT X0.1 [%]
28 ing lower limit 44201 limit command output
LO (0.0 – 100.0 [%])
output amount
Depends on accelerator
pedal operation
Accelerator pedal = 0
Accelerator pedal partial
Depends on accelerator
pressing (opened side) =
Accelerator THROTTLE opening ratio; output
29 93801 1
mode MODE acceleration mode on
Accelerator pedal partial
control
pressing (pressed side) =
2
Accelerator pedal press-
ing = 3
Traction setting Not used by this
30 94000 TRACTION DIAL — —
input value machine
Traction setting Not used by this
31 94001 TRACTION DIAL — —
input voltage machine
0: Lockup changing
Lockup chang-
Output the state of input switch OFF
32 ing switch input 95000 LOCK UP SW
signal 1: Lockup changing
signal
switch ON
ECMV output to 1st
ECMV output
clutch X1 [mA]
33 command value 31602 ECMV 1 DIR
Output command cur- (0 – 1000 [mA])
(1st)
rent value
ECMV output to 2nd
ECMV output
clutch X1 [mA]
(2nd)
rent value
ECMV output to 3rd
ECMV output
clutch X1 [mA]
(3rd)
rent value
ECMV output to 4th
ECMV output
clutch X1 [mA]
(4th)
rent value
ECMV output to FWD
ECMV output
clutch X1 [mA]
37 command value 31608 ECMV F DIR
(FWD)
rent value
ECMV output to L/U
ECMV output
clutch X1 [mA]
38 command value 31609 ECMV LU DIR
(L/U)
rent value
ECMV output
ECMV MOD/C Not used by this
39 command value 31640 — —
DIR machine
(MOD/C)
ECMV output to REV
ECMV output
clutch X1 [mA]
40 command value 31606 ECMV R DIR
(REV)
rent value
ECMV output Output to ECSS valve
X1 [mA]
41 command value 93300 ECSS V DIR Output command cur-
(0 – 1000 [mA])
(ECSS) rent value
Output 1st clutch fill time
value X0.01 [sec]
Fill time value
42 41802 FILL TIME 1 (State of gear change (0 – 2.55 [sec], No fill
(1st)
preceding immediately time: 0)
before)
WA500-6R 61
Display of
item name
Output 2nd clutch fill
time value X0.01 [sec]
Fill time value
(2nd)
before)
Output 3rd clutch fill
Fill time value
44 41804 FILL TIME 3 (State of gear change (0 – 2.55[sec], No fill time:
(3rd)
preceding immediately 0)
before)
Output 4th clutch fill
Fill time value
(4th)
before)
Output FWD clutch fill
Fill time value
46 41808 FILL TIME F (State of gear change (0 – 2.55 [sec],
(FWD)
preceding immediately No fill time: 0)
before)
Output REV clutch fill
Fill time value
47 41806 FILL TIME R (State of gear change (0 – 2.55 [sec],
(REV)
preceding immediately No fill time: 0)
before)
0*******
: Engine mode selector
SW OFF
1*******
: Engine mode selector
SW ON
*00*****
: (J/S shift-up/-down SW
D-IN0
not being operated)
: Engine mode
*10*****
selector SW
: (J/S shift-up SW being
D-IN1
operated)
: J/S shift-up SW
*01*****
D-IN2
: (J/S shift-down SW
: J/S shift-down SW
being operated)
D-IN3
***0****
: Air conditioner
: Air conditioner compres-
Input signal Output the state of input compressor operat-
48 40905 D-IN--0------7 sor stop
D_IN_0-7 signal ing
***1****
D-IN4
: Air conditioner compres-
: Shift mode L
sor operating
D-IN5
****00**
: Shift mode H
: Manual shift mode
D-IN6
****10**
: J/S or right FNR
: Shift mode L
valid SW
****11**
D-IN7
: Shift mode H
: C terminal signal
******0*
: Right FNR (J/S) selector
SW OFF
******1*
: Right FNR (J/S) selector
SW ON
*******1
: Cranking
62 WA500-6R
Display of
item name
10**0***
: Transmission cut-off SW
ON
11**0***
: Transmission cut-off SW
AND setting SW ON
D-IN8
**0*0***
: Transmission cut-
: Kick-down SW OFF
off SW
**1*0***
D-IN9
: Kick-down SW ON
: Transmission cut-
***00***
off point set SW
: Shift hold SW OFF
D-IN10
***10***
: Kick-down SW
: Shift hold SW ON
D-IN11
Input signal Output the state of input ****00**
49 40906 D-IN--8-----15 : Shift hold SW
D_IN_8-15 signal : Throttle lock set SW
D-IN13
OFF
: Throttle lock set
****01**
SW
: Throttle lock set SW ON
D-IN14
****0*0*
: Throttle lock
: Throttle lock resume SW
resume SW
OFF
D-IN15
****0*1*
: Left brake pedal
: Throttle lock resume SW
SW
ON
****0**0
: Left brake pedal SW
OFF
****0**1
: Left brake pedal SW ON
D-IN16
1000****
: Gear speed lever
: Gear speed lever at 1st
1st speed
speed
D-IN17
0100****
: Gear speed lever
: Gear speed lever at 2nd
2nd speed
speed
D-IN18
0010****
: Gear speed lever
: Gear speed lever at 3rd
3rd speed
speed
D-IN19
0001****
: Gear speed lever
Input signal Output the state of input : Gear speed lever at 4th
50 40907 D-IN-16-----23 4th speed
D_IN_16-23 signal speed
D-IN20
****100*
: Direction lever at F
: Direction lever at F
D-IN21
****010*
: Direction lever at
: Direction lever at N
N
****001*
D-IN22
: Direction lever at R
: Direction lever at
*******0
R
: Parking brake released
D-IN23
*******1
: Parking brake sig-
: Parking brake operating
nal
WA500-6R 63
Display of
item name
D-IN24
: Right FNR (J/S
1******0 FNR) F
: Right FNR (J/S FNR) F D-IN25
0101000* : Fill SW at F
: Traveling at F1 D-IN26
0010100* : Fill SW at R
: Traveling at R2 D-IN27
Input signal Output the state of input 0000010* : Fill SW at 1st
51 40908 D-IN-24-----31
D_IN_24-31 signal : 3rd speed neutral D-IN28
0100001* : Fill SW at 2nd
: Traveling at F4 D-IN29
0******1 : Fill SW at 3rd
: Right FNR (J/S FNR) R D-IN30
0******0 : Fill SW at 4th
: Right FNR (J/S FNR) N D-IN31
: Right FNR (J/S
FNR) at R
1*******
: Right FNR (J/S FNR) at
Input signal
N
D_IN_32-39
0******* D-IN32
(Transmission Output the state of input
52 40942 D-IN-32-----39 : Right FNR (J/S FNR) at : Right FNR (J/
controller does signal
F SFNR) at N
not have 33 –
0*******
39)
: Right FNR (J/S FNR) at
R
0000**00
: Fan reverse solenoid
OFF
0001**00 D-OUT3
: Fan reverse solenoid : Fan reverse sole-
ON noid
000*0*00 D-OUT4
: Fan neutral solenoid : Fan neutral sole-
Output signal SOL_OUT0 to 7
53 40949 D-OUT 0-7 OFF noid
D_OUT_0-7 '0' is displayed when
000*1*00 (if equipped)
setting current output
: Fan neutral solenoid ON D-OUT5
000**000 : Low temperature
: Low temperature bypass bypass solenoid
solenoid OFF (Optional)
000**100
:Low temperature bypass
solenoid ON
SOL_OUT8 to 11B,
Output signal Not used by this
54 40950 D-OUT 8-15 SIG_OUT0 to 1 00000000
D_OUT_8-15 machine
'0' is displayed when
SIG_OUT2 to 3,
Output signal HSW_OUT0 to 1, Not used by this
55 40951 D-OUT 16-23 00000000
D_OUT_16-23 BATT_RY_OUT machine
'0' is displayed when
111111 16-bit data is dis-
Output initial learning
(all clutches learned) played
Initial learning flag state of trigger time
56 94100 TRIG FR1234 000000 in the order of F, R,
flag of each clutch
(all clutches to be 1, 2, 3, and 4 on the
[F,R,1,2,3,4]
learned) monitor
64 WA500-6R
13. Diagnosis
1) Function of troubleshooting
The transmission controller monitors the input and output signals constantly for troubleshooting for
the system.
If any abnormality is detected by self-diagnosis, the information on it is transmitted through the net-
work to the machine monitor.
When abnormality occurs, it can be confirmed on the machine monitor.
WA500-6R 65
14. Pin assignment
66 WA500-6R

DEUTSCH-24P [CN-L02]
Input and Input and
1 T/C lock up SW. Input 13 Throttle with auto decel Input
2 Fan reverse SW. Input 14 NC Input
4 GND_SIG_D 16 PWR_OUT_SENS Output
5 A/C compressor signal Input 17 J/S shift up SW. Input
6 Starting switch(IGN-C) Input 18 Shift mode signal H Input
7 E.C.S.S. SW. Input 19 Throttle lock without auto decel Input
8 LH brake press. sensor Input 20 Input
9 T/M oil temp. sensor Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
11 J/S shift down SW. Input 23 Engine mode SW. Input
12 SW enabling J/S RH FNR Input 24 Shift mode signal L Input
Input and out- Input and out-
put signals put signals
1 NC Output 21 NC Input and output
2 ECMV fill SW.:4th Input 22 COMM_CAN_L_O Input and output
3 ECMV fill SW.:3rd Input 23 NC Input and output
4 232C_RxD Input 24 PWR_CTR_EXT Input
5 Shift lever:4th Input 25 Shift lever:2nd Input
6 Parking brake signal Input 26 Direction lever:N Input
7 ECMV fill SW.:1st Input 27 ECMV fill SW.:F Input
8 NC Output 28 J/S or RH FNR seesaw SW.:N Input
9 NC Output 29 GND_SIG_P
11 NC Output 31 NC
12 NC 32 COMM_CAN_H_O Input and output
13 ECMV fill SW.:2nd Input 33 NC Input and output
14 232_TxD Output 34 232C_GND
15 Shift lever:3rd Input 35 Shift lever:1st Input
16 Direction lever:R Input 36 Direction lever:F Input
17 ECMV fill SW.:R Input 37 J/S or RH FNR seesaw SW.:F Input
18 NC Output 38 J/S or RH FNR seesaw SW.:R Input
19 NC Output 39 GND_SIG_P
20 Output speed sensor Input 40 Input speed sensor Input
Input and Input and
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 TM power hold relay Output 24 PWR_CTR_KEY Input
5 ECMV:F. clutch Output 25 ECMV:1st clutch Output
6 ECMV:2nd clutch Output 26 ECMV:4th clutch Output
7 NC Output 27 Fan pump EPC Output
8 Indicator with built-in TM cut off SW. Output 28 Fan pump neutral solenoid Output
9 NC Input 29 RESUME/DECEL SW. Input
10 TM cut off SW. Input 30 Kick down SW. Input
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 PWR_OUT_5V_1 Output
15 ECMV:R. clutch Output 35 ECMV:lock up clutch Output
16 ECMV:3rd clutch Output 36 NC Output
17 E.C.S.S. solenoid Output 37 Fan pump reverse solenoid Output
18 Reverse lamp relay Output 38 NC Output
19 SET/ACCEL SW. Input 39 LH brake pedal SW. Input
20 TM cut off position set SW. Input 40 Shift hold SW. Input
WA500-6R 67
SEN02899-00

© 2007 KOMATSU
All Rights Reserved
68
SEN02900-00
WA500-6R

WA500-6R 60001 and up

Electric transmission control ........................................................................................................................... 2
Engine starting circuit...................................................................................................................................... 6
Engine stopping circuit.................................................................................................................................... 8
Preheating circuit ............................................................................................................................................ 9
Parking brake circuit ......................................................................................................................................11
Backup and stop lamp circuits ...................................................................................................................... 16
Small lamp and head lamp circuits ............................................................................................................... 18
Working lamp circuit...................................................................................................................................... 19
Horn circuit.................................................................................................................................................... 20
Wiper and window washer circuits ................................................................................................................ 21
Sensor........................................................................................................................................................... 24
KOMTRAX terminal system (if equipped) ..................................................................................................... 42
WA500-6R 1
Electric transmission control 1
2 WA500-6R
1. Brake valve 8. Gearshift lever

2. Transmission cut-off switch 9. Directional lever
3. Transmission cut-off set switch 10. Speed sensor
4. Relay 11. Transmission control valve
5. Fuse box 12. Hold switch
6. Transmission controller 13. Kickdown switch
7. Parking brake switch 14. Brake pressure sensor
Function
No. Function Operation
Selection of travel direction and
1 The travel direction can be changed by operating the directional lever.
neutral
2 Selection of gear speed The gear speed can be changed by operating the gearshift lever.
The gear can be shifted down by pressing the kickdown switch without operating
the gearshift lever. In the manual gear shift mode, the gear is shifted down to the
3 Kickdown 1st only while the transmission is in the forward 2nd. In the auto-shift mode, the
gear is shifted down according to the gear speed and travel speed before the
switch is pressed.
If the hold switch is pressed in the auto-shift mode, the current gear speed is held
4 Hold and is not shifted up even if the travel speed is increased. Even if the travel speed
lowers, the gear is not shifted down.
While the transmission cut-off selector is “ON”, the transmission is set in neutral
5 Transmission cut-off
at the adjusted pressing distance of the brake pedal.
The pressing distance of the brake pedal to set the transmission in neutral with
6 Transmission cut-off set
the transmission cut-off function can be adjusted.
The transmission cut-off function can be turned ON and OFF. While this function
7 Selection of transmission cut-off is “OFF”, the left brake pedal works as the ordinary brake (similarly to the right
brake pedal).
While the parking brake is applied, the transmission is set in neutral. With this
8 Neutralizer function, the machine does not travel while the parking brake is applied, thus sei-
zure of the parking brake is prevented.
While the directional lever is not in “neutral”, the engine does not start even if the
9 Neutral safety starting switch is operated, thus an accident caused by sudden start of the
machine is prevented.
When the machine travels in reverse, the backup lamp and backup buzzer are
10 Alarm
turned ON to warn around the machine.
WA500-6R 3
Combination switch
Outline
q The directional lever has 3 positions and the gearshift lever switch has 4 positions.The detent mecha-
nism is not installed to each switch but installed to the body of the combination switch. Each switch is
positioned with 2 pins and fixed to the body with 3 screws. If each lever is set in a desired position, the
switch connected by the shaft operates to supply the current to only the circuit of the desired position.
Function
No. Type Operation
1 Directional lever switch Selects the travel direction and neutral.
2 Gearshift lever switch Selects a gear speed.
3 Gearshift lever stopper Prevents the gearshift lever from moving to the 3rd or 4th position during work.
4 Turn signal Turn signal for L.H. and R.H. turns
Returns the turn signal lever automatically to neutral when the steering wheel is
5 Self-cancel
returned after turning to the right or left.
6 Lamp switch Selects the clearance lamp, headlamp, parking lamp, etc.
7 Dimmer switch Selects main beam and low beam.
8 Hazard switch Flashes turn signals to the left and right simultaneously.
9 Hazard pilot lamp Flashes while the hazard lamp flashes.
4 WA500-6R
Operation
q Shaft (2) of directional and gearshift lever (1) of
the combination switch is made one with mag-
net (3). As lever (1) moves, magnet (3)
moves, too.
q Control switch (5) having Hall IC's (4) in it is
installed under magnet (3). Hall IC (4) are
arranged on the board for each position.
q When the directional lever is set in the “F” posi-
tion, magnet (3) comes to directly above Hall
IC (4) of the “F” position of the control switch.
Magnet (3) magnetizes Hall IC (4) through the
clearance and case (6).
q Hall IC (4) is in the magnetism sensor circuit
and it detects the magnetism of magnet (3)
and sends the signal of the “F” position of the
directional lever to the current amplifier cir-
cuit.The current amplifier circuit outputs the
signal to operate the transmission valve.
WA500-6R 5
Engine starting circuit 1
Function
1. The neutral safety circuit is employed to
secure safety when the engine is started.
q The engine can not be started while the
directional lever is not in N (Neutral).
q The engine cannot start while the right
FNR selector switch (if equipped) is “ON”
or while the right FNR switch is not in N
(Neutral).
q The engine cannot start while the joystick
steering (if equipped) is “ON” or while
either of the joystick steering lever FNR
switch and joystick steering lever is not in
N (Neutral).
2. The KOMTRAX engine cut circuit is employed
to disable the engine from starting when the
KOMTRAX receives an engine cut command
issued through external operation.
6 WA500-6R
Operation
1. When starting switch is turned to “ON” position q While the right FNR switch (if equipped) is
q If the starting switch is turned to the “ON” used (the right FNR selector switch is
position, terminals B and BR of the start- ON), the current flows from the right FNR
ing switch are closed and the current flows selector switch to the transmission con-
from the battery through the starting troller to enable the controller. At this time,
switch and battery relay coil to the ground if the FNR switch is not in N (Neutral), the
and the contacts of the battery relay are work equipment controller outputs the cut-
closed. As a result, the power is supplied out current and the current flows to the
to each circuit of the machine. lever relay coil, cutting terminal 3 of the
Also, the current flows from terminal ACC lever relay out from terminal 6 of the same
of the starting switch into the engine con- relay.
troller power relay, operating it to provide
the power supply for operation to the 3. When starting switch is turned to “Start” posi-
engine controller, and the engine is ready tion
to start. q If the starting switch is turned to the “Start”
2. Neutral safety circuit position, the current flows through termi-
q If the directional lever is set in the N (Neu- nal B of the starting switch, terminal C of
tral) position, the current flows from con- the same switch, terminal 3 of the
tact (N) of the directional lever through the KOMTRAX engine cut relay, terminal 6 of
exchange relay to the neutral safety relay the same relay, terminal 3 of the neutral
coil, conducting terminal 3 of the neutral safety relay, terminal 5 of the same relay,
safety relay with terminal 5 of the same terminal 3 of the lever relay, and terminal 6
relay. of the same relay to the starting motor to
q While the joystick steering (if equipped) is start the engine.
used, if the joystick steering armrest is q At the same time, the current flows from
tilted forward and the joystick steering terminal C of the starting switch to the
selector switch is turned ON, the current engine controller, where the engine speed
flows from the joystick steering selector and coolant temperature signals are pro-
switch to the transmission controller to cessed to optimize the injection rate.
enable the controller. q While the directional lever is not in N
At this time, if the joystick steering lever (Neutral) or the right FNR switch is not in
FNR switch is not in N (Neutral), the work N (Neutral) (if the right FNR switch is
equipment controller outputs the cutout used) or the joystick steering lever FNR
current and the current flows to the lever switch is in N (Neutral) and the joystick
relay coil, cutting terminal 3 of the lever steering lever is not in N (Neutral) (if the
relay out from terminal 6 of the same joystick steering is used), the neutral
relay. safety relay does not operate and the
If the joystick steering lever is not in N engine does not start.
(Neutral), the work equipment controller q While the right FNR switch is not in N
outputs the cutout current and the current (Neutral) (if the right FNR switch is used)
flows to the lever relay coil, cutting termi- or the joystick steering lever FNR switch is
nal 3 of the lever relay out from terminal 6 in N (Neutral) and the joystick steering
of the same relay. lever is not in N (Neutral) (if the joystick
(If the joystick steering system is installed, steering is used), the lever relay does not
the joystick steering lock switch and joy- operate and the engine does not start.
stick steering selector switch are installed q When the KOMTRAX controller receives
instead of the right FNR selector switch an engine cut command issued through
indicated in the engine starting circuit dia- external operation, it grounds terminal 2 of
gram, and the joystick steering lever FNR the KOMTRAX engine cut relay to operate
switch is installed instead of the right FNR the relay. This cuts out the current from
switch.) terminal 6 of the KOMTRAX engine cut
relay to terminal 3 of the neutral safety
relay, disabling the engine from starting.
WA500-6R 7
Engine stopping circuit 1
Operation
q If the starting switch is set in the “OFF” posi-
tion, the current of terminal ACC is cut out and
the ACC signal to the engine controller is cut
out accordingly. Then the engine controller
stops the fuel supply to the engine.
As the fuel supply is stopped, the engine slows
down and stops. When the alternator stops
generating electricity, the voltage supply from
the R terminal of the alternator and the current
from the BR terminal of the starting switch are
cut out, the contact of the battery relay opens,
and the power supply provided to various cir-
cuits in the machine is cut out.
q About 10 seconds after the starting switch is
turned OFF, the current from the engine con-
troller to the 2 engine controller cut relays is
cut out. This turns the relay OFF and cuts out
the engine controller operating power supply to
prevent unexpected operation.
8 WA500-6R
Preheating circuit 1
(Automatic preheating system)
Outline
q The automatic preheating system is installed q The preheater pilot lamp on the main monitor
so that the engine will start easily in a cold dis- lights up during preheating. When the preheat-
trict. This system reduces and sets the pre- ing completes, the preheater pilot lamp goes
heating time properly according to the engine out.
coolant temperature when the starting switch is
operated.
q When the starting switch is set in the “ON posi-
tion”, the current flows to the electrical intake
air heater to preheat the intake air.
The engine controller determines the preheat-
ing time according to the coolant temperature
detected by the engine coolant temperature
sensor.
WA500-6R 9
Operation
q When the starting switch is set in the “ON”
position, the engine controller sends the sig-
nals to operate the heater relay and closes the
contact.
q The current flows from the battery through the
battery relay and heater relay to the electrical
intake air heater for preheating.
q When the preheating completes, the current
from the engine controller to the heater relay is
cut out, and the heater relay contact is opened.
q During preheating, the current flows through
the terminal (BR) of the starting terminal, termi-
nal 1 and terminal 2 of the preheating relay to
the engine controller to energize the coil of the
preheating relay. The preheater pilot lamp on
the main monitor lights up.
a When the preheating completes, the pre-
heater relay turns “OFF” and the pre-
heater pilot lamp goes out.
10 WA500-6R
Parking brake circuit 1

1. When starting switch is turned “OFF“
Operation
q If the starting switch is turned “OFF,” the con-
tacts of the battery relay open, and no current
flows to the parking brake circuit. While the
starting switch is “OFF,” the current does not
flow into parking brake solenoid valve and the
parking brake is kept applied, regardless of the
position of the parking brake switch, whether it
is “ON (applied)” or “OFF (released).”
WA500-6R 11
2. When starting switch is turned “ON“

2-1. When parking brake switch is turned “ON (actuate)” before starting switch is turned “ON“
Operation
q Since the parking brake selector switch is “ON
(actuate)”, the current flows through the battery
relay, contact 6 of the parking brake selector
switch, contact 5 of the same switch, and park-
ing brake safety relay coil to the chassis
ground, closing the terminal 3 and terminal 5 of
the parking brake safety relay. The current
from the battery relay keeps flowing into the
parking brake relay coil to hold its contacts until
the battery relay contacts open and the current
does not flow into the parking brake circuit any
more.
q At this time, the current does not flow into park-
ing brake solenoid and the parking brake is
kept applied.
q This signal is input to transmission controller to
keep the transmission in neutral and prevent
the parking brake from dragging while the
parking brake is applied.
q After that, if the parking brake switch is turned
“OFF (released)”, the current flows through the
battery relay, parking brake safety relay, con-
tact 4 of the parking brake selector switch, con-
tact 3 of the same switch, emergency brake
switch, and parking brake solenoid to the chas-
sis ground, releasing the parking brake.
12 WA500-6R
2-2. When parking brake switch is turned “OFF (released)” before starting switch is turned “ON“
Operation
q While the starting switch is “OFF”, the current
does not flow into the parking brake safety
relay and its contacts are open. Even if the
starting switch is turned “ON” at this time, the
current does not flow into the parking brake
solenoid. Accordingly, the parking brake is not
released automatically.
WA500-6R 13
3. When main brake oil pressure lowers (emergency brake is applied)
Operation
q If the main brake oil pressure lowers, the con-
tacts of the emergency brake switch installed
to the accumulator open. As a result, the cur-
rent flowing into parking brake solenoid valve
is stopped and the oil in the parking brake cyl-
inder is drained and the parking brake is
applied.
In this case, however, unlike the case where
the parking brake switch is turned “ON (actu-
ate)”, the transmission is not set in neutral
since the parking brake release signal is flow-
ing into the transmission controller.
By the above operation, when the emergency
brake is applied, the braking distance can be
reduced by using the engine as a brake. Also,
even if the emergency brake is applied, the
machine can be moved.
14 WA500-6R
4. Parking brake emergency release circuit
Operation
q When the vehicle stops due to engine trouble,
the oil pressure from the transmission pump to
the parking brake cylinder is cut out, triggering
the parking brake. Under this condition, oil
pressure in the main brake line is held in the
accumulator.
q When the emergency release switch is turned
to “ON (released)”, the buzzer sounds and the
current flows to the emergency parking brake
release solenoid valve, and the oil pressure
held in the accumulator of the main brake line
flows into the parking brake cylinder, releasing
the parking brake.
q The emergency release switch must be in the
“OFF” position during normal operation and
after emergency release is completed.
WA500-6R 15
Backup and stop lamp circuits 1

Stop lamp circuit
Operation
q When the brake pedal is pressed, the contact
of the stop lamp switch is closed to cause the
current to flow to the stop lamp relay coil. This
closes the contact of the relay to complete the
circuit from the fuse through the terminal 5 of
the stop lamp relay, terminal 3 of the same
relay, and right and left stop lamps to the chas-
sis ground, and the right and left stop lamps
light up.
q When the brake pedal is released, the contact
of the stop lamp switch is opened. This opens
the contact of the stop lamp relay, and the stop
lamps go out.
q Because the current flows through the stop
lamp circuit when the battery relay operates,
the stop lamps do not light up when the starting
switch is in the “OFF” position.
16 WA500-6R
Backup lamp circuit
Operation
q Because the current flows through the backup 3. When the joystick steering is used
lamp circuit when the battery relay operates, When the right FNR switch is used and even if
the backup lamps do not light up and the the directional lever is in N (Neutral), turning
backup buzzer does not sound when the start- the joystick steering lever FNR switch to R
ing switch is in the “OFF” position. causes the transmission controller to send the
signal to operate the backup lamp relay. The
1. When the directional lever is in the R position right and left backup lamps light up and the
When the directional lever is turned to the R backup buzzer sounds.
position, the transmission controller sends a
signal to the backup lamp relay to open its con-
tact. This completes the circuit from the fuse
through the terminal 5 of the backup lamp
relay, terminal 3 of the same relay, and right
and left backup lamps to the chassis ground,
and the right and left backup lamps light up. At
the same time, the backup buzzer sounds.
2. When the right FNR switch is used
Even if the directional lever is in N (Neutral),
turning the right FNR switch to R causes the
transmission controller to send the signal to
operate the backup lamp relay. The right and
left backup lamps light up and the backup
buzzer sounds.
WA500-6R 17
Small lamp and head lamp circuits 1
Operation
q Because the current flows through the small 2. When the lighting switch is in the Head position
lamp and head lamp circuits when the battery When the lighting switch is turned to the Head
relay operates, the small and head lamps do position, the current flows through the switch
not light up when the starting switch is in the and fuse to the small lamp and head lamp cir-
“OFF” position. cuits. The current flows from the head lamp
through the dimmer switch (Hi/Lo selector
1. When the lighting switch is in the Small posi- switch) to the chassis ground. The high beam
tion or low beam selected with the dimmer switch
When the lighting switch is turned to the Small lights up. The high beam signal is input to the
position, the current flows through the switch main monitor and turns on the high beam pilot
and fuse to the front, rear, right, and left small lamp on the main monitor.
lamps, and the lamps light up. The small lamp
signal is input to the main monitor and turns
the main monitor night lamp on. The circuit
supplies the current in the small lamp circuit to
the working lamp switch, prohibiting the work-
ing lamp from lighting up when the small lamps
are off.
18 WA500-6R
Working lamp circuit 1
Operation
q The current is supplied to the front and rear
working lamp switches from the small lamp cir-
cuit.
When the working lamp switch is turned “ON”,
the working lamp relay operates to close the
contact. The current flows through the fuse,
working lamp relay, and working lamp to the
chassis ground, and the working lamp lights
up.
At the same time, the indicator in the working
lamp switch lights up.
WA500-6R 19
Horn circuit 1
Operation
q Because the current flows through the horn cir-
cuit when the battery relay operates, the horn
does not sound when the starting switch is in
the “OFF” position.
1. When the steering wheel horn switch is

pressed
When the steering wheel horn switch is
pressed, the horn relay operates to close the
relay contact. The current flows through the
fuse, horn, and horn relay to the chassis
ground, and the horn sounds.
2. When the joystick steering horn switch is
pressed
When the joystick lever horn switch is pressed,
the horn relay operates to close the relay con-
tact. The current flows through the fuse, horn,
and horn relay to the chassis ground, and the
horn sounds.
20 WA500-6R
Wiper and window washer circuits 1
Operation
Because the current flows through the wiper and 3) When the front wiper switch is in the INT
window washer circuits when the battery relay (Intermittent) position
operates, the wiper and window washer do not The current flows through the fuse, terminal 7
operate when the starting switch is in the “OFF” of the front wiper switch, and terminal 2 of the
position. When the starting switch is turned “OFF” same switch to the wiper relay, and the relay
during operation, the operation stops. contact closes. Then the current flows
through the fuse, wiper relay, terminal 3 of the
1. Front wiper circuit front wiper switch, and terminal 5 of the same
1) When the front wiper switch is in the Lo posi- switch to the front wiper motor (Lo), and the
tion wiper operates at the low speed. The wiper
The current flows through the fuse, terminal relay repeats the timer-controlled operation
7 of the front wiper switch, and terminal 5 of where wiper makes reciprocating motions at
the same switch to the front wiper motor intervals of 4 – 6 seconds.
(Lo), and the wiper operates at the low 4) When the washer switch is in the “ON” posi-
speed. tion
2) When the front wiper switch is in the Hi posi- The current flows through the fuse and front
tion wiper switch to the washer motor, and the
The current flows through the fuse, terminal washer operates. At the same time, the cur-
7 of the front wiper switch, and terminal 4 of rent flows to the wiper relay and operates
the same switch to the front wiper motor (Hi), the wiper 0.2 – 0.8 seconds after the washer
and the wiper operates at the high speed. switch is turned “ON”.
The wiper relay moves the wiper 2 to 4 times
after the washer switch is turned “OFF”. This
operation occurs when the washer switch is
turned “OFF” after it has been “ON” while the
wiper makes the reciprocating motion more
than once.
WA500-6R 21
5) When the front wiper switch is in the “OFF”

position
When the front wiper switch is turned “OFF”
while the wiper is operating, contacts P1 and
P2 of the front wiper motor close. The cur-
rent flows through the fuse, contact P2 of the
wiper motor, contact P1 of the same motor,
wiper relay, terminal 3 of the front wiper
switch, and terminal 5 of the same switch to
the front wiper motor (Lo), and the wiper
operates. When the wiper comes to the stop
position, contacts P1 and P2 of the wiper
motor open and the wiper stops.
2. Rear wiper circuit

1) When the rear wiper switch is in the Lo posi-
tion
The current flows through the fuse, terminal
7 of the rear wiper switch, and terminal 9 of
the same switch to the rear wiper motor, and
the rear wiper operates.
2) When the rear wiper switch is in the Washer
position
the same switch to the washer motor, and
the washer operates.
3) When the rear wiper switch is in the Washer
or Lo position
the same switch to the rear wiper motor, and
the rear wiper operates. The current also
flows through the fuse, terminal 7 of the rear
wiper switch, and terminal 10 of the same
switch to the washer motor, and the washer
operates.
4) When the rear wiper switch is in the “OFF”
position
When the rear wiper switch is turned “OFF”
while the wiper is operating, contacts P1 and
P2 of the rear wiper motor close. The current
flows through the fuse, contact P2 of the
wiper motor, contact P1 of the same motor,
terminal 8 of the rear wiper switch, and ter-
minal 9 of the same switch to the rear wiper
motor, and the wiper operates. When the
wiper comes to the stop position, contacts
P1 and P2 of the wiper motor open and the
wiper stops.
22 WA500-6R
Relay
1. Case 2. Base
1. Case 2. Base
WA500-6R 23
Sensor 1
Input shaft speed sensor
Output shaft speed sensor
1. Magnet 3. Harness
2. Locknut 4. Connector
Function
q The input shaft speed sensor is installed on the
transmission unit input shaft and the output
shaft speed sensor is installed in the output
gear section at the transmission unit. Those
sensors emit pulse signals according to the
gear rotation signal, which are detected by the
transmission controller.
q Signals are converted from pulse to the num-
ber of rotation (rpm) in the transmission con-
troller, transmitted to the machine monitor over
the network. The rpm is then converted into
travel speed in the machine monitor for display.
24 WA500-6R
Left brake pressure sensor
1. Sensor
2. Lead wire
3. Connector
Function
q Installed to the brake pilot circuit and detecting
brake operating pressure, this sensor is used
to set brake pressure for the transmission cut-
off function and to operate the function.
a The brake pressure of this sensor changes
when either right or left brake pedal is pressed.
WA500-6R 25
Transmission oil temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
Axle oil temperature sensor
1. Thermistor
2. Plug
3. Harness
4. Connector
Function
q The oil temperature sensors convert changes
in temperature into changes in thermistor
resistance, and each controller detects temper-
atures.
q Transmission oil temperature sensor detects
the internal temperature of transmission case.
The temperature data is used by transmission
controller to select the temperature table of
electronic modulation so as to control modula-
tion best matched to the oil temperature.
q Data from torque converter oil temperature
sensor and hydraulic oil temperature sensor is
detected by the machine monitor and indicated
to the gauges. At the same time, the data is
transmitted to the transmission controller via
network and used as the cooling fan control
data.
q Axle oil temperature sensor detects the inter-
nal oil temperature of rear axle with the moni-
tor, and outputs a caution signal when the
temperature rises to a high level.
26 WA500-6R
Kick-down hold switch
1. Switch A (White wiring harness)

2. Spring
3. Harness
4. Switch B (Yellow wiring harness)
Function
q These switches are installed to the knob of the
lift arm control lever. Switch A (1) works as the
kick-down switch and switch B (4) works as the
hold switch.
q These switches are installed to the knob of the
lift arm control lever when load meter (if
equipped) is installed. Switch A works as the
cancel switch and switch B works as the subto-
tal switch.
q Both of switch A (1) and switch B (4) are of
automatic-reset type, that is, their contacts are
closed only while they are pressed.
WA500-6R 27
Joystick knob (if equipped)
1. Horn switch: horn sounding switch

2. Shift down switch: Selects a gear speed (shift down)
3. Shift up switch: Selects a gear speed (shift up)
4. Directional switch: Selects the travel direction and neutral
Function
q Directional switch is held at a selected posi-
tion. Transmission controller shifts gear
according to the signal from the directional
switch.
q Shift-up/-down switch selects circuit only while
the switch is being depressed, and the trans-
mission controller uses this signal for gear
shifting operation accordingly.
q The N.C. (normally close) side of the shift up/
down switch is not connected to the controller.
q Horn switch operates the relay and sounds the
horn while it is being depressed.
28 WA500-6R
Right FNR switch (if equipped)
Function
q Directional switch is held at a selected posi-
tion. Transmission controller shifts gear
according to the signal from the directional
switch.
WA500-6R 29
Lift arm angle sensor (if equipped)
1. Oil seal
2. Case
3. Resistor assembly
4. Brush
5. Shaft
6. Connector
Function
q The lift arm angle sensor is installed to the
front frame. When the lift arm angle changes,
the shaft receives the sliding resistance
through the link installed to the lift arm and the
lift arm angle is detected from that sliding resis-
tance.
The angle sensor is installed to a machine
installed with a load meter or electric work
equipment lever.
30 WA500-6R
Loader pump pressure sensor

Lift arm cylinder bottom pressure sensor
Lift arm cylinder head pressure sensor (load meter) (if equipped)
1. Sensor 2. Connector
Function Operation
q Installed to the inlet port circuit for the control q When oil pressure led from the pressure input
valve, these sensors convert pump discharge port applies pressure to the diaphragm of oil
pressure to voltage and transmit to the gover- pressure sensor, the diaphragm is deformed
nor pump controller. from deflection.
q Gauge layer is installed to the opposite of the
diaphragm. Deflection of the diaphragm is con-
verted into output voltage by the resistance of
the gauge layer and is sent to the amplifier.
q After amplifying the voltage, the amplifier
transmits the voltage to the governor controller.
q Relational expression of pressure P (MPa {kg/
cm2}) and output voltage (V)
V = 0.08 {0.008} x P + 0.5
Function (lift arm sensors)

q Installed on the bottom and rod pipes of the lift
arm cylinder, these sensors measure cylinder
pressure for loaded/unloaded judgment and
load weight calculation.
WA500-6R 31
Fuel level sensor
1. Connector 4. Body 7. Spacer

2. Float 5. Spring
3. Arm 6. Contact
Function
q The fuel level sensor is installed to the side of
the fuel tank. The float moves up and down
according to the fuel level.
The float moves the variable resistor through
the arm. The voltage signal is sent to the
machine monitor to indicate the fuel level.
Also, when the machine monitor indicator
reaches a specified position, caution lamp is lit.
32 WA500-6R
Parking brake pressure switch

Stop lamp pressure switch
1. Case
2. Tube
3. Connector
Function
q When the parking brake is released, oil pres-
sure is fed to the brake piston. The oil pressure
operates the pressure switch to turn out the
parking brake pilot lamp on the machine moni-
tor.
q When the foot brake is stepped on and the
brake operating pressure is generated, the
pressure switch contact is closed, the relay is
operated and stop lamp lights up.
WA500-6R 33
Air cleaner clogging sensor
1. Indicator
2. Spring
3. Adapter
Function
q The air cleaner clogging sensor is installed to
the air cleaner outlet. If the air cleaner is
clogged and the pressure reaches the speci-
fied level (negative pressure), caution lamp on
the machine monitor lights up to output a warn-
ing.
34 WA500-6R
Transmission clogging sensor
1. Body Function
2. Tube q The clogging sensor is installed to the filter
3. Connector section. If the filter is clogged and the pressure
difference between the lower and higher sides
A: Take-out port on low pressure side reaches a specified level, the switch turns
B: Take-out port on high pressure side OFF, and the maintenance caution lamp lights
up. At the same time, a message appears to
the character display to warn on abnormal situ-
ation.
Operating pressure: 275 kPa {2.8 kg/cm2}

Principle of switching: Differential pressure
sliding piston type
WA500-6R 35
Steering oil pressure sensor switch
1. Body 3. Tube
2. Shaft 4. Connector
Function
q The steering oil pressure sensor switch detects
operation of diverter valve spool, which is
tripped to operate when the steering oil pres-
sure drops.
q If the steering oil pressure drops and the spool
operates, the switch piston is turned OFF and
the circuit opens.
36 WA500-6R
Radiator coolant level sensor
1. Stopper 4. Plug
2. Float 5. Tube
3. Sensor 6. Connector
Function
q This sensor is installed on the coolant sub-
tank. If the coolant level lowers below the
specified level, the float lowers and the switch
is turned “OFF” and the caution lamp on the
machine monitor lights up for warning.
WA500-6R 37
Brake accumulator pressure switch (front and rear)
1. Case
2. Tube
3. Connector
Function
q If the brake accumulator oil pressure lowers,
the contact becomes OPEN, and the caution
lamp lights up on the machine monitor to warn
of abnormality.
38 WA500-6R
Battery electrolyte level sensor
1. Body 4. Packing
2. Connector 5. Pin
3. Filter
Function
q The battery electrolyte level sensor is installed
to the battery. If the battery electrolyte level
lowers below the specified level, the sensor tip
is exposed to air and a signal of voltage
change is generated. The signal is sent to the
machine monitor to warn of abnormal situation.
WA500-6R 39
Accelerator pedal sensor
1. Pedal
2. Connector
Accelerator signal
q Accelerator pedal installed to the floor is pro-
vided with accelerator sensor for the engine
controller. When the accelerator pedal is
stepped on, the potentiometer shaft inside the
accelerator sensor starts rotation and resis-
tance value changes accordingly. Potentiome-
ter is applied with a constant level of voltage
from the engine controller. Voltage signal is
transmitted to the engine controller according
to the depressed angle of accelerator pedal. In
addition, the depressed angle is transmitted to
each controller over the network as the accel-
erator pedal opening data.
Idle validation signal

q This sensor is installed in the same case
where the accelerator sensor is installed.
While the accelerator pedal is released, signal
2 is connected to the ground, and when the
accelerator pedal is stepped on, signal 3 is
connected to the ground. Using those signals,
the engine controller detects whether the
accelerator pedal is stepped on.
40 WA500-6R
Emergency brake pressure switch (front)

Emergency brake pressure switch (rear)
1. Case
2. Tube
3. Connector
Function
q When the brake accumulator pressure lowers,
the switch contact opens. Circuit between the
parking brake switch and parking brake sole-
noid is cut off, and the parking brake is tripped
to operate.
WA500-6R 41
KOMTRAX terminal system (if equipped) 1
q The KOMTRAX terminal sends various infor-

mation on the machine by a wireless communi-
cation. The KOMTRAX operator refers to this
information in the office, and various services
can be provided for the customer.
a To be provided with the KOMTRAX termi-

nal service, it is necessary to sign up sep-
arately.
Information that can be sent from the

KOMTRAX terminal is as follows:
1. Operation history
2. Service meter
3. Location information
4. Error history
42 WA500-6R
KOMTRAX terminal
1. DRC connector (40-pole) contacts

2. (Do not connect)
3. GPS antenna connector
4. ORBCOMM antenna connector
Outline
q The KOMTRAX terminal can acquires various
machine information with intra-machine net-
work or input signals and transmit the informa-
tion via a radio communication antenna.
Equipped with a CPU (central processing unit),
this terminal has the radio communication and
GPS functions.
q The display monitor has LED lamps and a 7-
segment indicator lamp for inspection and trou-
bleshooting.

q DRC connector
Input and Input and
output output
1 232C (0CH) control signal Input 21 Inspection mode Input
2 232C (0CH) control signal Output 22 Inspection mode Input
3 232C (0CH) control signal Input 23 232C (0CH) control signal Input
4 232C (0CH) reception Input 24 (if equipped) Input
5 232C (0CH) transmission Output 25 (if equipped) Input
6 CAN shield GND — 26 (if equipped) Input
7 CAN signal (L) Input/output 27 Terminal C input (Hi side) Input
8 CAN signal (H) Input/output 28 Alternator terminal R input Input
9 S-NET shield GND — 29 EXGND —
10 S-NET signal — 30 (if equipped) Output
11 232C (0CH) shield GND — 31 (If equipped) (5 V MAX) Input
12 Write signal Input 32 (If equipped) (5 V MAX) Input
13 232C (1CH) reception Input 33 232C (0CH) control signal Input
14 232C (1CH) transmission Output 34 (if equipped) Input
15 232C (0CH) control signal Output 35 (if equipped) Output
16 (if equipped) Input 36 ACC input Input
17 (if equipped) Input 37 Power supply GND —
18 (if equipped) Output 38 Power supply GND —
19 (if equipped) Output 39 Constant power supply (12 V/24 V) Input
20 Engine start output Output 40 Constant power supply (12 V/24 V) Input
WA500-6R 43
SEN02900-00

© 2007 KOMATSU
All Rights Reserved
44
SEN02926-02
WA500-6R

WA500-6R 60001 and up
20 Standard value table 1

Standard service value table
Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 3
WA500-6R 1
SEN02926-02 20 Standard value table
Standard service value table for engine 1
Machine Model WA500-6R

Engine SAA6D140E-5
Standard value Service limit
Item Measurement Conditions Unit
for new machine value
High idle 2,120 ± 50 2,120 ± 50
Low idle 790 ± 25 790 ± 25
• Engine coolant temperature:
Engine speed Engine speed rpm
Within operating range
set min. low 700 ± 25 700 ± 25
idle (*1)
Exhaust • All revolution ranges
°C Max. 670 720
temperature • Atmospheric temperature: 20°C
Intake air pressure kPa Min. 89 76
• At rated output
(Boost pressure) (mmHg) {Min. 670} {570}
At sudden
% Max. 40 50
acceleration
• Engine coolant temperature: (Low o High) (Bosch index) (Max. 4.0) (5.0)
Exhaust gas color
At rated output Max. 1.5 2.5
(Bosch index)
At high idle Max. 1.0 2.0
Intake valve 0.35 —
Valve clearance • Normal temperature mm
Exhaust valve 0.57 —
• At rated output kPa Max. 2.94 3.92
Blow-by pressure
• Engine coolant temperature: Min. 70°C (mmH2O) {Max. 300} {400}
At rated output
SAE0W30EOS Min. 0.34 0.21
Engine oil temperature: Min.
SAE5W40EOS {Min. 3.5} {2.1}
80°C MPa
Oil pressure SAE10W30DH
At low idle {kg/cm2}
SAE15W40DH Min. 0.10 0.08
Engine oil temperature: Min. SAE30DH {Min. 1.0} {0.8}
80°C
Oil temperature • All engine speed ranges (Inside oil pan) °C 90 – 110 120
Alternator belt Deflection made by finger pressure of about 
mm 13 – 16 13 – 16
tension 98 N {10 kg}
*1: Denotes the low idle speed when the engine speed was decreased to the minimum speed with the RPM
idle-up/down selector switch.
2 WA500-6R
Standard service value table for chassis 1

Machine model WA500-6R
Category

Item Measurement conditions Unit
N o FORWARD, 5.9 ± 2.9 5.9 ± 2.9

Directional
REVERSE {0.6 ± 0.25} {0.6 ± 0.25}

lever
Operating • Engine stopped N

effort FORWARD, • Measure at center of lever knob {kg} 5.9 ± 2.9 5.9 ± 2.9
REVERSE o N {0.6 ± 0.25} {0.6 ± 0.25}
5.9 ± 2.9 5.9 ± 2.9
1st o 2nd
{0.6 ± 0.25} {0.6 ± 0.25}
Operating 5.9 ± 2.9 5.9 ± 2.9
2nd o 3rd
effort {0.6 ± 0.25} {0.6 ± 0.25}
Gearshift lever
5.9 ± 2.9 5.9 ± 2.9

3rd o 4th
• Engine stopped N {0.6 ± 0.25} {0.6 ± 0.25}
• Measure at center of lever knob {kg} 5.9 ± 2.9 5.9 ± 2.9
4th o 3rd
{0.6 ± 0.25} {0.6 ± 0.25}
5.9 ± 2.9 5.9 ± 2.9
Stroke 3rd o 2nd
{0.6 ± 0.25} {0.6 ± 0.25}
5.9 ± 2.9 5.9 ± 2.9
2nd o 1st
{0.6 ± 0.25} {0.6 ± 0.25}
HOLD o RAISE Max. 10.8 Max. 16.2
(*2) {Max. 1.1} {Max. 1.7}
Max. 15.2 Max. 22.9
RAISE o HOLD
{Max. 1.6} {Max. 2.4}
HOLD o Max. 10.8 Max. 16.2
LOWER (*2) {Max. 1.1} {Max. 1.7}
Lift arm
LOWER o
Operating effort
— —
HOLD
• Engine speed: Low idle (*1)
LOWER o N Max. 18.6 Max. 28.4
• Hydraulic oil temperature: Within
FLOAT {kg} {Max. 1.9} {Max. 2.9}
Work equipment control lever
operating range
Max. 10.8 Max. 16.2
FLOAT o HOLD
{Max. 1.1} {Max. 1.7}
Max. 10.8 Max. 16.2
HOLD o DUMP
{Max. 1.1} {Max. 1.7}
HOLD o TILT Max. 10.8 Max. 16.2
Bucket
(*2) {Max. 1.1} {Max. 1.7}
Max. 10.8 Max. 16.2
TILT o HOLD
{Max. 1.1} {Max. 1.7}
HOLD io
40 ± 10 40 ± 15
RAISE (*2)
HOLD io
Lift arm 40 ± 10 40 ± 15
LOWER (*2)
• Engine speed: Low idle (*1)
Stroke
HOLD io
• Hydraulic oil temperature: Within mm 45 ± 10 45 ± 15
FLOAT
operating range
HOLD o DUMP 40 ± 10 40 ± 15
Bucket
HOLD o TILT
40 ± 10 40 ± 15
(*2)
*1: Denotes the low idle speed when the engine speed was decreased to the minimum speed with the
RPM idle-up/down selector switch.
*2: The value shows the value before the detent.
WA500-6R 3

Category

• Engine stopped
Play mm Max. 40 50 –— 100
• Machine facing straight to front
• Flat, level, straight, dry, and
paved road N 9.8 ± 2.0
Operating effort Max. 19.6 {2.0}
Steering wheel
• Engine speed: Low idle (Bucket {kg} {1.0 ± 0.2}

empty) (*1)
• Engine speed: High idle
Turns (Not including play) Turns 4.0 ± 0.3 Max. 4.5
• Left lock – right lock
Low idle (*1) • Engine started Max. 6.0 Max. 7.0

Operating • Hydraulic oil temperature: Within
sec.
time operating range
High idle • Left lock – right lock Max. 3.5 Max. 4.0

paved road N 5.8 - 11.2
Operating effort Max. 19.5 {1.99}
Joystick steering
• Engine speed: Low idle (Bucket {kg} {0.59 - 1.14}

empty) (*1)
• Engine started
• Hydraulic oil temperature: 45 -
Operating time 55 °C sec. Max. 5.4 Max. 6.4
• Left lock – right lock
• Engine started
N Max. 107.9
Operating effort • Measure at 150 mm from ful- Max. 58.8 {6.0}
Accelerator pedal
{kg} {11.0}
crum of pedal.
a For measuring posture, see Fig.
Neutral (a1) A at end of this section 52 —
Operating • Engine speed: Low idle (*1)
deg.
angle • Hydraulic oil temperature: Within
Max. (a2) operating range 17 —
• a2 = a1 – a3
N Max. 363 ± 39.2 Max. 520.3
Operating effort
{kg} {Max. 37 ± 4} {Max. 53}
a For measuring posture, see Fig.
Brake pedal
Neutral (a1) B at end of this section 53 —

Operating • Engine speed: Low idle (*1)
deg.
angle • Hydraulic oil temperature: Within
Max. (a2) operating range 16 (+1/0) —
• a2 = a1 – a3
Play mm 5 ± 0.5 —
A Max. 2.5 —
Fitting of wheel lock ring a For measuring posture, see Fig.
C at end of this section
Tire
B mm Max. 4.0 —
• Tire inflation pressure: Specified
Clearance of wheel lock pressure
C 2 – 15 —
ring
4 WA500-6R
Category Machine model WA500-6R

P-mode 1,840 ± 100 1,840 ± 200

Torque converter stall
• Engine coolant temper-
E-mode 1,810 ± 100 1,810 ± 200
ature: Within operating
Engine speed
range
• Torque converter oil P-mode 2,100 ± 100 2,100 ± 200
Hydraulic stall temperature: Within rpm
operating range E-mode 2,000 ± 100 2,000 ± 200
• Hydraulic oil tempera-
ture: Within operating
P-mode 1,800 ± 100 1,800 ± 300
Torque converter stall + range
hydraulic stall
E-mode 1,765 ± 100 1,765 ± 300
3.34 ± 0.15 3.34 ± 0.15

Low idle (*1)
Main relief {34 ± 1.5} {34 ± 1.5}
pressure 3.64 ± 0.15 3.64 ± 0.15
High idle • Torque converter oil tempera- {37.1 ± 1.5} {37.1 ± 1.5}
ture: Within operating range
Torque converter inlet oil pres- • Engine speed: High idle 0.64 ± 0.2 0.64 ± 0.2
sure {6.5 ± 2} {6.5 ± 2}
Transmission, torque converter
Torque converter outlet port oil 0.39 ± 0.1 0.39 ± 0.1

pressure {4.0 ± 1.0} {4.0 ± 1.0}
3.24 ± 0.2 3.24 ± 0.2
1st
{33 ± 2} {33 ± 2}
MPa 3.28 ± 0.2 3.28 ± 0.2
2nd
{kg/cm2} {33.5 ± 2} {33.5 ± 2}
3.28 ± 0.2 3.28 ± 0.2
• Torque converter oil 3rd
{33.5 ± 2} {33.5 ± 2}
temperature: Within
ECMV output (clutch) oil pres- 3.19 ± 0.2 3.19 ± 0.2
operating range 4th
sure {32.5 ± 2} {32.5 ± 2}
• Engine speed: Hi idle
• Manual switch: ON 1.86 ± 0.15 1.86 ± 0.15
Lockup
{19 ± 1.5} {19 ± 1.5}
3.38 ± 0.2 3.38 ± 0.2
Forward
{34.5 ± 2} {34.5 ± 2}
3.34 ± 0.2 3.34 ± 0.2
Reverse
{34 ± 2} {34 ± 2}
• Hydraulic oil temperature: Within 24.5 24.5
Steering relief pressure operating range (+1.18/–0.49) (+1.18/–1.47)
• Engine speed: High idle {250 (+12/–5)} {250 (+12/–15)}
Steering
operating range 3.72 (+0.2/0) 3.72 (+0.2/–0.2)

Orbit-roll basic pressure MPa
• Engine speed: High idle {38 (+2/0)} {38 (+2/–2)}
{kg/cm2}
• Steering wheel operation
operating range 1.27 ± 0.1 1.27 ± 0.2
LS pressure
• Engine speed: Low idle {13.0 ± 1} {13.0 ± 2}
• Steering wheel: Stopped
WA500-6R 5

Category

• Point where
5.88
• Engine brake oil pres- 5.88 (+0.49/0)
Charge cut-in pressure (+0.98/–0.49)
speed: Low sure warning {60 (+5/0)}
Accumulator
{60 (+10/–5)}
idle (*1) lamp goes out
MPa
• Hydraulic oil • Point where oil
{kg/cm2}
temperature: pressure is 9.8
Within operat- 9.8 (+0.98/0)
Charge cut-out pressure going up and (+1.47/–0.49)
ing range {100 (+10/0)}
then starts to {100 (+15/–5)}
go down
1st 7.7 ± 0.4 7.7 ± 0.4
12.5 ± 0.6 12.5 ± 0.6

2nd
P-mode (14.2 ± 0.7) (14.2 ± 0.7)
• ( ): at lockup 22.3 ± 1.1 22.3 ± 1.1
3rd
(23.4 ± 1.2) (23.4 ± 1.2)
34.9 ± 1.7 34.9 ± 1.7
4th
FOR- (38.8 ± 1.9) (38.8 ± 1.9)
km/h
WARD
1st 7.3 ± 0.4 7.3 ± 0.4
12.5 ± 0.6 12.5 ± 0.6

2nd
E-mode (13.5 ± 0.7) (13.5 ± 0.7)
• ( ): at lockup 20.9 ± 1.0 20.9 ± 1.0
3rd
(22.2 ± 1.1) (22.2 ± 1.1)
Power train
32.1 ± 1.6 32.1 ± 1.6

4th
(36.7 ± 1.8) (36.7 ± 1.8)
Travel speed (Bucket empty)
1st 8.6 ± 0.4 8.6 ± 0.4
13.0 ± 0.7 13.0 ± 0.7

2nd
P-mode (15.9 ± 0.8) (15.9 ± 0.8)
• ( ): at lockup 24.8 ± 1.2 24.8 ± 1.2
3rd
(26.2 ± 1.3) (26.2 ± 1.3)
37.5 ± 1.9 37.5 ± 1.9
4th
REVE (43.2 ± 2.2) (43.2 ± 2.2)
km/h
RSE
1st 8.1 ± 0.4 8.1 ± 0.4
13.0 ± 0.7 13.0 ± 0.7

2nd
E-mode (15.1 ± 0.8) (15.1 ± 0.8)
• ( ): at lockup 23.2 ± 1.2 23.2 ± 1.2
3rd
(25.0 ± 1.3) (25.0 ± 1.3)
35.0 ± 1.8 35.0 ± 1.8
4th
(41.0 ± 2.1) (41.0 ± 2.1)
6 WA500-6R

• Hydraulic oil temperature: Within 4.9 (+0.69/0) 4.9 (+0.88/–0.2)

Brake oil pressure
operating range {50 (+7/0)} {50 (+9/–2)}
• Engine stopped MPa
• Keep brake pedal depressed at
{kg/cm2} Max. 0.49 Max. 0.49
Drop in brake pressure 4.9 MPa {50 kg/cm2} and mea-
{Max. 5} {Max. 5}
sure drop in oil pressure after 5
min.
Wheel brake

pressure
paved road
• Braking initial speed: 20 km/h,
Performance m Max. 4 Max. 4
Braking delay: Within 0.1 sec.
• Brake pedal pressing force:
Specified pressing force 294 ±
29.4 N {30 ± 3 kg}
• Measure braking distance
Disc wear • Measure with disc wear indicator mm 0 Max. 4.0
When brake 3.53 ± 0.15 3.53 ± 0.15
Parking released • Torque converter oil tempera- {36 ± 1.5} {36 ± 1.5}
MPa
brake inlet ture: Within operating range
When brake {kg/cm2} Min. 0.14 Min. 0.14
pressure • Engine speed: Low idle (*1)
operated {Min. 1.4} {Min. 1.4}
Parking brake

pressure
• Flat paved road with 1/5 (11° 20')
grade. Dry, paved road surface
Performance — Holds in position Holds in position
• Machine at operating condition
a For measuring posture, see
Figs. D and E at end of this sec-
tion
Disc thickness mm 3.2 ± 0.1 2.77
Work equipment EPC

EPC valve basic pressure 3.72 (+0.2/0) 3.72 (+0.2/–0.2)
operating range
(Orbit-roll basic pressure) {38 (+2/0)} {38 (+2/–2)}
MPa
Lift arm RAISE, • Hydraulic oil temperature: Within {kg/cm2}
EPC valve
FLOAT; Bucket operating range 3.72 (+0.2/0) 3.72 (+0.2/–0.2)
output pres-
DUMP, TILT, Lift • Engine speed: High idle {38 (+2/0)} {38 (+2/–2)}
sure
arm LOWER • Control lever operated fully
WA500-6R 7

Category

• Hydraulic oil temperature: Within 33.3

Work equipment relief pres- (+1.47/–0.49) 33.3 ± 1.47
operating range
sure {340 ± 15}
• Engine speed: High idle {340 (+15/–5)}
operating range
2.26 ± 0.1 2.26 ± 0.2
Unload pressure • Engine speed: High idle MPa
{23 ± 1} {23 ± 2}
• Work equipment control lever: {kg/cm2}
Neutral
operating range 1.37 ± 0.1 1.37 ± 0.2
LS differential pressure
• Engine speed: High idle {14 ± 1} {14 ± 2}
• Lift arm lever: at half stroke
P-mode 7.2 ± 0.5 Max. 8.9
Lift arm RAISE range
• Engine speed: High E-mode 8.1 ± 0.5 Max. 9.7
idle
Work equipment speed
• Apply no load P-mode 4.2 ± 0.5 Max. 5.4

Lift arm LOWER a For measuring posture,
see Figs. F and G at
E-mode 4.2 ± 0.5 Max. 5.4
end of this section
Work equipment
sec.
P-mode 2.5 ± 0.3 Max. 3.4
Bucket full stroke range
• Engine speed: High E-mode 2.7 ± 0.3 Max. 3.5
Bucket
idle
tilt back
Moving bucket • Apply no load P-mode 1.8 ± 0.3 Max. 2.6
from level posi- a For measuring posture,
tion see Figs.H and J at
E-mode 1.9 ± 0.3 Max. 2.7
end of this section
Retraction of lift arm cylin- operating range
• Stop engine and leave for 5 min- Max. 40 Max. 40
der rod
Hydraulic drift
utes, then measure for 15 min-

utes.
mm
• Apply no load to bucket and set
lift arm and bucket in level posi-
Retraction of bucket cylin- tion. Max. 20 Max. 20
der rod a For measuring posture, see Fig.
K at end of this section
Proximity switch
Clearance of bucket posi-

mm 3–5 —
tioner proximity switch
8 WA500-6R


Min. 95°C
Max. fan speed • Hydraulic oil temperature: Min. 1,055 ± 50 1,055 ± 100
95°C
• Torque converter oil tempera-
ture: Min. 105°C
• Engine speed: Low idle (*1) rpm
Max. 75°C
• Hydraulic oil temperature: Max.
Min. fan speed 170 ± 30 170 ± 50
75°C
Hydraulic drive fan

ture: Max. 85°C
• Air conditioner OFF
Min. 95°C
17.7 ± 2.5 17.7 ± 2.5
Fan drive pressure • Hydraulic oil temperature: Min.
{180 ± 25} {180 ± 25}
95°C
ture: Min. 105°C MPa
• Engine speed: High idle {kg/cm2}
Min. 95°C
Fan reverse solenoid output 19.6 ± 2.5 19.6 ± 2.5
• Hydraulic oil temperature: Min.
pressure {200 ± 25} {200 ± 25}
95°C
ture: Min. 105°C
WA500-6R 9
Machine posture and procedure for performance measurement
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
10 WA500-6R
a Fig. G a Fig. K
a Fig. H
a Fig. J
WA500-6R 11
SEN02926-02


© 2017 KOMATSU
All Rights Reserved
12
SEN02927-04
WA500-6R

WA500-6R 60001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Measuring engine speed............................................................................................................................... 10
Measuring exhaust gas color ........................................................................................................................ 12
Measuring exhaust temperature ................................................................................................................... 14
Adjusting valve clearance ............................................................................................................................. 16
Testing compression pressure ...................................................................................................................... 17
Measuring blow-by pressure......................................................................................................................... 19
Measuring engine oil pressure...................................................................................................................... 20
Measuring intake air (boost) pressure .......................................................................................................... 21
Handling fuel system equipment................................................................................................................... 23
Releasing residual pressure in fuel system .................................................................................................. 23
Testing fuel pressure..................................................................................................................................... 24
Testing return rate and leakage .................................................................................................................... 25
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing leakage in fuel system ...................................................................................................................... 30
Handling reduced cylinder mode operation .................................................................................................. 31
WA500-6R 1
SEN02927-04 30 Testing and adjusting
Handling no injection cranking operation ...................................................................................................... 31

Handling controller voltage circuit ................................................................................................................. 32
Testing and adjusting alternator belt tension................................................................................................. 33
Testing and adjusting air conditioner compressor belt tension...................................................................... 34
Adjusting transmission speed sensor............................................................................................................ 35
Measuring directional lever (Steering wheel specification) ........................................................................... 37
Testing and adjusting power train oil pressure .............................................................................................. 38
Flushing procedure for torque converter and transmission hydraulic circuit ................................................. 51
Method of moving machine when transmission valve is broken ................................................................... 54
2 WA500-6R
Tools for testing, adjusting, and troubleshooting 1
Symbol
Q'ty
Testing and adjusting item Part Number Name Remarks
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9

Measuring exhaust gas
A Commercially
color 2 Smoke meter 1
available
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299 °C
temperature
Commercially
Adjusting valve clearance C Clearance gauge 1
available
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1310 Adapter 1
pressure 2
6261-71-6150 Gasket 1
Measuring blow-by
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil
F Pressure gauge:
pressure 790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
1 MPa {10 kg/cm2}
Measuring intake air –101 – 200 kPa
G 799-201-2202 Boost gauge kit 1
(boost) pressure {–760 – 1,500 mmHg}
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Testing fuel pressure H
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 x 1.25 mm o R1/8
3
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 5 mm x 2 – 3 m
available
Testing return rate and Commercially
leakage
J 4 Hose 1 15 mm x 2 – 3 m
available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring directional
lever (Steering wheel K 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
specification)
WA500-6R 3
Symbol
Q'ty
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting Pressure gauge:

L 790-261-1204 Digital hydraulic tester 1
power train oil pressure 60 MPa {600 kg/cm2}
799-101-5220 Nipple 1 10 x 1.25 mm
2 Pressure gauge:
07002-11023 O-ring 1
1 MPa {10 kg/cm2}
Method of moving machine
when transmission valve is M 794-423-1190 Plug 1 20 x 1.5 mm
broken
Testing and adjusting
N 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
steering wheel
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
60 MPa {600 kg/cm2}
Testing steering oil
Q 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
pressure
2
07002-11023 O-ring 1
3 799-401-3200 Adapter 1 Size 03
Differential pressure
4 799-401-2701 1
gauge
1 799-205-1100 Tachometer kit 1 Digital indication: 6 – 99999.9 rpm
Pressure gauge:
2 {25, 60, 400, 600 kg/cm2}
Testing hydraulic drive fan R Pressure gauge:

60 MPa {600 kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
3
07002-11023 O-ring 1
4 799-401-3500 Adapter 1 Size 06
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
Bleeding air from 60 MPa {600 kg/cm2}
S
hydraulic drive fan circuit 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3500 Adapter 1 Size 06
4 790-261-1130 Coupling 1
4 WA500-6R
Symbol
Q'ty
— 792-610-1703 Gas charging tool 1

A 1 792-610-2310 Extension 1
2 792-610-1260 Nipple (for Japan) 1 Size: W22-14 x W23-14
B 792-610-1270 Hose 1
C 792-610-2410 Bushing 1
Testing of accumulator D 792-610-1400 Regulator 1
nitrogen gas pressure and 792-610-1310 Nipple (for Russia) 1 GOST
procedure for charging
accumulator with nitro- 792-610-1320 Nipple (for USA) 1 CGA No.351
gen gas 792-610-1330 Nipple (for USA) 1 ASA B-571-1965
E DIN 477-1963
792-610-1350 Nipple (for Germany) 1 NEN 3268-1966
SIS-SMS2235/2238
792-610-1360 Nipple (for UK) 1 BS 341Part1-1962
Commercially
F Nitrogen gas cylinder 1
available
1 793-520-1821 Nipple 1
Testing wheel brake oil 2 793-520-1810 Joint 1

U
pressure 3 385-10178481 Bleeder screw 1
4 793-520-1831 Gauge assembly 1 G1/4 o R1/8
Measuring wear of wheel Commercially
V Slide calipers 1
brake disc available
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
Measuring parking brake 790-261-1204 Digital hydraulic tester 1
W 60 MPa {600 kg/cm2}
oil pressure
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3100 Adapter 1 Size 02
Testing wear of parking Commercially
X Slide calipers 1
brake disc available
1 79A-264-0021 Push-pull scale 1
Measuring and adjusting
Y Commercially
work equipment lever 2 Scale 1
available
Pressure gauge:
Testing and adjusting 1 {25, 60, 400, 600 kg/cm2}
work equipment PPC oil Z
Pressure gauge:
pressure 790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
2 799-401-3200 Adapter 1 Size 03
WA500-6R 5
Symbol
Q'ty
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
60 MPa {600 kg/cm2}
Measuring work
ZA 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
equipment oil pressure
2
07002-11023 O-ring 1
Differential pressure
3 799-401-2701 1
gauge
4 799-401-3200 Adapter 1 Size 03
799-601-4101
or
799-601-4201
or T-adapter assembly 1
799-601-9000
or
799-601-9200
For DT2P (No. 1 – No. 6 injector)
For DT2P (Resistor)
Diagnosis for engine
related controller, sensor, ZB For DT2P 
actuator and harness (Electrical priming pump timer)
For DT2P (Fan reverse solenoid)
799-601-9020 • T-adapter for DT 1 For DT2P (Coolant level sensor)
For DT2P (Fuel level sensor)

For DT2P 
(Battery electrolyte level sensor)
For DT2P 
(Fan pump EPC solenoid)
6 WA500-6R
Symbol
Q'ty
799-601-4101
799-601-4201
For AMP3P 
799-601-4240(*) • Socket for AMP 1
(Ambient pressure sensor)
For AMP3P 
799-601-9420 • T-adapter for AMP 1
(Common rail pressure sensor)
799-601-4260 • T-adapter for DTP 1 For DTP4P (Engine controller)
• T-adapter for  For FRAMATOME3P 
799-601-4130 1
FRAMATOME (Ne speed sensor)
• T-adapter for  For FRAMATOME3P 
799-601-4150 1
FRAMATOME (Engine oil pressure sensor)
For PACKARD2P 
(Fuel temperature sensor)
795-799-5530(*) • Socket for PACKARD 1
For PACKARD2P 
(Coolant temperature sensor)
For PACKARD2P (Charge tem-
795-799-5540(*) • Socket for PACKARD 1 perature (Boost temperature) sen-
sor)
For SUMITOMO2P (Supply
799-601-9430(*) • Socket for SUMITOMO 1
pump)
For SUMITOMO3P 
799-601-4330(*) • Socket for SUMITOMO 1
(Bkup speed sensor)
For SUMITOMO3P (Charge pres-
Diagnosis for engine 799-601-4250(*) • Socket for SUMITOMO 1
sure (Boost pressure) sensor)
related controller, sensor, ZB
actuator and harness 799-601-9000
799-601-9200
For DT3P (CAN connector)
799-601-9030 • T-adapter for DT 1 For DT3P 
(CAN terminal resistance)
For DT6P 
799-601-9050 • T-adapter for DT 1
(Electrical priming pump)
For DT12P(B) (Intermediate con-
nector (Engine))
799-601-9120 • T-adapter for DT(B) 1
For DT12P(B) (Intermediate con-
nector (No.1 – No.6 injector))
For DT12P(Gr) (Intermediate con-
799-601-9110 • T-adapter for DT(Gr) 1
nector (Engine controller))
799-601-4101 T-adapter assembly 1
799-601-4220 • T-adapter for DRC 1 For DRC60P (Engine controller)
For DRC26-50P 
799-601-4211 • T-adapter for DRC 1
(Engine controller)
799-601-7000
or
or
799-601-7400
For SWP6P (Engine power mode
799-601-7050 • T-adapter for SWP 1
selector switch)
(*): Shows not T-adapter but socket. (Gr): Gray, (B): Black
WA500-6R 7
Symbol
Q'ty
799-601-4101
or
799-601-4201
799-601-9000
or
799-601-9200
799-601-9020 • T-adapter for DT 1 For DT2P
799-601-9000
799-601-9200
799-601-9060 • T-adapter for DT(Gr) 1 For DT8P(Gr)
799-601-9070 • T-adapter for DT(B) 1 For DT8P(B)
799-601-9110 • T-adapter for DT(Gr) 1 For DT12P(Gr)
799-601-9120 • T-adapter for DT(B) 1 For DT12P(B)
799-601-9130 • T-adapter for DT(G) 1 For DT12P(G)
799-601-9140 • T-adapter for DT(Br) 1 For DT12P(Br)
Diagnosis for chassis
related controller, sensor, ZC 799-601-9350 • T-adapter for DRC 1 For DRC40P
actuator and harness 799-601-9360 • T-adapter for DRC 1 For DRC24P
799-601-9000
799-601-9100
799-601-9290 • T-adapter for HD24 1 For HD24-31P
799-601-7400
799-601-8000
799-601-7080 • T-adapter for M 1 For M1P
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7020 • T-adapter for X 1 For X2P
799-601-7150 • T-adapter for S 1 For S10P
(Gr): Gray, (B): Black, (G): Green, (Br): Brown
8 WA500-6R
Symbol
Q'ty
799-601-7000
or
or
799-601-7400
799-601-7050 • T-adapter for SWP 1 For SWP6P
Diagnosis for chassis 799-601-7060 • T-adapter for SWP 1 For SWP8P
related controller, sensor, ZC 799-601-7400
actuator and harness or T-adapter assembly 1
799-601-8000
OUT OF KIT
Measuring coolant
temperature and oil — 799-101-1502 Digital thermometer 1
temperature
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}

—
effort and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Scale 1
hydraulic drift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Circuit tester 1
resistance available
WA500-6R 9
Measuring engine speed 1 2. Measuring torque converter stall speed
k
1) Referring to “Special function of machine
Put chocks under the tires.
k
monitor (EMMS)“, select the real-time
When measuring, check that there are no monitoring function of the service mode.
persons around the machine. 2) Select the two-item simultaneous monitor-
ing (2 ITEMS) and then enter the following
a Measure the engine speed under the following code numbers directly.
condition. a Monitoring items
q Engine coolant temperature: [1] Code No. 01001: ENG SPEED
Within operating range (Engine speed)
q Hydraulic oil temperature: [2] Code No.40100: TC OIL TEMP
Within operating range (Torque converter oil temperature)
q Torque converter oil temperature:
1. Measuring engine speed (low idle and high

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

4) Turn off the transmission cut-off switch
and press the left brake pedal securely.
5) Set the transmission auto shift and man-
ual shift selector switch in the MANUAL
position.
6) Set the gear shift lever or gear shift switch
to the 4th speed while keeping the direc-
tional lever, joystick steering directional
switch or right directional switch at the N
(Neutral) position.
7) Release the parking brake.
8) While pressing the brake pedal, set the
directional lever, joystick steering direc-
3) Start the engine, set it in the measuring tional switch or right directional switch to
condition, and measure the engine speed. the F (forward) or R (reverse) position.
k Keep pressing the brake pedal
securely.
9) While running the engine at high idle,
press the accelerator pedal gradually.
When the torque converter stalls, mea-
sure the engine speed.
a Measure the stall speed 2 – 3 times.
a Do not keep stalling the torque con-
verter for more than 20 seconds. Take
care that the torque converter oil tem-
perature will not exceed 120°C.
a Measure the torque converter stall
speed when the power mode and
economy mode are turned on.
10 WA500-6R
3. Measuring hydraulic stall speed 4. Measuring torque converter stall and

1) Referring to “Special function of machine hydraulic stall (full stall) speed
monitor (EMMS)“, select the real-time 1) Set the machine monitor in the same way
monitoring function of the service mode. as in “2. Measuring torque converter stall
2) Select the two-item simultaneous monitor- speed“.
ing (2 ITEMS) and then enter the following 2) Start the engine.
code numbers directly. 3) Turn off the transmission cut-off switch
a Monitoring items and press the left brake pedal securely.
[1] Code No. 01001: ENG SPEED 4) Set the transmission auto shift and man-
(Engine speed) ual shift selector switch in the MANUAL
[2] Code No. 04401: HYD TEMP position.
(Hydraulic oil temperature) 5) Set the gear shift lever to the 4th speed
while keeping the directional lever, joystick
steering directional switch or right direc-
tional switch at the N (Neutral) position.
tional switch or right directional switch to
the F (forward) or R (reverse) position.
securely.
8) While running the engine at high idle, stall
the torque converter and relieve the lift
arm cylinder or bucket cylinder on the
extraction side simultaneously and mea-
sure the engine speed at this time.
3) Run the engine at high idle. a Do not keep stalling the torque con-
4) Relieve the lift arm cylinder or bucket cyl- verter for more than 20 seconds. Take
inder on the extraction side and measure care that the torque converter oil tem-
the engine speed. perature will not exceed 120°C.
a Measure the hydraulic stall speed a Measure the full stall speed when the
when the power mode and economy power mode and economy mode are
mode are turned on. turned on.
WA500-6R 11
Measuring exhaust gas color 1 2. Measuring with smoke meter A2

1) Insert the probe of smoke meter A2 in the
a Measuring instruments for exhaust gas color outlet of the muffler (exhaust pipe) and fix
Symbol Part No. Part Name it to the exhaust pipe with a clip.
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
k When installing and removing the measur-

ing instruments, take care not to touch a
hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2.
a Measure the exhaust gas color under the fol-
lowing condition.
q Engine coolant temperature:
Within operating range 2) Connect the hose of the probe, receptacle
of the accelerator switch, and air hose to
1. Measuring with handy smoke checker A1 smoke meter A2.
1) Stick a sheet of filter paper to smoke a Keep the pressure of the supplied
checker A1. compressed air at 1.5 MPa {15 kg/
2) Insert the exhaust gas intake pipe in the cm2} or below.
muffler (exhaust pipe). 3) Connect the power cable to a 100 V AC
3) Start the engine and heighten the engine receptacle.
coolant temperature to the operating a Confirm that the smoke meter power
range. switch is in the OFF position, before
4) Accelerate the engine suddenly or run it at connecting the power cable to an out-
high idle and operate the handle of smoke let.
checker A1 so that the filter paper will 4) Loosen the cap nut of the suction pump
absorb the exhaust gas. and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter
A2.
5) Take out the filtering paper and compare it

with the attached scale for judgement.
6) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
12 WA500-6R
6) Start the engine and keep it running until

the engine coolant temperature rises to
the operating range.
7) Accelerate the engine suddenly or run it at
high idle and press the accelerator pedal
of smoke meter A2 and collect the
exhaust gas into the filter paper.
8) Put the polluted filtering paper on non-pol-
luted filtering paper (more than 10 sheets)
in the filtering paper holder, and read the
indicated value.
WA500-6R 13
Measuring exhaust temperature 1

a Measuring instrument for exhaust temperature
Symbol Part No. Part Name
B 799-101-1502 Digital thermometer
k Install and remove the measuring instru-

ment after the exhaust manifold is cooled.
a Measure the exhaust temperature under the
following condition.
q Hydraulic oil temperature:
5. Procedure for periodic measurement done in
preventive maintenance
1. Open the engine left side cover.
a To prevent the torque converter from over-
heating, increase the exhaust temperature
2. Remove the heat insulation cover.
once through full-stall operation (torque
converter stall + hydraulic stall), and then
3. Remove exhaust temperature pickup plug (1)
measure the exhaust temperature while
at the bottom of exhaust manifold.
only the torque converter is stalled.
1) Start the engine and heighten the coolant
temperature to the operating range.
2) Turn off the transmission cut-off switch
and press the left brake pedal securely.
position.
to the 4th speed while keeping the direc-
switch or right directional switch at the N
(Neutral) position.
4. Install sensor [1] of digital thermometer B and directional lever, joystick steering direc-
connect them to meter [2]. tional switch or right directional switch to
a Take care that the wiring harness of the the F (forward) or R (reverse) position.
digital thermometer will not touch a hot
securely.
part during measurement.
7) Press the accelerator pedal gradually to
the high idle. While running the engine at
high idle, stall the torque converter and
relieve the lift arm cylinder or bucket cylin-
der on the extraction side simultaneously.
(full stall)
a Increase the exhaust temperature to
about 650°C (the state of (a) in the
figure).
a Do not keep stalling the torque con-
verter for more than 20 seconds. Take
care that the torque converter oil tem-
perature will not exceed 120°C.
8) As the exhaust temperature reached

about 650°C, release the hydraulic relief
14 WA500-6R
and then decrease the exhaust tempera-

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

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

surement, and make sure that the machine is
back to normal condition.
WA500-6R 15
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
a Adjusting tool for valve clearance nut (4).
a After setting the No. 1 cylinder to the com-
Symbol Part No. Part name pression top dead center, adjust the valve
Commercially clearance of the No. 1 cylinder.
C Clearance gauge
available
4. Insert clearance gauge C in the clearance
1. Remove 6 cylinder head covers (1), referring between rocker arm (5) and crosshead (6) and
to Disassembly and assembly, "Removal and adjust the valve clearance with adjustment
installation of cylinder head assembly". screw (3).
a With the clearance gauge inserted, turn
the adjustment screw so that clearance
gauge can move with a light force.
a Valve clearance
Intake valve: 0.35 mm,
Exhaust valve: 0.57 mm
5. While fixing adjustment screw (3), tighten lock-

nut (4).
3 Locknut:
45.1 – 51.0 Nm {4.6 – 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.
2. Rotate the crankshaft forward to bring the

stamped “1.6TOP” line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the hexagonal
part at the end of the water pump drive
shaft.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, rotate the crankshaft
one more turn.
6. After adjusting the No. 1 cylinder, rotate the
crankshaft forward by 120° and adjust the
clearance of each cylinder according the firing
order.
a Firing order: 1 – 5 – 3 – 6 – 2 – 4
7. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
16 WA500-6R
Testing compression pressure 1

a Testing tools for compression pressure
Symbol Part No. Part name
1 795-502-1590 Compression gauge
D 795-471-1310 Adapter
2
6261-71-6150 Gasket
k Care must be exercised in measuring the

compression pressure in order to avoid
burn injury from touching the exhaust man-
ifold or muffler, or pinching by rotating part.
a Measure the compression pressure after the
engine is warmed up (Engine oil temperature:
40 – 60°C). 4. Install adapter D2 to the mounting hole on the
injector and compression gauge D1.
1. Remove cylinder head cover (1) of the cylinder a Fit the gasket to the adapter D2 end with-
to be check for the compressing pressure, out fail
referring to Disassembly and assembly, a Fix the adapter with the injector holder.
"Removal and installation of cylinder head 3 Holder mounting bolt:
assembly". 58.8 – 73.5 Nm {6.0 –7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
5. Install rocker arm assembly (2) and adjust the

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

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

injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wir-
ing harness on the injector side and the
bracket on the rocker housing side and 6. Set the mode to the no injection cranking oper-
r e m o v e t h e i n j e c t o r w ir i n g h a r n e s s ation, referring to the service mode of "Special
functions of machine monitor (EMMS)".
k Be sure to set no injection cranking
(Loosen the 2 terminal nuts alternately)
from the injector.
a Pass a wire, etc. under the fuel path pro- mode. Otherwise engine may start and
jected sideways and pull up the injector this may create a dangerous condition.
(Do not pry the injector top up).
7. Rotate the engine cranking with the starting
motor and measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
WA500-6R 17
8. After finishing testing, remove the testing tools

and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
a Change the copper gasket and the O-
ring for a new part.
2) Tighten bolt (13) and washer (14)
temporarily.
2 Spherical portion of washer:
Engine oil
3) Tighten sleeve nut (15) of the fuel
high-pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
a Install the injector wiring harness accord-

ing to the following procedure.
1) Install the injector wiring harness to
the rocker arm housing and fix the
connector side with the plate.
2) Fix the clamp in the intermediate
position with the clip.
3) Tighten the nut on the injector side.
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
4) Secure the clamp and spacer with the
bolt.
3 Rocker arm assembly mounting
bolt: 93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance, referring to
“Adjusting valve clearance.“
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
18 WA500-6R
Measuring blow-by pressure 1 right directional switch at the N (Neutral) posi-

tion.
a Blow-by pressure measurement tools
Symbol Part No. Part Name 7. Release the parking brake.
E 799-201-1504 Blow-by checker
8. While pressing the brake pedal, set the direc-
tional lever, joystick steering directional switch
a Measure the blow-by pressure under the fol-
or right directional switch to the F (forward) or
lowing condition.
R (reverse) position.
k Keep
pressing the brake pedal
securely.
9. Press the accelerator pedal gradually to the
high idle. While running the engine at high idle,
stall the torque converter and measure the
blow-by pressure.
1. Stop the engine. Install nozzle [1] and hose [2]
a Do not keep stalling the torque converter
of blow-by checker E to blow-by hose (1) and
for more than 20 seconds. Take care that
connect them to gauge [3].
the torque converter oil temperature will
not exceed 120°C.
a Normally, the blow-by pressure should be
measured while the engine is operated at
the rated output. In the field, however, an
approximate value can be obtained by
stalling the torque converter.
a If it is impossible to run the engine at the
rated output or stall the torque converter,
measure while the engine is running at
high idle. The value obtained in this case
is about 80% of the blow-by pressure at
the rated output.
a Precaution for measuring blow-by pres-
sure
2. Start the engine and increase the engine cool- The blow-by pressure may vary largely
ant temperature to the operating range. with the engine condition. If the measured
value is judged abnormal, check for
3. Drain oil in the hose while running the engine increase of oil consumption, bad exhaust
at medium speed or above. gas color, deterioration of oil, high deterio-
a Insert approximately half of the gauge and ration speed of oil, etc. which are related
hose connection to the hose and then to the abnormal blow-by pressure.
repeat opening the self-seal of the hose to
drain oil.
a If Pm kit (A) is available, the air bleeding
coupling (790-261-1130) in it may be
used.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
4. Turn off the transmission cut-off switch and

press the left brake pedal securely.
5. Set the transmission auto shift and manual

shift selector switch in the MANUAL position.
6. Set the gear shift lever or gear shift switch to

the 4th speed while keeping the directional
lever, joystick steering directional switch or
WA500-6R 19
Measuring engine oil pressure 1 4. Start the engine and heighten the coolant tem-
a Engine oil pressure measurement tools perature to the operating range.
Symbol Part Number Part name 5. Measure the engine oil pressure when the
799-101-5002 Hydraulic tester engine is run at low idle or high idle speed.
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
a Measure the engine oil pressure under the fol-

lowing condition.
1. Open the engine right side cover.
2. Remove engine oil pressure pickup plug (1)

(R1/4) on the cylinder block.

3 Oil pressure pickup plug:
45 – 49 Nm {4.6 – 5 kgm}
3. Install nipples [1] and [2] of hydraulic tester F1

and connect them to hydraulic tester F2.
a Quick nipple (799-101-5210) is usable
since the plug hole size is R1/4.
20 WA500-6R
Measuring intake air (boost) 3. Remove intake air (boost) temperature pickup
pressure 1 plug (3) (R1/8) in the rear side of the air intake
manifold.
a Measuring instruments for intake air (boost)
pressure
G 799-201-2202 Boost gauge kit
k When installing and removing the measur-

ing instruments, take care not to touch a
hot part of the engine.
a Measure the intake air pressure (boost pres-
sure) under the following condition.
Within operating range 4. Install nipple [1] in boost gauge kit G and con-
nect pressure gauge [2].
1. Remove rear top hood (1).
5. Start the engine.

2. Remove cover (2) between the engine and
cooling. 6. Turn off the transmission cut-off switch and
press the left brake pedal securely.
7. Set the transmission auto shift and manual

shift selector switch in the MANUAL position.

the 4th speed while keeping the directional
lever, joystick steering directional switch or
right directional switch at the N (Neutral) posi-
tion.
9. Release the parking brake.
WA500-6R 21
10. While pressing the brake pedal, set the direc-

tional lever, joystick steering directional switch
or right directional switch to the F (forward) or
R (reverse) position.
securely.
11. Press the accelerator pedal gradually to the

high idle. While running the engine at high idle,
stall the torque converter and measure the
intake air pressure (boost pressure).
a Do not keep stalling the torque converter
for more than 20 seconds. Take care that
the torque converter oil temperature will
not exceed 120°C.

22 WA500-6R
Handling fuel system equipment 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
WA500-6R 23
Testing fuel pressure 1 4. Run the engine at high idle and measure the
a Testing tools for fuel pressure fuel pressure.
a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
H 2 799-401-2320 Hydraulic tester {1.5 – 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
a The fuel pressure shall be checked only in the

low pressure circuit situated between the feed
pump, fuel filter and supply pump.
k The pressure check is not available in the
high pressure circuit between the supply
pump, common rail and injector because
extremely high pressure is generated there.
1. Open the engine right side cover.
2. Remove fuel pressure pickup plug (1) on the

fuel filter head.
5. After finishing testing, remove the testing tools
and return the removed parts.
3. Install adapter H3 and nipple [1] of hydraulic

tester H1 and connect them to hydraulic tester
H2.
24 WA500-6R
Testing return rate and leakage 1

Type of engine having intake manifold equipped with return block
a Testing tools for fuel return rate and leakage

1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
J Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil container with capacity of

approximately 20 l to receive fuel that flows
out during inspection.
WA500-6R 25
1. Preparation work
1) Open the engine right side cover.
2) Remove tube (3) between common rail (1)
and supply pump (2).
3) Insert spacer J1 to supply pump (2) side
and tighten the currently removed joint
bolt again.
a Connect the return pipe to the fuel
tank again, too.
a Be sure to provide a gasket to both
ends of the spacer.
2. Testing leakage from pressure limiter

1) Lay test hose J3 so that it will not slacken
and put its end in the oil container.
2) Set the mode that allows confirming the
engine speed, referring to "4. Real-time
monitoring function" of "Special functions
of machine monitor (EMMS)".
3) Start the engine and run it at the rated out-
put.
4) When the engine speed is stabilized,
check the leakage amount per minute with
measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Leakage
Engine speed
(cc/min)
Rated-output
Max. 10
operation
4) Insert joint J2 to common rail (1) side and

tighten again the removed joint bolt.
a Be sure to fit the gaskets to both ends
of the joint.
5) Connect inspection hose J3 to the tip of
joint J2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a Above completes the preparations
needed for testing the leakage from
the pressure limiter.
5) After finishing testing, stop the engine.
3. Testing return rate from injector tainer while testing the return rate from the
a Keep the hose on the pressure limiter side injector.
connected and keep its end in the oil con- 1) Open the air cleaner inspection cover.
26 WA500-6R
2) Disconnect return tube (5) of return block a You may test for 20 seconds and
(4) and connect inspection hose J4 judge by multiplying the result by 3.
instead. a If the supply pump is not supplying
a Stop the return hose with a plug, etc. fuel, the engine speed may not rise.
and fix it to the fuel tank. In this case, record the engine speed,
Plug: 07376-70315 too, during the test.
a Bind the connecting part of the test a If the return rate (spill) from the injec-
hose with a wire, etc. to prevent it tor is in the following range, it is nor-
from coming off. mal.
Rated output speed Limit of return rate
(rpm) (spill) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
3) Lay test hose J4 so that it will not slacken

and put its end in the oil container.
7) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
4) Set the mode that allows confirming the

engine speed, referring to "4. Real time
monitoring function" of "Special functions
of machine monitor (EMMS)".
5) Stall the torque converter while the engine

is run at high idle. Then as the engine
speed is stabilized, measure the return
rate per minute with measuring cylinder
J5.
a Refer to section “Testing engine
speed” for the torque converter stall-
ing procedure.
6) When the engine speed is stabilized,
check the leakage amount per minute with
measuring cylinder J5.
WA500-6R 27
Bleeding air from fuel circuit 1 4. Turn “ON” switch (3) of electric priming pump
(2) installed to the right frame.
a Bleed air from the fuel circuit in the following a The electric priming pump operates and
cases according to this procedure. lamp (4) blinks.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first
time after the fuel piping or supply pump is
replaced
a If the fuel filters were replaced, do not fill the
main filter and prefilter with the fuel.
1. Turn the starting switch to the “OFF” position.
2. Check that the fuel valve on the fuel tank side

is open.
3. Turn lever (1) of the air bleeding piping to the

horizontal position to open the fuel circuit
valve. a The electric priming pump has a timer in it
to start and stop itself automatically (See
the following figure).
a The electric priming pump stops while the
lamp is blinking. This phenomenon is not
abnormal, however.
a If the switch is turned to the “OFF” position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
k While the electric priming pump is
operating, pressure is applied to the
fuel circuit. Do not loosen the air
bleeding plug at this time, since the
fuel may spout out.
Reference: The operating procedure sticker is

stuck near the air bleeding piping lever.
5. After the specified time (approx. 7 minutes),

lamp (4) goes off and the electric priming pump
stops automatically.
a When performing air bleeding due to fuel
filter replacement, the air bleeding work is
completed now.
6. If the fuel was used up and air was sucked in

the fuel system, or the fuel piping or supply
pump was replaced and there is not fuel in the
fuel circuit, turn switch (3) “ON” after the elec-
tric priming pump stops automatically.
28 WA500-6R
7. When lamp (4) goes off, the air bleeding work

is completed.
8. Turn lever (1) of the air bleeding piping to the

vertical position to close the fuel circuit valve.
9. Start the engine with the starting motor.

k When starting the engine, check that there
is no person around it.
a Do not operate the starting motor continu-
ously for more than 20 seconds.
q After starting the engine, run it at low
idle for about 5 minutes to bleed all air
from the fuel circuit.
q Stop the engine and check that the air
bleeding valve is closed.
10. If the engine does not start, try to start it again
according to the following procedure.
a Carry out the work with the air bleeding
valve closed. (Do not open the air bleed-
ing valve after step 7.)
a After the engine fails to start, wait for
about 2 minutes before trying to start
again.
1) Turn the electric priming pump switch ON.
2) While the electric priming pump is operat-
ing, crank the engine.
q If the engine does not start, repeat the
above operation.
a Do not operate the starting motor continu-
ously for more than 20 seconds.
a If the engine fails to start, wait for about 2
minutes and try to start again.
3) After starting the engine, run it at low idle
for about 5 minutes to bleed all air from
the fuel circuit.
4) Stop the engine and check that the air
bleeding valve is closed.
5) After the above operation, start the engine
normally.
WA500-6R 29
Testing leakage in fuel system 1 9. Inspect the fuel piping and components for fuel
k
leakage.
Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If fuel leakage is recognized, repeat the
After testing the fuel system or removing procedure from step 1 after repairing the
its parts, test it for fuel leakage according leakage.
to the following procedure. a If no fuel leakage is detected, the check is
a Clean and degrease the engine and the parts completed.
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

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

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

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

leakage.
for fuel leakage.
leakage.
6. Run the engine at high idle.
7. Inspect the fuel piping and components for fuel

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

a Stall the torque converter or relieve the
hydraulic pump, referring to “Testing
engine speed.“
30 WA500-6R
Handling reduced cylinder mode Handling no injection cranking

operation 1 operation 1
a Reduced cylinder mode operation means to a No injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- q When a machine or engine has been stored for
lows. a long time, implementing the no injection
cranking before starting the engine lubricates
1. This operation is used to find out a cylinder the engine parts and thus prevents its seizure.
which does not output power normally (or, a The no injection cranking operation is set from
combustion in it is abnormal). the service mode of the machine monitor.
For details, see "Service mode 6. No injection
2. When a cylinder is selected for the reduced cranking function" of Special functions of
cylinder mode operation, if the engine speed machine monitor (EMMS).
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Compression leakage through cylinder
head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a The reduced cylinder mode operation is
set from the service mode of the machine
monitor.
For details, see "Service mode 5. Cylinder
cut-out function" of Special functions of
machine monitor (EMMS).
WA500-6R 31
Handling controller voltage circuit

1. Disconnection or connection of the connector
between the engine controller and engine must
be done after turning off the starting switch.
2. It is prohibited to start the engine when T-

adapter is inserted or connected, for trouble-
shooting purpose, to the connector between
the engine controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
32 WA500-6R
Testing and adjusting alternator 6. Using 2 mounting bolts, install belt cover (1).
belt tension 1 a Check for breakage of the pulleys, wear of
the V-grooves, contact of V belts and V-
Testing
grooves, and contact of the belt covers
1. Open the engine right side cover. and rotating parts.
a V belt must be replaced with a new one if
2. Using a finger, press the belt at midpoint it is stretched out and its adjustment allow-
between the alternator pulley and water pump ance is lost or when cut or crack is
pulley to check deflection (a). observed on it.
a Pressing force: a Whenever a V belt was replaced, test and
Approx. 98 N {Approx. 10 kg} adjust it again after operating an hour.
a Deflection (a): 13 – 16 mm a After tightening the bolt, make sure the
belt tension is normal following the proce-
dure described above.
Adjusting
a If the deflection of the belt is abnormal, adjust it 7. Restore the original state after the testing and
according to the following procedure. adjusting.
1. Remove 2 mounting bolts and then remove
belt cover (1).
a Remove the belt cover only when the belt
is replaced.
2. Loosen 2 mounting bolts (3) of alternator (2) as

well as lock bolt (4) of adjustment rod (5).
3. Loosen the lock nut of adjustment rod (5), slide

alternator (2) using adjustment nut (6) and
then adjust the belt tension.
4. While fixing adjustment screw (6), tighten the

locknut of adjustment rod (5).
5. Tighten lock bolt (4) of adjustment rod (5) and

2 mounting bolts (3) of alternator (2).
WA500-6R 33
Testing and adjusting air Adjusting

conditioner compressor belt a If the deflection of the belt is abnormal, adjust it
tension 1 according to the following procedure.
Testing
1. Loosen locknut (2), slide air conditioner com-
1. Open the engine left side cover. pressor (4) along with the bracket using adjust-
ment nut (3) and then adjust tension of air
2. Using a finger, press the belt at midpoint conditioner compressor belt (5).
between the supply pump pulley and compres-
sor pulley to check deflection (a). 2. While fixing adjustment screw (3), tighten lock-
a Pressing force: nut (2).
Approx. 59 N {Approx. 6 kg}
a Deflection (a): Approx. 10 mm 3. Tighten 4 mounting bolts (1) of the bracket.
a Check for breakage of the pulleys, wear of
the V-grooves, and contact of the V belts
and V-grooves.
a V belt must be replaced with a new one if
it is stretched out and its adjustment allow-
ance is lost or when cut or crack is
observed on it.
a Whenever a V belt was replaced, test and
adjust it again after operating an hour.
a After tightening the bolt, make sure the
belt tension is normal following the proce-
dure described above.
4. Restore the original state after the testing and

adjusting.
34 WA500-6R
Adjusting transmission speed sensor 1

1) Loosen locknut (2) of transmission input
shaft speed sensor (1).
2) Screw in transmission input shaft speed
sensor (1) until its tip lightly contacts
against the tooth tip of gear (3).
a Before installing the sensor, check
that its tip is free from steel chips and
flaws.
2 Threaded portion:
Gasket sealant (LG-5)
3) From that position, return transmission
input shaft speed sensor (1) by 1/2 – 1
turn.
q Clearance between speed sensor
and gear: 0.75 – 1.5 mm
4) Fix speed sensor (1) with locknut (2).
3 Locknut:
49.0 – 68.6 Nm {5 – 7 kgm}
WA500-6R 35
2. Transmission output shaft speed sensor

1) Loosen locknut (5) of transmission output
shaft speed sensor (4).
2) Screw in transmission output shaft speed
sensor (4) until its tip lightly contacts
against the tooth tip of gear (6).
a Before installing the sensor, check
that its tip is free from steel chips and
flaws.
2 Threaded portion:
3) From that position, return transmission
output shaft speed sensor (4) by 1/2 – 1
turn.
q Clearance between speed sensor
and gear: 0.75 – 1.5 mm
4) Fix speed sensor (4) with locknut (5).
3 Locknut:
49.0 – 68.6 Nm {5 – 7 kgm}
36 WA500-6R
Measuring directional lever

(Steering wheel specification) 1
Measuring instrument
K 79A-264-0021 Push-pull scale
k Put chocks under the tires securely.
Operating effort of directional lever

1. Stop the engine.
2. Install tool K or a spring balance to a point 10

mm from the control lever end and pull it in the
operating direction to measure the operating
effort at that time.
a Measure the operating effort at each gear
speed.
a Shape of the lever shown in figure is not
identical with that on WA500-6.
Stroke of directional lever

1. Stop the engine.
2. Make mark (a) at the center of the control lever

knob. Move the knob in the operating direction
and measure its stroke.
a Shape of the lever shown in figure is not
identical with that on WA500-6.
WA500-6R 37
Testing and adjusting power train oil pressure 1
38 WA500-6R
a Testing and adjusting instruments for power 1. Remove rear frame left side cover (12) and
train oil pressure right side cover (13).
Symbol Part Number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Oil pressure measuring point and measuring

gauge
Measuring
No. Measured oil pressure gauge
MPa {kg/cm2}
1 Main relief pressure 6 {60}
Torque converter relief (Inlet)
2 2.5 {25}
pressure
3 Torque converter outlet pressure 1 {10}
4 Lockup clutch pressure 6 {60}
5 Transmission F clutch pressure 6 {60}
6 Transmission R clutch pressure 6 {60}
7 Transmission 1st clutch pressure 6 {60}
8 Transmission 2nd clutch pressure 6 {60}
9 Transmission 3rd clutch pressure 6 {60}
10 Transmission 4th clutch pressure 6 {60}
11 Lubrication pressure 1 {10}
k Put chocks under the tires.

a Measure the power train oil pressure under the
WA500-6R 39
Measuring 4) While running the engine at low idle and

1. Measuring transmission main relief pres- high idle, measure the transmission main
sure relief pressure.
1) Remove transmission main relief pressure
pickup plug (1) (10 x 1.25 mm).
5) After finishing measurement, remove the

measuring instruments and return the
2) Connect nipple L2 and oil pressure gauge
removed parts.
[1] in hydraulic tester L1.
a Use the oil pressure gauge with
capacity 6 MPa {60 kg/cm2}.
3) Start the engine and then maintain the

tional switch or right directional switch at
the N (Neutral) position.
40 WA500-6R
2. Measuring torque converter relief pressure 4) While running the engine at high idle,
(inlet pressure) measure torque converter relief pressure
1) Remove torque converter relief pressure (inlet pressure).
(inlet pressure) pickup plug (2) (10 x 1.25
mm).
k Prepare an oil pan since oil flows
out as the pickup plug is removed.

removed parts.
a Use the oil pressure gauge of 2.5
MPa {25 kg/cm2}.

WA500-6R 41
3. Measuring torque converter outlet pressure 5) Remove the measurement tool after the
1) Remove torque converter outlet pressure measurement, and make sure that the
pickup plug (3) (10 x 1.25 mm). machine is back to normal condition.

a Use the oil pressure gauge of 1 MPa
{10 kg/cm2}.

measure torque converter outlet pressure.
42 WA500-6R
4. Measuring lockup clutch pressure (Lockup 8) Measure the lockup clutch oil pressure as
clutch specification) the lockup pilot lamp came on while travel-
k This measurement is done in the traveling is continued with the engine at high
ing condition. Reasonable care, there- idle.
f o r e , m u s t b e pa i d t o s a f e t y o f
surrounding area.
1) Remove lockup clutch pressure pickup
plug (4) (10 x 1.25 mm).

3) Turn the torque converter lockup switch

ON.
ual shift selector switch in the AUTO posi-
tion.
5) Start the engine and turn the parking
brake switch OFF.
to 2nd position.
7) Start traveling while setting the directional
lever, joystick steering directional switch
or right directional switch to the F (for-
ward) or R (reverse) position.
WA500-6R 43
5. Measuring F (forward) clutch pressure 8) Measure the F (forward) clutch oil pres-
1) Remove F (forward) clutch oil pressure sure when the engine is run at high idle.


position.
4) Press the brake pedal.
brake switch OFF.
6) Set the gear shift lever to the 4th speed
7) Run the engine at low idle and while
pressing the brake pedal, set the direc-
switch or right directional switch to the F
(forward).
securely.
44 WA500-6R
6. Measuring R (reverse) clutch pressure 8) Measure the R (reverse) clutch oil pres-
1) Remove R (reverse) clutch oil pressure sure when the engine is run at high idle.


position.
brake switch OFF.
switch or right directional switch to the R
(reverse).
securely.
WA500-6R 45
7. Measuring 1st clutch pressure 3) Set the transmission auto shift and man-
1) Remove 1st clutch oil pressure pickup ual shift selector switch in the MANUAL
plug (7) (10 x 1.25 mm). position.
brake switch OFF.
6) Set the gear shift lever to the 1st speed
while maintaining the directional lever, joy-
stick steering directional switch or right
directional switch at the N (Neutral) posi-
tion.
(forward) or R (reverse) position once and
then return it to N (Neutral) again.
securely.
a Above operation is needed because
moving the gear shift lever does not
change the gear speed if the direc-
tional lever, joystick steering switch or
right directional switch is set at the N
(neutral) position.
measure the 1st clutch oil pressure.

46 WA500-6R
8. Measuring 2nd clutch pressure 3) Set the transmission auto shift and man-
1) Remove 2nd clutch oil pressure pickup ual shift selector switch in the MANUAL
brake switch OFF.
6) Set the gear shift lever to the 2nd speed
while maintaining the directional lever, joy-
stick steering directional switch or right
directional switch at the N (Neutral) posi-
tion.
2) Connect nipple L2 and oil pressure gauge k Keep pressing the brake pedal
[1] in hydraulic tester L1. securely.

a Use the oil pressure gauge with a Above operation is needed because
capacity 6 MPa {60 kg/cm2}. moving the gear shift lever does not
(neutral) position.
measure the 2nd clutch oil pressure.

WA500-6R 47
9. Measuring 3rd clutch pressure 3) Set the transmission auto shift and man-
1) Remove 3rd clutch oil pressure pickup ual shift selector switch in the MANUAL
brake switch OFF.
6) Set the gear shift lever to the 3rd speed
securely.
a Above operation is needed because
moving the gear shift lever does not
(neutral) position.
measure the 3rd clutch oil pressure.

48 WA500-6R
10. Measuring 4th clutch pressure 3) Set the transmission auto shift and man-
1) Remove 4th clutch oil pressure pickup ual shift selector switch in the MANUAL
brake switch OFF.
2) Connect nipple L2 and oil pressure gauge securely.

[1] in hydraulic tester L1. a Above operation is needed because
a Use the oil pressure gauge with moving the gear shift lever does not
capacity 6 MPa {60 kg/cm2}. change the gear speed if the direc-
(neutral) position.
measure the 4th clutch oil pressure.

WA500-6R 49
11. Measuring lubrication pressure 5) Remove the measurement tool after the
1) Remove lubrication pressure pickup plug measurement, and make sure that the
(11) (10 x 1.25 mm). machine is back to normal condition.
Adjusting
1. Adjusting transmission main relief valve
k Stop the engine before starting adjust-
ment of the transmission main relief
valve.
a If the transmission main relief pressure is
out of the specified range, adjust it accord-
1) Remove plug (13) from transmission and
torque converter relief valve (12).
2) Install elbow [2] and nipple [3] in hydraulic

tester L1 and connect oil pressure gauge
[1] to them.
2) Remove inner spring (15) and outer spring

(14).
3) Adjust the main relief pressure by chang-
ing the number of shims (16).
a Standard shim thickness:
4.5 mm (0.5 mm x 9 pieces)
a Quantity of adjustment per shim:
3) Start the engine and then maintain the 0.039 MPa {0.39 kg/cm2}
4) Measure the lubrication pressure as the
engine is run at high idle.
2. Adjusting torque converter relief valve

a Adjustment of the torque converter relief
valve is not available.
50 WA500-6R
Flushing procedure for torque 3) Loosen hexagonal portion (a) of two trans-
converter and transmission mission oil filter cases (2) to remove the
cases.
hydraulic circuit 1 a After removing the transmission oil fil-
a Metal chips and dirt in the torque converter and ter case, clean inside of the case as
transmission hydraulic circuit shorten the lives well as removed parts other than the
of the torque converter and transmission and filter.
can cause internal breakage. Accordingly, 4) Remove 2 filter elements (4) and replace
flush the hydraulic circuit to remove the metal them with 2 flushing elements (561-15-
chips and dirt. 55670).
5) Install 2 transmission oil filter cases (2).
1. Flush the hydraulic circuit in the following 3 Hexagonal portion (a) of transmis-
cases. sion oil filter case:
1) When metal chips are circulated in the 58.8 – 78.5 Nm {6 – 8 kgm}
hydraulic circuit because of damage of the 3 Drain plug:
torque converter, transmission, or another 49 – 58.8 Nm {5 – 6 kgm}
hydraulic device.
2) When the torque converter or transmis-
sion is overhauled or repaired.
2. Install the element for flushing.

1) Remove cover (1) on the transmission oil
filter installation position situated on the
left side of the machine.
2) Remove drain plugs (3) on 2 transmission

oil filter cases (2) to drain oil.
a Before draining oil, prepare an oil
pan.
WA500-6R 51
3. Fill the transmission case with oil. 4. Flush the hydraulic circuit according to the fol-
Add oil through oil filler (5) to the specified lowing procedure.
level. Run the engine to circulate the oil 1) Start the engine and run it at low idle with-
through the system. Then, check the oil level out operating the gear shift lever or direc-
again. tional lever for about 20 minutes.
a Increase the engine speed to about
5 Transmission case:
1,500 rpm sometimes.
76 l (Refill capacity)
a If the engine coolant temperature
gauge does not rise to the operating
range because of low atmospheric
temperature, continue the warm-up
operation further.
2) Operate or drive the machine for at least
20 minutes.
a Use all the gear speeds (Forward,
reverse, and 1st – 4th).
3) Run the engine at low idle for about 20
minute, similarly to 4-1).
5. Replace the filter element.

1) Replace element (4) used for flushing with
new element (424-16-11140) following the
same procedure as 2.
k Using the element used for flush-
ing for long hours causes prema-
ture clogging. Accordingly, be sure
to replace it with new one.
a Replace the current O-ring with a new
one, coat it with a small amount of oil
and then install it.
2) Add oil and check the oil level again.
52 WA500-6R
6. Replace the transmission last chance filter. 2) Loosen hexagonal portion (b) of the trans-
1) Remove cover (6) on the left side of the mission last chance filter case (7) to
rear frame. remove the cases.
a After removing the transmission oil fil-
ter case, clean inside of the case as
well as removed parts other than the
filter.
3) Remove filter element (8) and replace it
with a new element (561-15-55670).
4) Install transmission last chance filter case
(7).
a Replace the current O-ring with a new
one, coat it with a small amount of oil
and then install it.
3 Hexagonal portion (b) of transmis-
sion oil filter case:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
WA500-6R 53
Method of moving machine when transmission valve is broken 1

a Position of ECMV devices and connector numbers
a Device for moving machine when transmission k When working while the oil temperature is
valve is broken still high, take care not to burn your body.
1. Remove cover (1) on the left side of the rear
M 794-423-1190 Plug frame.
a Remove mud and dirt from around the
a Even the machine became not movable ECMV.
because of a failure on the transmission valve
portions (electrical system, solenoid valve,
spool, etc.), install plug M to enable moving the
machine.
k Installing plug M to the ECMV is the means
for moving the machine from a dangerous
job site to a safe place for repair. This
approach should be resorted only when the
machine is not movable at any gear speed
because of a failure on the transmission
control valve and should not be employed
for any other purpose.
k When moving the machine by this method,
observe the procedure and take care of
safety.
k Lower the work equipment to the ground
fully, apply the parking brake, and put
chocks under the tires so that the machine
will not move.
k When applying this means, stop the engine.
54 WA500-6R
2. Disconnect the connector of the 2nd ECMV 4. Press the brake pedal securely.
and the connector of the F or R ECMV.
q F ECMV (Forward) connector: 5. Start the engine and release the parking brake
F.SW and F.PS gradually to start and move the machine.
q R ECMV (Reverse) connector: a If the parking brake cannot be released
R.SW and R.PS because of a trouble in the electrical sys-
q 2nd ECMV (2nd speed) connector: tem, see “Method of releasing parking
2.SW and 2.PS brake manually“.
a Select either F ECMV or R ECMV k Remove the chocks.
depending on the machine moving direc- k If the engine is started, the transmis-
tion (Forward or Reverse) sion is engaged and the machine starts
immediately. Accordingly, when start-
3. Remove 2 solenoids (2) on the 2nd ECMV and ing the engine, check the moving direc-
the F or R ECMV and install plug M. tion of the machine and secure safety
q For forward travel: around the machine thoroughly and
F solenoid and 2nd solenoid keep pressing the brake pedal.
q For reverse travel: k After moving the machine, stop the
R solenoid and 2nd solenoid engine, apply the parking brake, and
a If a wrong solenoid is removed, the trans- put chocks under the tires.
mission may be broken. Take care.
a Install each plug with its projection side 6. After moving the machine, remove the devices
toward the ECMV. And make sure that the and return the removed parts.
O-ring is fitted to the mating face.
a Take care that mud or dirt will not enter the
removed solenoids and valves.
WA500-6R 55
SEN02927-04

© 2019 KOMATSU
All Rights Reserved
56
SEN02928-04
WA500-6R

WA500-6R 60001 and up

Testing and adjusting steering stop valve ....................................................................................................... 3
Testing and adjusting steering wheel .............................................................................................................. 5
Testing steering oil pressure ........................................................................................................................... 7
Bleeding air from steering cylinder circuit ..................................................................................................... 10
Testing hydraulic drive fan .............................................................................................................................11
Bleeding air from hydraulic drive fan circuit .................................................................................................. 14
Measuring brake pedal ................................................................................................................................. 16
Measuring brake performance ...................................................................................................................... 17
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas.... 18
Testing and adjusting accumulator charge pressure..................................................................................... 25
Testing wheel brake oil pressure................................................................................................................... 27
Measuring wear of wheel brake disc............................................................................................................. 29
Bleeding air from brake circuit ...................................................................................................................... 30
Releasing residual pressure in brake accumulator circuit............................................................................. 32
Testing parking brake performance............................................................................................................... 33
Measuring parking brake oil pressure ........................................................................................................... 34
WA500-6R 1
Testing wear of parking brake disc................................................................................................................ 37

Method of releasing parking brake manually ................................................................................................ 38
Measuring and adjusting work equipment control lever ................................................................................ 39
Testing and adjusting work equipment PPC oil pressure .............................................................................. 40
Measuring work equipment oil pressure ....................................................................................................... 42
Bleeding air from work equipment circuit ...................................................................................................... 48
Releasing residual pressure in work equipment circuit ................................................................................. 49
Method of moving machine when removing operator cab (when splittable cab is used) .............................. 50
Testing and adjusting bucket positioner ........................................................................................................ 51
Testing and adjusting lift arm position detecting lever................................................................................... 53
Checking proximity switch operation indication lamp.................................................................................... 54
Procedure for testing diodes ......................................................................................................................... 55
Preparations for work on troubleshooting of electrical system ...................................................................... 56
2 WA500-6R
Testing and adjusting steering

stop valve 1
Testing
1. Straighten the front frame and rear frame.
2. Make sure locknut (2) of stopper bolt (1) is not

loosened.
3. Start the engine and turn the steering wheel to

the right and left. Make sure that a clearance is
maintained between the front frame stopper
and rear frame stopper when above operation
is executed.
k Stop the engine before measuring the
clearance.
a If the checkup is not available because of
missing frame stopper and the like, do
necessary repair and then make sure
clearance is provided on both sides.
a Measure clearance (a) between front
frame (4) and rear frame (5) on both sides
as the turning was stopped due to the con-
tact of steering stop valve (3) and stopper
bolt (1).
q Standard clearance (a): 36 ± 5 mm
WA500-6R 3
Adjusting
a When clearance (a) between front frame (4)
and rear frame (5) is out of the specified range,
adjust it in the following procedure.
1. Loosen locknut (2) and then tighten stopper
bolt (1) to set distance (b) to the minimum.
6. Start the engine, turn the machine and then

measure clearance (a) between front frame (4)
and rear frame (5) as the turning is stopped
due to the contact of steering stop valve (3)
and stopper bolt (1). Make sure clearance (a)
is compliant with the standard dimension on
2. Run the engine at low idle and then bring front both sides.
frame (4) and rear frame (5) into contact each
other by turning the steering wheel slowly.
k Take care in this operation so that your
body or arm may not be caught
between the front and rear frames.
3. Stop the engine and then loosen stop bolt (1)

until it touches the contact surface of steering
stop valve (3).
a Take care not to loosen the stopper bolt
excessively. Excessive loosening can
result in pushing spool (6) at the tip of
steering stop valve (3).
4. Start the engine and return the steering wheel

slowly at low idle to set the machine the
straight travel condition. Then stop the engine.
5. Rotate stopper bolt (1) 8.5 turns in the loosen-

ing direction and then fix it with locknut (2).
a Adjust both the right and left side accord-
ing to above 1 – 5 methods.
4 WA500-6R
Testing and adjusting steering 3. Turn the steering wheel to the left and make
wheel 1 mark (C) at a position where the operating
effort becomes heavy. Then, measure the
a Testing and adjusting device for steering wheel
straight distance between marks (B) and (C).
Sym-
Part No. Part name
bol
N 79A-264-0021 Push-pull scale
Measuring play of steering wheel

a Measure the play of the steering wheel under
the following condition.
q Engine: Stopped
q Position of machine:
Straight travel condition
Measuring method
1. Move the steering wheel to the right and left 2
– 3 times and check that the steering mecha-
nism is in neutral, and then make mark (A) on
the machine monitor frame.
2. Turn the steering wheel to the right and make

mark (B) at a position where the operating
effort becomes heavy.
WA500-6R 5
Measuring operating effort of steering wheel Measuring operating time of steering wheel
a Measure the operating effort of the steering a Measure the operating time of the steering
wheel under the following condition. wheel under the following condition.
q Road surface: Flat, level, paved and dried q Road surface: Flat, level, paved and dried
q Engine coolant temperature: q Engine coolant temperature:
Within operating range Within operating range
q Hydraulic oil temperature: q Hydraulic oil temperature:
Within operating range Within operating range
q Tire inflation pressure: q Tire inflation pressure:
Specified pressure Specified pressure
q Engine speed: Low idle (Bucket empty) q Engine speed: Low idle and high idle
Measuring method Measuring method

1. Install push-pull scale N on the steering wheel 1. Start the engine.
knob. a After starting the engine, raise the bucket
a Be sure to install push-pull scale N at the about 400 mm and release the frame lock
center. bar.
2. Start the engine. 2. Turn the steering wheel to the right or left
a After starting the engine, raise the bucket stroke end.
about 400 mm and release the frame lock
bar. 3. Turn the steering wheel to the right or left
stroke end and measure the full-stroke time.
3. Pull push-pull scale N in the tangential direc- a Do not turn the steering wheel forcibly but
tion and read the value while the steering turn it at the speed of 60 revolutions per
wheel is moving smoothly. minute.
a The operating effort is not the value indi- a Measurement should be taken at low idle
cated when the steering wheel starts mov- and high idle turning the machine both in
ing. the right and left direction.
a The shape in the figure is not identical with a The shape in the figure is not identical with
that on WA500-6. that on WA500-6.
6 WA500-6R
Testing steering oil pressure 1 1. Steering relief pressure

a Measuring instruments for steering oil pressure 1) Remove steering circuit pressure pickup
plug (2) (10 x 1.25 mm) on the right steer-
Symbol Part Number Part name ing cylinder head side.
1
799-101-5220 Nipple (10 x 1.25 mm)
Q 2
07002-11023 O-ring
3 799-401-3200 Adapter (Size 03)
4 799-401-2701 Differential pressure gauge
a Measure the steering oil pressure under the

2) Connect nipple Q2 and oil pressure gauge
Measuring
k Loosen the oil filler cap of the hydraulic
[1] in hydraulic tester Q1.
tank to release the internal pressure of the {400 kg/cm2}.
hydraulic tank, then operate the steering
wheel 2 – 3 times to release the residual
pressure from the piping.
k Apply frame lock bar (1).
WA500-6R 7
3) Run the engine at high idle and turn the 2. Steering pilot circuit pressure
steering wheel to the right. When the 1) Remove side covers (3) and (4) of the
steering relief valve operates, measure steering valve situated in the left side of
the oil pressure. the machine.
a When the gauge was connected to
the steering circuit pressure pickup
plug on the left side steering cylinder
head, measure the pressure by turn-
ing the steering wheel counterclock-
wise.
2) Remove steering pilot circuit pressure

hose (6) or (7) of steering valve assembly
(5).

removed parts.
3) Connect adapter Q3 and steering pilot cir-

cuit pressure hose (6) or (7).
4) Connect nipple [2] and oil pressure gauge
8 WA500-6R
5) While running the engine at high idle, 2) Remove steering LS circuit pressure hose
measure the oil pressure as the steering (11) of steering valve assembly (5).
wheel is turned.
q When measuring at hose (6): Turn
the steering wheel clockwise (or turn
the joystick steering lever rightward)
q When measuring at hose (7): Turn
the steering wheel counterclockwise
(or turn the joystick steering lever left-
ward)
3) Connect adapter Q3 and steering LS cir-

cuit pressure hose (11).

removed parts.
3. Steering LS circuit pressure

1) Remove side covers (3) and (4) of the
steering valve situated in the left side of
the machine.
5) While running the engine at low idle, mea-

sure the oil pressure as the steering wheel
is stopped.

removed parts.
WA500-6R 9
Adjusting Bleeding air from steering

k When adjusting the oil pressure, be sure to cylinder circuit 1
stop the engine.
1. Steering relief pressure a Before starting the operation, make sure the
1) If the steering relief pressure is abnormal, specified level of hydraulic oil is provided.
adjust steering relief valve (8) of steering a If the steering valve or the steering cylinder
valve assembly (5) in the following proce- was removed and installed, bleed air from the
dure. steering circuit according to the following pro-
cedure.
1. Run the engine at idle for about 5 minutes.
2. While running the engine at low idle, steer the

machine to the right and left 4 – 5 times.
a Stop the piston rod about 100 mm before
each stroke end and take care not to
relieve the circuit.
3. While running the engine at high idle, perform

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

piston rod to the stroke end and relieve the cir-
2) Loosen locknut (9) and turn adjustment cuit.
screw (10) to adjust the pressure.
a Adjustment screw:
q turned to the right, the pressure
rises.
q turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment screw:
Per turn: 17.9 MPa {182.5 kg/cm2}
3 Locknut:
27 – 31 Nm {2.8 – 3.2 kgm}
10 WA500-6R
Testing hydraulic drive fan 1 Tachometer kit R1

a Testing tools for hydraulic drive fan
1 799-205-1100 Tachometer kit
2
R
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
4 799-401-3500 Adapter (Size 06)
k Set the bucket bottom horizontally and

lower it to the ground, and then put chocks
under the tires.
k When removing the oil pressure pickup
2) While running the engine at high idle and
plug and disconnecting the hose, loosen
low idle, measure the fan speed.
the oil filler cap of the hydraulic tank to
release the internal pressure of the tank.
removed parts.
a Measurement condition
q Engine coolant temperature: Min. 95°C
q Hydraulic oil temperature: Min. 95°C
Min. 105°C
1. Measuring fan speed

1) Set probe [2] to stand [1] of tachometer kit
R1 and stick reflection tape [3] to the fan.
WA500-6R 11
2. Measuring fan drive oil pressure 6) While running the engine at high idle,
1) Open radiator grille (1). measure the fan drive oil pressure.
2) Remove fan net (2) at the center.

3) Disconnect P port hose (4) of fan motor measuring instruments and return the
(3). removed parts.
4) Connect adapter R4 and hose (4).

5) Connect nipple R3 (10 x 1.25 mm) and oil
pressure gauge [1] in hydraulic tester R2.
{400 kg/cm2}.
12 WA500-6R
3. Measuring fan reverse solenoid output 5) Turn the cooling fan reverse switch ON.
pressure 6) While running the engine at high idle,
1) Open radiator grille (1). measure the fan reverse solenoid drive oil
2) Remove fan net (2) at the center. pressure.
a Measure the fan forward and reverse
drive oil pressures. When the fan is
reversed, check that the solenoid
operates and the specified oil pres-
sure is applied.
3) Remove fan reverse solenoid output pres-

sure pickup plug (10 x 1.25 mm) (5) from
fan motor (3).

removed parts.
3 Fan reverse solenoid output pres-
sure pickup plug:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
4) Connect nipple R3 (10 x 1.25 mm) and oil

pressure gauge [1] in hydraulic tester R2.
{400 kg/cm2}.
WA500-6R 13
Bleeding air from hydraulic drive 3) As oil free from air started to flow out of air
fan circuit 1 bleeder (3), tighten air bleeder (3).
3 Air bleeder:
a Testing tools for bleeding air from hydraulic
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
drive fan circuit
4) Start the engine and run it at low idle for 5
minutes minimum.
799-101-5002 Hydraulic tester 2. Bleeding air from fan motor circuit
1 1) Open radiator grille (4).
2) Remove fan net (5) at the center.
799-101-5220 Nipple (10 x 1.25 mm)
S 2
07002-11023 O-ring
3 799-401-3500 Adapter (Size 06)
4 790-261-1130 Coupling
a Before starting the operation, make sure the

specified level of hydraulic oil is provided.
1. Bleeding air from fan pump

1) Remove pump side cover (1) on the right
side of the machine.
3) Disconnect P port hose (7) of fan motor

(6).
2) Stop the engine and then loosen air

bleeder (3) of fan pump (2) to connect air
bleeding hose [1].
14 WA500-6R
4) Connect adapter S3 and hose (7).

5) Connect nipple S2 (10 x 1.25 mm) and
hose [1] in hydraulic tester S1 and also
connect air bleeder coupling S4 to the out-
let end of hose.
a Put the outlet end of the hose in an oil
receiver.
6) Run the engine. When the oil flows out of

the outlet end of the hose, stop the
engine.
7) After finishing bleeding air, remove the
tools and return the removed parts.
WA500-6R 15
Measuring brake pedal 1

q Engine speed: Low idle
Measuring pressing angle of pedal

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

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

measure pressing angle (a2) from pressing
angle (a1) to pressing angle (a3) (a2 = a1 –
a3).
q (a2): Pressing angle at pressing effort of
321 ± 32.1 N {32.8 ± 3.3 kg}
16 WA500-6R
Measuring brake performance 1
a Measure the brake performance under the fol- Measuring method

lowing condition.
1. Start the engine and drive the machine.
q Road : Flat, level, paved,
and dried.
q Braking initial speed : 20 km/h
4th position for run up.
q Tire inflation pressure: Specified pressure
q Tire size : 29.5-25-22PR
3. When the travel speed becomes the braking
q Brake pedal pressing force:
initial speed of 20 km/h, press the left brake
Specified pressing force
pedal with the specified force.
294 ± 29.4 N {30 ± 3 kg}
a Decide the approach course and braking
q Pressing time lag : 0.1 second
point in advance and apply the brake at
that braking point.
4. Measure the distance from the braking point to

the stop point.
a Perform the above measurement 3 times
and obtain the average.
WA500-6R 17
Testing of accumulator nitrogen Method for testing accumulator nitrogen gas

gas pressure and procedure for pressure
charging accumulator with nitro- A single accumulator can also be tested.
Shape of accumulators for front brake, rear brake,
gen gas 1 and parking brake are the same.
a Testing instrument 1. Stop the engine, depress the brake pedal
repeatedly until the reaction force is not
detected to completely release the oil pressure
- 792-610-1703 Gas charging tool from the brake circuit.
A 1 792-610-2310 Extension a As a guide, by depressing the brake pedal
2 792-610-1260 Nipple (for Japan) approximately 30 times, the reaction force
B 792-610-1270 Hose
of the brake pedal is not detected and the
oil pressure is released.
C 792-610-2410 Bushing
D 792-610-1400 Regulator 2. Remove the plug (2) and cap (3) from accumu-
792-610-1310 Nipple (for Russia) lator (1).
792-610-1320 Nipple (for USA)
3. Connect the gas charging tool A to gas valve
E 792-610-1330 Nipple (for USA)
(4) of accumulator (1) according to the follow-
792-610-1350 Nipple (for Germany) ing procedure.
792-610-1360 Nipple (for UK)
Commercially
F Nitrogen gas cylinder
available
k Put on the appropriate protective equip-

ment (goggles, leather gloves, protective
clothes) so that the leaked nitrogen gas
does not come in contact with your skin or
clothes. Perform the work on the windward
side as much as possible.
k When using the nitrogen gas indoors or on
an ill-ventilated location, ventilate the
room, etc. and observe the Industrial Safety
and Health Law, Ordinance on Prevention
of Anoxia, etc. 1) Install the extension A1 which is attached
k The accumulator is charged with high-pres- to the gas charging tool A to the gas valve
sure nitrogen gas, and incorrect operation (4).
may cause an explosion which will lead to
serious injury or death. When handling,
always observe the following.
q Do not bring open flame close to it or do
not dispose of it in fire.
q Do not perform drilling, welding or flame-
cutting.
q Do not hit or roll it, or subject it to any
impact.
q When disposing of the accumulator, use
the gas charging tool A outdoors to dis-
charge the nitrogen gas in the accumulator.
q Before disassembly and removal, be sure
to lower the charged gas pressure to the
ambient pressure.
q Be sure to use the nitrogen gas for charging.
q Do not charge explosive gas such as oxy-
gen.
q Follow this procedure always when han-
dling accumulator.
18 WA500-6R
2) Turn the handle (a) of the gas charging Table 1: Accumulator charging gas pres-
tool A fully to the let (Between accumula- sure chartt
tor (1) and gas charging tool A: Close). Ambient Charging nitrogen gas
Turn the handle (b) fully to the right to temperature front rear front rear
°C Remarks
close. MPa kg/cm2
a The gas does not leak from the hose 15 10.52 6.09 107.14 61.92
connection to the atmosphere, since 16 10.55 6.12 107.51 62.14
the valve (5) on the hose connection 17 10.59 6.14 107.88 62.35
side of the gas charging tool A is a 18 10.63 6.16 108.26 62.57
19 10.66 6.18 108.63 62.78
check valve (one way).
Standard gas
a The valve is closed by turning the 20 10.70 6.20 109.00 63.00
pressure
handle (a) counterclockwise. The 21 10.74 6.22 109.37 63.22
valve is open by turning the handle 22 10.77 6.24 109.74 63.43
(a) clockwise (Between charge valve 23 10.81 6.26 110.12 63.65
and accumulator: Open). 24 10.85 6.28 110.49 63.86
a The handle (a) is a screw-in type to 25 10.88 6.31 110.86 64.08
open the valve. 26 10.92 6.33 111.23 64.29
a The valve is open (open to the atmo- 27 10.96 6.35 111.60 64.51
28 10.99 6.37 111.98 64.72
sphere) by turning the handle (b) to
29 11.03 6.39 112.35 64.94
the let (counterclockwise). The valve
30 11.07 6.41 112.72 65.15
is closed (close to the atmosphere) by 31 11.10 6.43 113.09 65.37
turning the handle (b) to the right 32 11.14 6.45 113.46 65.58
(clockwise). 33 11.17 6.48 113.84 65.80
a The handle (b) is a screw-in type to 34 11.21 6.50 114.21 66.01
close the valve. 35 11.25 6.52 114.58 66.23
36 11.28 6.54 114.95 66.44
37 11.32 6.56 115.32 66.66
38 11.36 6.58 115.70 66.87
39 11.39 6.60 116.07 67.09
40 11.43 6.62 116.44 67.30
41 11.47 6.64 116.81 67.52
42 11.50 6.67 117.18 67.73
43 11.54 6.69 117.56 67.95
44 11.58 6.71 117.93 68.16
45 11.61 6.73 118.30 68.38
a Adjust the gas pressure by proceed-

ing to the step 5 if the gas pressure is
too high when comparing the gas
3) Connect the gas charging tool A to the pressure shown by the gauge and the
extension A1. specified gas pressure shown in
4) Put the cover to the valve (5) so that no Table 1.
rain, snow, sand, or dust enters. a Proceed to the step 6, and adjust the
gas pressure by referring to “Method
4. Slowly turn handle (a) of gas charging tool A for charging nitrogen gas pressure in
clockwise and read the value of the gauge. brake accumulator” if the gas pres-
a Do not turn the handle (a) more than 1.5 sure is too low when comparing the
turns after the charge gas pressure is dis- gas pressure shown by the gauge
played. Gas valve (4) may break by doing and the specified gas pressure shown
so. in Table 1.
a Check that gas is not leaked. a If the gas pressure is correct, proceed
1) The indication varies with the ambient to the step 7.
temperature at the measurement time.
See the table below when measuring.
a Specified gas pressure = Standard
gas pressure x ((273 + t)/(273 + 20))
q All values in the formula are °C.
q t: Gas temperature at testing (may be
regarded as ambient temperature)
WA500-6R 19
5. When reducing the nitrogen gas pressure in 9. Apply soapy water to gas valve (4) of the accu-
the accumulator after testing the nitrogen gas mulator, and check that the nitrogen gas is not
pressure in the accumulator leaked.
a Initial state: The handle (a) is open.
1) Turn the handle (b) to the left slowly to dis- 10. Install the cap (3) and plug (2) to accumulator
charge the nitrogen gas gradually from the (1).
thread part of the handle (b) until the 3 Plug (2):
gauge of the gas charging tool A indicates 73.5 to 98.0 Nm {7.5 to 10.0 kgm}
that the pressure is the specified pressure
shown in the Table 1, and close the valve
by turning the handle (b) clockwise to
adjust the nitrogen gas pressure in the
accumulator (1).
2) Perform the adjustment according to the
procedure in Step 7 or after.
6. When charging the nitrogen gas pressure in

the accumulator after testing the nitrogen gas
pressure in the accumulator
1) Turn the handle (a) to the left until it stops,
and close the valve.
2) Turn the handle (b) counterclockwise
gradually, and discharge the nitrogen gas Method for charging nitrogen gas in brake
remaining in gas charging tool A, and let it accumulator
open state. (Between handle (b) and A single accumulator can also be charged.
atmosphere: Open for bleeding air from
1. Stop the engine, depress the brake pedal
the hose)
repeatedly until the reaction force is not
3) Proceed to step 3. 5. of “Method for charg-
detected to completely release the oil pressure
ing nitrogen gas pressure in brake accu-
from the brake circuit.
mulator” and after, charge the nitrogen
a As a guide, by depressing the brake pedal
gas in the accumulator to adjust the gas
approximately 30 times, the reaction force
pressure.
of the brake pedal is not detected and the
oil pressure is released.
7. Turn the handle (a) to the left until it stops, and
close the valve.
2. Remove the plug (2) and cap (3) from accumu-
lator (1).
8. Remove the gas charging tool A from accumu-
lator (1) according to the following procedure,
and restore the machine.
1) Turn the handle (b) counterclockwise to
open the valve, and discharge the nitro-
gen gas remaining in gas charging tool A
from the thread part of the handle (b).
2) Remove the gas charging tool A.
3) Remove the extension A1.
20 WA500-6R
3. Connect the gas charging tool A and nitrogen 6) Turn the handle (c) of the regulator D fully
gas cylinder C to gas valve (4) of accumulator counterclockwise until it stops. Connect
(1) according to the following procedure. the regulator D to the nitrogen gas cylin-
1) Turn the handle (a) of gas charging tool A der F.
counterclockwise until it stops. (Between
accumulator (1) and gas charging tool A:
Close)
a The valve is closed by turning the
handle (a) counterclockwise. The
valve is open by turning the handle
(a) clockwise (Between charge valve
and accumulator: Open).
a The handle (a) is a screw-in type to
open the valve.
2) Turn the handle (b) counterclockwise for
opening. (Between handle (b) and atmo-
sphere: Open for bleeding air from the
hose)
a The valve is open (open to the atmo- a Connect the regulator D by using
sphere) by turning the handle (b) to another nipple E depending on the
the let (counterclockwise). The valve specification of the nitrogen gas cylin-
is closed (close to the atmosphere) by der.
turning the handle (b) to the right a The regulator is closed (stops dis-
(clockwise). charging the gas) by turning the han-
a The handle (b) is a screw-in type to dle (c) counterclockwise. The regulator
close the valve. is open (discharging the gas) by turn-
ing the handle (c) clockwise.
a The handle (c) is a screw-in type to
open the regulator.
7) Connect the hose B to the bushing C and
the regulator D.
4. Bleed air from the hose according to the follow-

ing procedure.
1) Open the valve (d) of the nitrogen gas cyl-
inder F until the pressure on the cylinder
side of the regulator D is approximately 7
MPa {70 kg/cm2} .
2) Set the pressure on the hose side of the
regulator D approximately 0.19 to 0.29
MPa {2 to 3 kg/cm2} by slightly turning the
handle (c) clockwise. When the nitrogen
gas starts discharged from the thread part
of the handle (b), close the valve by turn-
ing the handle (b) clockwise.
3) Turn the handle (c) counterclockwise to
close the valve of the regulator.
3) Install the extension A1 attached to gas

charging tool A to gas valve (4) of accu-
mulator (1).
4) Connect the gas charging tool A to the the
extension A1.
5) Connect the bushing C to the gas charg-
ing tool A.
WA500-6R 21
Table 1: Accumulator charging gas pres-

sure chart
Ambient Charging nitrogen gas
temperature front rear front rear
°C Remarks
MPa kg/cm2
15 10.52 6.09 107.14 61.92
16 10.55 6.12 107.51 62.14
17 10.59 6.14 107.88 62.35
18 10.63 6.16 108.26 62.57
19 10.66 6.18 108.63 62.78
Standard gas
20 10.70 6.20 109.00 63.00
pressure
21 10.74 6.22 109.37 63.22
22 10.77 6.24 109.74 63.43
23 10.81 6.26 110.12 63.65
24 10.85 6.28 110.49 63.86
25 10.88 6.31 110.86 64.08
26 10.92 6.33 111.23 64.29
27 10.96 6.35 111.60 64.51
28 10.99 6.37 111.98 64.72
29 11.03 6.39 112.35 64.94
30 11.07 6.41 112.72 65.15
31 11.10 6.43 113.09 65.37
32 11.14 6.45 113.46 65.58
33 11.17 6.48 113.84 65.80
34 11.21 6.50 114.21 66.01
5. Charge the nitrogen gas to the accumulator 35 11.25 6.52 114.58 66.23
according to the following procedure. 36 11.28 6.54 114.95 66.44
a The valve (d) is kept open from the step 37 11.32 6.56 115.32 66.66
4.1). 38 11.36 6.58 115.70 66.87
39 11.39 6.60 116.07 67.09
1) Turn the handle (a) clockwise slowly, and
40 11.43 6.62 116.44 67.30
stop turning it in a light response.
41 11.47 6.64 116.81 67.52
a Do not turn handle (a) excessively, 42 11.50 6.67 117.18 67.73
otherwise it damages the accumula- 43 11.54 6.69 117.56 67.95
tor valve core and gas may leak. 44 11.58 6.71 117.93 68.16
Operate handle (a) carefully. 45 11.61 6.73 118.30 68.38
2) Turn the handle (a) clockwise slowly to
open the valve of the regulator D gradually,
and charge the nitrogen gas to the accu-
mulator until the pressure gauge is the
specified pressure shown in the Table 1.
a Turn the handle (c) sometimes during
the work to close the valve of the reg-
ulator D so that the pressure is stable.
Check the nitrogen gas pressure of
the accumulator (1) by using the
gauge of the gas charging tool A.
3) The gas pressure varies with the tempera-
ture at the measurement. See the Table 1
shown below and check the gas pressure.
a Specified gas pressure = Standard
gas pressure x ((273 + t)/(273 + 20))
q All values in the formula are °C.
q t: Gas temperature at charging (may
be regarded as ambient temperature)
22 WA500-6R
6. When the gauge of the gas charging tool indi- 8. Apply soapy water to gas valve (4) of the accu-
cates that the pressure exceeds the specified mulator, and check that the nitrogen gas is not
gas pressure shown in Table 1. leaked.
1) Turn the handle (a) counterclockwise to
close the valve of the regulator D.
2) Turn the handle (b) counterclockwise
slowly to discharge the nitrogen gas grad-
ually from the thread part of the handle (b)
until the gauge of the gas charging tool A
indicates that the pressure is the specified
pressure shown in the Table 1, and close
the valve by turning the handle (b) clock-
wise to adjust the nitrogen gas in the
accumulator (1).
9. Install the cap (3) and plug (2) to accumulator

(1).
3 Plug (2):
73.5 to 98.0 Nm {7.5 to 10.0 kgm}
10. Within 1 week of charging with the nitrogen

gas, perform the brake operation test to check
that the nitrogen gas pressure is not lowered.
7. When the accumulator is charged with the

Check brake operation confirmation
nitrogen gas to the pressure as the Table
shows, remove the tools according to the fol- After 5 minutes or longer of engine stop, the oil
lowing procedure. pressure of the brake circuit is lowered and the cor-
1) Turn the handle (a) and (c) counterclock- rect test cannot be performed. Perform the brake
wise to close the valve of the accumulator operation test within 5 minutes after the engine
and the regulator D. stops.
2) Close the valve (d) of nitrogen gas cylin- 1. Place the machine on a level ground, and set
der F. the parking brake switch to parking (P) posi-
3) Turn the handle (b) counterclockwise to tion.
open the valve, discharge the nitrogen gas
remaining in the gas charging tool A and 2. Start the engine, run it at medium speed for a
the hose B from the thread part of the minute, and stop the engine.
handle (b).
4) Remove the hose B, regulator D, bushing
C, and nipple E.
5) Remove the gas charging tool A from the
extension A1.
6) Remove the extension A1 from the gas
valve (4) of the accumulator (1).
WA500-6R 23
3. Turn the starting switch to ON position. 4. When the nitrogen gas is no longer dis-
Depress the brake pedal several times, and charged, left the handle (a) as it is, and remove
co unt the nu mbe r of tim es the bra ke is the gas charging tool A from the accumulator
depressed when the brake oil pressure caution (1).
lamp lights up.
q When the brake is depressed less than 5 5. Remove the extension A1.
times: The accumulator nitrogen gas pres-
sure may be low 6. Dispose of the accumulator.
q When the brake is depressed more than 5 a Dispose of the accumulator (1) while the
times: The accumulator nitrogen gas pres- gas valve (4) is left opened at the step 4.
sure is normal
Method for discharging the nitrogen gas when

disposing of the accumulator
a The discharging of the nitrogen gas is neces-
sary when accumulator body is disposed of.
1. Connect the gas charging tool A1 to the exten-
sion A1 by referring to steps 1 to 3 of “Testing
accumulator nitrogen gas pressure”.
2. Turn the handle (a) clockwise slowly, and stop

turning it in a light response.
a Do not turn handle (a) excessively, other-
wise it damages the accumulator valve
core and gas may leak. Operate handle
(a) carefully.
3. Turn the handle (b) counterclockwise slowly.

When the nitrogen gas starts discharged from
the thread part of the handle (b), let it as it is,
and discharge it gradually into atmosphere.
24 WA500-6R
Testing and adjusting 3. Measure the accumulator charge cut-in pres-

accumulator charge pressure 1 sure.
Run the engine at low idle and then measure
a Testing and adjusting instruments for accumu-
the oil pressure at which the brake oil pressure
lator charge pressure
caution lamp of the machine monitor is turned
Symbol Part Number Part name off.
799-101-5002 Hydraulic tester a Cut-in pressure: 5.9 (+0.5/0) MPa
T {60 (+5/0) kg/cm2}
4. Measure the accumulator charge cut-out pres-
a Measure the accumulator charge pressure
sure.
under the following condition.
After the accumulator charge cut-in operation,
the rising oil pressure gauge lowers suddenly.
Measure the oil pressure at this time.
a Cut-out pressure: 9.8 (+0.98/0) MPa
k
{100 (+10/0) kg/cm2}
Put chocks under the tires securely.
k While the engine is stopped, press the
brake pedal at least 100 times to release the
pressure from the accumulator circuit.
Measuring
1. Remove front cover (1) of the accumulator
installation position situated on the right side of
the machine.

Adjusting
a If the accumulator charge cut-out pressure is
adjusted, the cut-in pressure changes accord-
ing to the valve area ratio.
2. Connect oil pressure gauge [1] of hydraulic
1. Remove cover (3) in the accumulator installa-
tester T to accumulator charge pressure mea- tion position.
suring nipple (2).
{400 kg/cm2}.
WA500-6R 25
2. Loosen locknut (5) of accumulator charge a Adjustment screw:

valve (4) and turn adjustment screw (6) to q turned to the right, the pressure rises.
adjust the pressure. q turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjust-
ment screw: 5.59 MPa {57 kg/cm2}
3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
a After finishing measurement, check the
accumulator charge cut-in and cut-out
pressures again according to the above
measurement procedure.
26 WA500-6R
Testing wheel brake oil pressure 1 2) Remove bleeder screw (2).

a Measuring tools for wheel brake oil pressure
1 793-520-1821 Nipple
2 793-520-1810 Joint
U
3 385-10178481 Bleeder screw
4 793-520-1831 Gauge assembly
k Even when the brake pedal is not usable

due to troubles on brake-related equip-
ment, highly pressurized oil in the accumu-
lator can burst out. Thus, it is required to
release pressure in the accumulator circuit
by pressing the brake pedal 100 times mini-
mum while maintaining the engine at 3) Install nipple U1, joint U2, bleeder screw
stopped state. U3 and gauge assembly U4.
k Apply the parking brake and put chocks 4) Connect hose [1] to bleeder screw U3 and
under the tires securely. then bleed air from the wheel brake circuit
a Measure the oil pressure of the front brakes referring to "Bleeding air from wheel brake
(right and left) and rear brakes (right and left) circuit".
similarly. 5) Start the engine and measure the wheel
a Measure the wheel brake oil pressure under brake oil pressure as the left brake pedal
the following condition. is pressed.
Measuring
1. Wheel brake oil pressure
1) Remove cover (1).
WA500-6R 27
2. Drop in wheel brake oil pressure 5) Start the engine and accumulate pressure
1) Remove cover (1). in the accumulator.
6) Stop the engine and press the left brake to
set the oil pressure to 6 MPa {60 kg/cm2}.
Maintain this state for 5 minutes and then
measure the pressure drop.
a Use care so that the brake pedal may
not be moved for 5 minutes.
a Remove the measuring instruments
after the measurement and return the
currently removed parts to their origi-
nal position. Then bleed air from the
wheel brake circuit. For details, see
"Bleeding air from wheel brake cir-
cuit".
2) Remove bleeder screw (2).
3) Install nipple U1, joint U2, bleeder screw

U3 and gauge assembly U4.
4) Connect hose [1] to bleeder screw U3 and
then bleed air from the brake circuit. For
details, see “Bleeding air from wheel
brake circuit“.
28 WA500-6R
Measuring wear of wheel brake 3. While shaft (2) is inserted, measure projection
disc 1 (X) from guide (3) with slide calipers V.
a Keep pressing the brake pedal during
Symbol Part No. Part name measurement.
a If projection (X) shown in the figure is 0 or
Commercially
V Slide calipers less, replace the disc.
available
q Wear (y): y = 4.0 – X: Max. 4.0 mm
k Stop the machine in a level place and put
chocks under the tires.
1. Remove cap (1).
2. Lightly press the brake pedal to the stroke end.
4. After testing, return cap (1).

3 Cap (1):
29.4 – 39.2 Nm {3.0 – 4.0 kgm}
WA500-6R 29
Bleeding air from brake circuit 1 4) Press the brake pedal and loosen bleeder
screw (2) about 1/2 turn to drain the oil.
k
Tighten bleeder screw (2) a nd the n
Stop the machine on a level ground and release the brake pedal slowly.
apply the parking brake.
k Lock the tires with chocks and support the a This work must be performed by 2 work-
lift arm with the fall prevention rod. ers. One worker presses the brake pedal
and the other drain the oil through the
a After removing and installing a brake circuit bleeder screw.
part, bleed air from the brake circuit according a If the accumulator pressure decreases,
to the following procedure. start the engine to increase the pressure.
a Bleed air from the front brake circuit and rear
brake circuit according to the same procedure. 5) Repeat the above operation. When no
bubbles are contained in the oil flowing
1. Bleeding air from slack adjuster out of hose, press the pedal fully and
1) Start the engine and increase the accumu- tighten bleeder screw (2) while the oil is
lator pressure. Check that the accumula- flowing out.
3 Bleeder screw:
tor pressure is increased and stop the
engine. 7 – 9 Nm {0.7 – 0.9 kgm}
2) Remove inspection cover (1) on the front
side of the machine. 6) Similarly to the above, bleed air from rear
slack adjuster (3).
3) Connect one end of hose to bleeder screw

(2) of the front slack adjuster and put the
other end in an oil receiver.
30 WA500-6R
2. Bleeding air from brake cylinder 4) Repeat the above operation. When no
1) Remove cover (1). bubbles are contained in the oil flowing
out of hose [1], press the pedal fully and
tighten bleeder screw (2) while the oil is
flowing out.
3 Bleeder screw:
7 – 9 Nm {0.7 – 0.9 kgm}
5) Similarly to the above, bleed air from each

brake cylinder.
a Bleed air from the brake cylinders in
order from the one farthest from the
brake valve.
Air bleeding order of cylinders
(1) Left rear brake cylinder
O
2) Connect one end of hose [1] to bleeder (2) Right rear brake cylinder
screw (2) and put the other end in an oil O
receiver. (3) Right front brake cylinder
O
(4) Left front brake cylinder
a After bleeding air, carry out the brake perfor-

mance test to check for abnormality.
Then, drain oil again through each bleeder
screw to see if any bubbles are contained in it.
k Never bleed air while the engine is running

since the drive shaft is rotating.
a After finishing bleeding air, run the engine at

low idle and check the oil level in the hydraulic
tank. If the level is low, add oil up to the speci-
3) Press the brake pedal and loosen bleeder fied level.
screw (2) about 1/2 turn to drain the oil.
Tigh te n bleede r screw (2) and then
release the brake pedal slowly.
a This work must be performed by 2 work-

ers. One worker presses the brake pedal
and the other drain the oil through the
bleeder screw.
a If the accumulator pressure decreases,
start the engine to increase the pressure.
WA500-6R 31
Releasing residual pressure in

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

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

release the pressure from the brake accumula-
tor circuit.
32 WA500-6R
Testing parking brake

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

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

and then release the brake gradually. At this
time, the machine must not move.
a When the engine is stopped, the parking
brake is turned ON (to park) automatically.
a Measure the parking brake performance
on an uphill and a downhill.
WA500-6R 33
Measuring parking brake oil 3) Connect nipple W2 and oil pressure

pressure 1 gauge [1] of hydraulic tester W1.
a Measuring instruments for parking brake oil
pressure
1
W 799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
3 799-401-3100 Adapter (Size 02)
k Put chocks under the tires.

k Install and remove the measuring instru-
ments after the oil temperature lowers fully.
a Measure the parking brake oil pressure under

the following condition.
q Engine coolant temperature: 4) While running the engine at low idle, mea-
sure the parking brake inlet pressure.
k Keep pressing the brake pedal for
q Power train oil temperature:
Within operating range safety.
a Measure the oil pressure both at ON
1. Parking brake inlet pressure and OFF of the parking brake.
1) Remove rear frame left side cover (1). a If the parking brake solenoid valve
output pressure is normal and parking
brake inlet pressure is abnormal, fail-
ure on the parking brake emergency
release valve can be suspected.
2) Remove parking brake inlet pressure

pickup plug (10 x 1.25 mm) (2).

34 WA500-6R
2. Parking brake emergency release valve 5) While running the engine at low idle, mea-
pilot pressure (Transmission ECMV basic sure the parking brake pilot pressure.
pressure) k Keep pressing the brake pedal for
1) Remove rear frame left side cover (1). safety.
a Measure the oil pressure at turning
OFF of the parking brake.
2) Disconnect parking brake emergency

release valve pilot pressure hose (4).
3) Install adapter W3 and connect parking

brake pilot pressure hose (3).
[1] in hydraulic tester W1.
WA500-6R 35
3. Parking brake solenoid valve output pres- 5) Run the engine at low idle and measure
sure output pressure of the parking brake sole-
1) Remove rear frame left side cover (1). noid valve.
k Keep pressing the brake pedal for
safety.
a Measure the oil pressure at turning
OFF of the parking brake.
a If the parking brake pilot pressure is
normal and parking brake solenoid
valve output pressure is abnormal,
failure on the check valve on the
parking brake solenoid inlet side or
failure on the parking brake solenoid
can be suspected.
2) Disconnect parking brake solenoid valve

output pressure hose (3).

3) Install adapter W3 and connect parking

brake solenoid valve output pressure hose
(5).
[1] in hydraulic tester W1.
36 WA500-6R
Testing wear of parking brake 4. If depth (a) exceeds the repair limit, remove
disc 1 parking brake disc (4) and measure its disc
(W), referring to Disassembly and assembly
Measuring instruments
volume, "Removal of parking brake disc".
Symbol Part No. Part name q Service limit thickness (W): 2.97 mm
Commercially a If the parking brake disc thickness is
X Slide calipers below the service limit, replace the disc.
available
a If the parking brake does not work effectively,

check the parking brake disc for wear accord-
k Lower the work equipment fully and put
chocks under the tires.
k When checking, stop the engine.
1. Drain the oil from the transmission case.

6 Transmission case: 76 l
2. Remove either of 2 plugs (1).
q Refilling with oil (Transmission case)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
3. Measure depth (a) from the end of cage (2) to

piston (3) with slide calipers X.
q Depth (a) when disc is new: 28.9 mm
q Depth (a) when disc is worn to limit: 30.0 mm
WA500-6R 37
Method of releasing parking brake 3. Prepare 2 cage mounting bolts (2) and tighten
manually 1 them alternately in plug (1) installation position.
a Remove 2 bolts (2) on the diagonal posi-
a The parking brake is controlled hydraulically. If
tions.
you cannot release the parking brake because
a Tighten 2 bolts (2) to pull piston (3) and
of a trouble in the transmission, emergency
release the parking brake.
release solenoid valve, etc., you can move the a Tighten the 2 bolts gradually and evenly.
machine by releasing the parking brake manu- (After they reached the seats, give about 4
ally.
k
turns further to them.)
Releasing the parking brake manually is a
means to move the machine from a danger-
ous job site to a safe place. Apply this
means only in an emergency.
k Lower the work equipment to the ground
and put chocks under the tires to prevent
the machine from moving.
k When applying this means, stop the engine.
1. Drain the oil from the transmission case.

6 Transmission case: 76 l
2. Remove 2 plugs (1). (Right and left)

4. After moving to a safe place, restore the
machine to the original condition.
2 Mounting bolt (2): Adhesive (LT-2)
3 Mounting bolt (2):
98 – 123 Nm {10 – 12.5 kgm}
q Refilling with oil (Transmission case)

After releasing the parking brake manually, add
oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
38 WA500-6R
Measuring and adjusting work 2. Stroke of work equipment control lever

equipment control lever 1 1) Operate the work equipment control lever
and measure its stroke at each position.
a Measuring and adjusting tools for work equip-
a Apply a mark to the lever knob and
ment control lever
measure the stroke with scale Y2.
Symbol Part No. Part name a If the stroke is out of the standard
1 79A-264-0021 Push-pull scale range, check the linkage for play and
the bushing for wear.
Y Commercially
2 Scale a The shape in the figure is not identical
available
with that on WA500-6.
a Measure and test the work equipment control
lever under the following condition.
q Engine speed: Low idle
k Apply the frame lock bar to the frame.
Measuring
1. Operating effort of work equipment control
lever
1) Install and fix tool Y1 to the work equip-
ment control lever.
a Install tool Y1 to the center of the
knob.
a Operate the work equipment control
lever at the ordinary operating speed
and measure the minimum necessary
effort to operate the knob.
a The shape in the figure is not identical
with that on WA500-6.
WA500-6R 39
Testing and adjusting work 2) Disconnect hose (3) between accumulator

equipment PPC oil pressure 1 for PPC (2) and shut-off valve.
a Measurement at pickup plug (4)
a Testing and adjusting instruments for work
installation position is difficult.
equipment PPC oil pressure
1
Z 790-261-1204 Digital hydraulic tester
2 799-401-3200 Adapter (Size 03)
k Loosen the oil filler cap of the hydraulic oil

tank gradually to release the internal pres-
sure of the hydraulic tank
k Operate the work equipment control lever 2
– 3 times to release pressure from the PPC
accumulator circuit.
a Measure the work equipment PPC oil pressure
under the following condition.
Measuring
1. PPC oil pressure (shut-off valve basic pres-
sure)
1) Remove front cover (1) in the accumulator
installation position situated on the right
side of the machine.
3) Connect adapter Z2 and hose (3).

[1] of hydraulic tester Z1.
40 WA500-6R
5) Maintain the work equipment lock lever at 2) Connect adapter Z2 and hose (4).
LOCK position. 3) Connect nipple [2] and oil pressure gauge
6) Start and run the engine at high idle and [1] of hydraulic tester Z1.
then measure the PPC oil pressure (shut- a Use the oil pressure gauge with
off valve basic pressure). capacity 6 MPa {60 kg/cm2}.
7) Remove the measurement tool after the 4) Set the work equipment lock lever to Free
measurement, and make sure that the position.
machine is back to normal condition. 5) Start and run the engine at high idle and
then measure the PPC oil pressure (shut-
2. PPC oil pressure (shut-off valve output off valve output pressure).
pressure) k Do not operate the work equipment
1) Disconnect target PPC circuit hose (4) of control lever.

measurement from the articulate on the
right side of the machine.

a Adjustment of PPC oil pressure is not
available.
WA500-6R 41
Measuring work equipment oil 2) Disconnect hose (4) from union (3) of
pressure 1 work equipment control valve (2).
a Measuring instruments for work equipment oil
pressure
1
799-101-5220 Nipple (10 x 1.25 mm)
ZA 2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
4 799-401-3200 Adapter (size 03)
Measuring
1. Preparation work
1) Lower section (b) to the ground keeping 3) Connect adapter ZA4 between union (3)
(a) of bucket 30 – 50 mm off the ground. and hose (4).
2) After stopping the engine, lower bucket 4) Connect nipple [2] in hydraulic tester ZA1
bottom (a) and (b) to the ground operating and oil pressure gauge [1] of hydraulic
the work equipment control lever. Make tester ZA1.
sure they are on the ground. a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.
2. Measurement of work equipment relief

pressure 5) Start the engine and raise the lift arm up
1) Remove front frame left side cover (1). about 400 mm. Then measure the oil
pressure when the bucket is tilted back at
high idle.
42 WA500-6R
6) Remove the measurement tool after the 3) Connect adapter ZA4 between union (3)
measurement, and make sure that the and hose (4).
machine is back to normal condition. 4) Connect nipple [2] in hydraulic tester ZA1
k After measuring the oil pressure, and oil pressure gauge [1] of hydraulic
release pressure in the circuit and tester ZA1.
then remove the oil pressure a Use the oil pressure gauge of 40 MPa
gauge, nipple and adapter using {400 kg/cm2}.
the same procedure as 1. Prepara-
tion work.
3. Measurement of unload pressure

1) Remove front frame left side cover (1).
5) Start and run the engine at high idle and

then measure the oil pressure when all
levers are set to neutral.
2) Disconnect hose (4) from union (3) of

work equipment control valve (2).

k After measuring the oil pressure,
release pressure in the circuit and
then remove the oil pressure
gauge, nipple and adapter using
the same procedure as 1. Prepara-
tion work.
WA500-6R 43
4. Measurement of LS differential pressure 4) Connect adapter ZA4 between union (3)

a Before measuring LS differential pressure, and hose (4).
make sure the work equipment relief oil 5) Connect nipple [2] in hydraulic tester ZA1
pressure and work equipment PPC oil and oil pressure gauge [1] of hydraulic
pressure are normal. tester ZA1 or differential pressure gauge
a Determine the LS differential pressure by ZA3.
measuring the work pump discharge pres- a When using the differential oil pres-
sure and LS pressure (negative pressure sure gauge, connect its high-pressure
of actuator) at the same time and calculat- side. (Connect the low-pressure side
ing the difference between them. to LS.)
1) Remove front frame left side cover (1). The differential pressure gaug e
requires 12 V power supply. Thus,
connect a battery.
{400 kg/cm2}.
Since the differential pressure is 1.5
MPa {15 kg/cm 2 } at maximum, the
same gauge can be used throughout
the measurement.
2) Remove side cover (4) on the work equip-

ment pump.
3) Disconnect hose (4) from union (3) of

work equipment control valve (2).
44 WA500-6R
6) Remove LS pressure pickup plug (10 x

1.25 mm) (6) from work equipment pump.
8) Start the engine and raise the lift arm

upward about 400 mm.
7) Connect nipple ZA2 and oil pressure 9) Start and run the engine at high idle and
gauge [1] or differential pressure gauge then measure the work equipment pump
ZA3 of hydraulic tester ZA1. discharge pressure and LS pressure
a When using the differential oil pres- (actuator negative pressure) at the same
sure gauge, connect its low-pressure time under the following conditions.
side. (Connect the high-pressure side q When the lift arm lever set to half
to PS.) stroke
The differential pressure gauge a Prevent the lift arm cylinder from turn-
requires 12 V power supply. Thus, ing to full stroke as long as measure-
connect a battery. ment is continued.
a Use the oil pressure gauge of 40 MPa a Calculation of LS differential pres-
{400 kg/cm2}. sure:
Since the differential pressure is 1.5 LS differential pressure = Pump dis-
MPa {15 kg/cm 2 } at maximum, the charge pressure – LS pressure
same gauge can be used throughout
the measurement.

k After measuring the oil pressure,
release pressure in the circuit and
then remove the oil pressure
gauge and nipple using the same
procedure as 1. Preparation work.
WA500-6R 45
Adjusting
a Adjustment of the unload valve is not available.
1. Adjusting work equipment relief pressure

1) Remove front frame right side cover (7).

2) Loosen locknut (9) of main relief valve (8)

of work equipment control valve (2) and
then adjust the pressure by turning adjust-
ment screw (10).
a Adjustment screw:
q When turned clockwise, the oil
pressure is heightened.
q When turned counterclockwise,
the oil pressure is lowered.
adjustment screw:
12.55 MPa {128 kg/cm2}
3 Locknut:
29.4 – 39.2 Nm {3 – 4 kgm}
46 WA500-6R
2. Adjusting LS differential pressure

1) Loosen locknut (12) of LS valves (11) of
work equipment pump assembly (5) and
then adjust the pressure by turning adjust-
ment screw (13).
a Adjustment screw:
q Turning the screw clockwise the
increases pressure.
q Turning it counterclockwise
decreases the pressure.
adjustment screw:
1.3 MPa {13.3 kg/cm2}
3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}
a After the adjustment, measure LS dif-

ferential pressure again using the
procedure for measurement.
WA500-6R 47
Bleeding air from work equipment 2. Bleeding air from hydraulic cylinder
circuit 1 1) Start the engine and run it at low idle for 5
minutes minimum.
1. Bleeding air from work equipment pump
2) While running the engine at low idle,
(piston pump)
repeat raising and lowering of the lift arm 4
1) Remove side cover (1) on the work equip-
– 5 times.
ment pump.
a Do not operate the piston rod beyond
a position 100 mm in front of the
stroke end to prevent relieving.
3) Implement operation of 2) above with the
engine at high idle. Then operate the pis-
ton rod to the stroke end at low idle to
relieve it.
4) Implement the same operation as 2) and
3) above for the bucket and steering, too.
a When a cylinder is replaced, this
operation should be implemented
before connecting the piston rod.
2) Stop the engine and then loosen air bleed-

ing plug (3) of work equipment pump (2)
by 1/2 to 1 turn.
3) As oil free from air started to flow out of air

bleeding plug (3) of work equipment pump
(2), tighten air bleeding plug (3).
3 Air bleeding plug (3):
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
4) Start the engine and run it at low idle for 5
minutes minimum.
48 WA500-6R
Releasing residual pressure in 2) Loosen locknut (4) of ECSS pressure

work equipment circuit 1 relief plug (3) on work equipment control
valve (2).
1. Releasing residual pressure from the cir- 3) Loosen adjustment plug (5) 1/2 – 1 turn to
cuit between respective hydraulic cylinders release the accumulator pressure.
and control valve
a When disconnecting the pipes between
respective hydraulic cylinders and work
equipment, release the residual pressure
in the circuit according to the following
procedure.
1) Stop the engine.
2) Loosen the oil filler cap gradually to
release the internal pressure of the
hydraulic tank
3) Set the work equipment lock lever to Free
position.
4) Turn the starting switch ON.
5) Release residual pressure operating the
work equipment control lever.
2. Releasing residual pressure from ECSS

(travel damper) circuit
k When disconnecting the piping of the
ECSS circuit (between the accumulator
for ECSS and work equipment control
valve), release pressure of the accumu-
lator for the ECSS according to the fol-
lowing procedure.
1) Remove front frame left side cover (1).
4) After releasing residual pressure, tighten

plug (5) and locknut (4) securely in this
order.
a Loosen locknut (4) to the maximum
before tightening plug (5). After tight-
ening plug (5), tighten locknut (4).
3 Plug:
19.6 – 27.5 Nm {2.0 – 2.8 kgm}
3 Locknut:
19.6 – 27.5 Nm {2.0 – 2.8 kgm}
WA500-6R 49
Method of moving machine when 3. Start the engine and set emergency parking
removing operator cab (when brake release switch (3) to the release side to
splittable cab is used) 1 enable moving the machine to a maintenance
shop or safe place.
a It might be sometimes required to remove the k Remove the chocks to move the
operator cab to move a machine into a mainte- machine.
nance shop. Or moving a machine to a safe
place after removing, for instance, damaged
operator cab. In such case, using the emer-
gency parking brake release switch allows
moving the machine.
a In a situation like above, the emergency park-
ing brake release switch is used instead of the
parking brake switch used on the machine.
The harness is prepared only for moving the
machine to a maintenance shop or moving it
from a work site to a safer place. It should not
be used for any purpose other than above.
k Lower the work equipment to the ground,
apply the parking brake and then put
chocks under the tires so that the machine
may not move. 4. After moving the machine, return the emer-
gency parking brake release switch to the orig-
1. Remove operator cab assembly (1), referring inal position.
to Disassembly and assembly, "Removal and
installation of operator cab".
2. Remove fuse box cover (2).
50 WA500-6R
Testing and adjusting bucket Adjusting

positioner 1 1. Adjusting clearance
1) Adjust switch nut (5) so that clearance (b)
a Engine coolant temperature: Within operating
between the tip of switch protector (4) and
range
switch (1) and sensing surface (2) may
a Hydraulic oil temperature: Within operating
conform to the standard value. Then fix
range
them to adjusted positions.
a Standard clearance (b): 0.5 – 1.0 mm
3 Switch nut:
Testing
1. Stop the engine and make sure clearance (a)
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
between bucket-levelness detecting proximity
switch (1) and detection bar (3), and between
maximum tilt detecting proximity switch (2) and
detection bar (3) is within the standard value.
a Clearance (a): 3 – 5 mm
2) Using shims and the proximity switch

bracket mounting bolt, adjust clearance
(a) between proximity switch (1) and sens-
ing surface (2) and detection bar (3) to the
standard value. Then fix them to the
adjusted positions.
a Clearance (a): 3 – 5 mm
a Using shims, adjust detection bar (3)
so that clearance (a) may conform to
the standard value along every stroke
of the detection bar.
2. While running the engine at high idle, check

the operating position.
(Calculate the mean repeating above opera-
tion 3 times.)
WA500-6R 51
2. Adjusting bucket-levelness detecting prox- 3. Adjusting maximum tilt detecting proxim-

imity switch ity switch
1) Start the engine and raise the bucket. 1) Set height (c) of pin center of the lift arm
2) Activate bucket-levelness detecting prox- end to 1,000 mm from the ground surface.
imity switch (1) while operating the bucket
at 1,500 rpm.
3) Lower the bucket to the ground.
4) Make sure the bucket angle is set in the
range of 0° – 1° downward to the ground.
Repeat above 3 times and if the angle
does not conform to the above angle,
adjust it according to the following proce-
dure.
5) Loosen 2 mounting bolts of bucket-level-
ness detecting proximity switch bracket
(6) to slide bracket (6) installing position
and adjust it.
6) Make sure 3 times that the bucket angle is
set in the range of 0° – 1° downward to the
2) Tilt the bucket to the maximum position.
ground.
3) Loosen 2 mounting bolts of maximum tilt
detecting proximity switch bracket (7) to
slide bracket (7) installing position and
adjust it.
q Set distance (d) between the end of
detection bar (3) and the center of
maximum tilt detecting proximity
switch (2) to 50 mm.
52 WA500-6R
Testing and adjusting lift arm

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

clearance (a) between lift arm angle sensor (1)
and detection lever (2) to the standard value.
Then tighten bolt (3).
WA500-6R 53
Checking proximity switch

operation indication lamp 1
Proximity switch operation indication lamp
(red)
The proximity switch is provided with the lamp for
indicating the switch operating status. Use this
lamp for the adjustment.
q A: Operation indication lamp (red)
Relative position of proximity

Operation indi-
Proximity switch switch sensing surface and Remarks
cation lamp
sensed object
Bucket-levelness detecting prox- Placed in vicinity ON Operated as the switch center
imity switch and maximum tilt
Placed apart OFF approaches
detecting proximity switch
54 WA500-6R
Procedure for testing diodes 1 2) Put the red probe (+) of the test lead to the
anode (P) of and the black probe (–) to the
a Check an assembled-type diode (3 pins) and cathode (N) of diode, and confirm the indi-
independent diode (2 pins) in the following cated value.
manner. 3) Determine acceptability of the diode from
a The conductive directions of the assembled- the indicated value.
type diode (3 pins) are indicated on the surface q Indicated value remains unchanged:
of the diode as shown in the following figure. Conduction is absent (Failure)
q The indicated value changes: The
diode has conductivity (Normal) (See
a below.)
a A value between 460 to 600 is indi-
cated for silicon diodes.
a The conductive directions of the single diode

(2 pins) is indicated on the surface of the diode
as shown in the following figure.
2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
(–) to the cathode (N) of diode.
2] Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q With the connection 1] above, the
pointer is not moved. It swings, how-
ever, wh en the conn ectio n 2 ] is
employed. Normal (However, magni-
tude of the pointer's move (indicating
the resistance value) varies depend-
ing on the given tester model and the
measurement range selected).
q The pointer swings with both the con-
nections of 1] and 2]:
1. When using digital type circuit tester Defective (Internal short circuit)
1) Switch the testing mode to diode range q The pointer does not swing with both
and confirm the indicated value. the connections of 1] and 2]:
a Voltage of the battery inside is dis- Defective (Internal breaking of wire)
played with conventional circuit tes-
ters.
WA500-6R 55
Preparations for work on

troubleshooting of electrical
system 1
a When carrying out troubleshooting of an elec-
trical circuit related to the machine monitor,
transmission controller, work equipment con-
troller or KOMTRAX terminal, expose the
related connectors according to the following
procedure.
1. Machine monitor
1) Disconnect the following connectors from
cover (1).
q L58 connector: Parking brake switch
2) Remove interior covers (2).
q L59 connector: ECSS switch
3) Remove cover (1).
q L65 connector: Machine monitor mode
selector switch 2
q L66 connector: Machine monitor mode
selector switch 1
q L67 connector: Front working 
lamp switch
q L68 connector: Rear working 
lamp switch
q L69 connector: Load meter mode 
selector switch 
(if equipped)
q L70 connector: Load meter mode 
display switch 
(if equipped)
q L72 connector: Beacon lamp switch 
(if equipped)
4) Remove bracket mounting bolt (4) of
a Pull out switches from the cover and
machine monitor (3) to turn over the
then disconnect the connectors.
machine monitor.
a Do not try to forcibly disconnect the
a Take care in this operation so that the
connectors inserting your hand
wiring harness may not be forcibly
through the bottom of the cover. Such
pulled.
action can damage the connectors or
switches.
56 WA500-6R
5) Connect T-adapter for troubleshooting to 2. Transmission controller

the following wiring connectors of machine 1) Remove covers (5) and (6) through the
monitor (3). rear side of the operator seat.
q L51, L52, L53, L54, L55, L56 and L57
connectors
2) Connect T-adapter used for troubleshoot-

ing to connectors L02, L03 and L04 of
transmission controller (7).
a When it is difficult to remove or install
the connectors, do it after removing
the transmission controller first.
a Connectors are fixed with screws.
Loosen the screws before discon-
necting them.
a When the connectors were returned
to the original position, tighten the
screw to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
WA500-6R 57
3. Work equipment controller 4. KOMTRAX terminal

1) Remove covers (5) and (6) through the 1) Remove covers (5) and (6) through the
rear side of the operator seat. rear side of the operator seat.
2) Connect T-adapter for troubleshooting to 2) Connect T-adapter for troubleshooting to

connectors L05, L06 and L07 of work L80 connector of KOMTRAX terminal (9).
equipment controller (8). a When it is difficult to connect or dis-
a When it is difficult to remove or install connect the connectors, do it after
the connectors, do it after removing removing KOMTRAX terminal.
the work equipment controller first. a Connectors are fixed with screws.
a Connectors are fixed with screws. Loosen the screws before discon-
Loosen the screws before disconnecting them.
necting them. a When the connectors were returned
a When the connectors were returned to the original position, tighten the
to the original position, tighten the screw to the specified torque.
screw to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}
3 Screw: 2.82 Nm {0.288 kgm}
58 WA500-6R
WA500-6R 59
SEN02928-04

© 2019 KOMATSU
All Rights Reserved
60
SEN02929-02
WA500-6R

WA500-6R 60001 and up

Starting KOMTRAX terminal operations (if equipped) .................................................................................... 2
Indicator lamps of KOMTRAX terminal (if equipped) ...................................................................................... 8
Machine monitor-based adjustment at replacement, disassembly and assembly,
and additional installation for each sensor and controller ..........................................................................11
Special functions of machine monitor (EMMS) ............................................................................................. 13
WA500-6R 1
Starting KOMTRAX terminal operations 1

(if equipped)
Procedure for starting use of KOMTRAX

If installed before 1) Fill the form shown in "Request for ORBCOMM terminal activation" and send it to KOMTRAX
delivery Service Hot Line by facsimile or mail.
It takes 2 – 3 weeks after the request is delivered to the KOMTRAX Service Hot Line until
KOMTRAX can be used.
2) Register distributor machine with the KOMTRAX client personal computer.
For the procedure, see "Global KOMTRAX Web Reference Manual (For Key Person).
For information to be checked in advance, see "Application for start of use"
3) Press the "start" button on the KOMTRAX client personal computer.
If installed after 1) Fill the form shown in "Request for ORBCOMM terminal activation" and send it to KOMTRAX
delivery Service Hot Line by facsimile or mail.
It takes 2 – 3 weeks after the request is delivered to the KOMTRAX Service Hot Line until
KOMTRAX can be used.
2) Install the devices according to the "installation procedure".
3) Carry out the procedures shown in "Inspection of machine for starting ORBCOMM".
4) Register distributor machine with the KOMTRAX client personal computer.
For information to be checked in advance, see "Application for start of use"
5) Press the "start" button on the KOMTRAX client personal computer.
2 WA500-6R
TO : KOMTRAX service Hotline Important

Phone : +81-463-22-8780
Fax : +81-463-22-8448
Address : 3-25-1 Shinomiya, Hiratsuka-shi, Kanagawa 254-8555, Japan
e-mail : cs_kom@komatsu.co.jp
Request for Orbcomm Terminal Activation
Please fill in the form below and fax or send by mail to Customer Support Gr., Kltd. to activate Orbcomm ter-
minal.
t Terminal Information
Terminal Parts Number : (Please fill in terminal P/N & S/N or put on enclosed sticker here)
Terminal S/N : P/N : . S/N : .
Terminal Activation Date

(YY/MM/DD) .
of your choice (Note) :
Country to use : .
Machine info. Model-Type-#S/N : - . # .
t Custormer’s Contact Address
Company (or Plant) : ( ).
Phone number : (Country-Area - Local-Local) - - - .
Fax number : (Country-Area - Local-Local) - - - .
e-mail address : .
Name (Please print) (Frist Middle Family) .
Signature : .
Notes)
q It will take two or three weeks to activate Orbcomm terminal after being received this sheet. Therefore,
please enter terminal activation date of your choice three weeks after or later the submission of this
sheet.
q Orbcomm terminal is unable to communicate before registration being completed.
WA500-6R 3
Station opening check in machine side 3. When about 3 to 5 seconds elapsed after the
a Complete steps 3. to 5. within 60 seconds. If starting switch was set to ACC, make sure that
60 seconds or above elapsed, begin with step the 7-segment indicator lamp changes to
1. again. hyphen “–” on the KOMTRAX terminal.
1. Turn OFF the starting switch and then, after
making sure 5 seconds have elapsed, proceed
to the next step.
2. Visually check that check connectors 1 and 2

are connected.
q Check connector 1: CHK0
q Check connector 2: CHK1
4. Disconnect inspection connector 1, and wait

for about 3 to 5 seconds as it is.
a Ensure that the connector is discon-
nected.
5. Reconnect inspection connector 1, and wait for

about 3 to 5 seconds as it is.
a If the KOMTRAX terminal detects that
the connector was disconnected and
connected, the dot on the 7-segment
indicator lamp blinks a few times.
4 WA500-6R
6. Make sure that the 7-segment indicator lamp is a As [Normal] is indicated, proceed to the
indicated normally on the KOMTRAX terminal. next step.
a If so, the 7-segment indicator lamp will a If “–” remains displayed, execute steps 1.
indicate characters “d”, “0”, and “–” repeat- to 5. again.
edly for 30 seconds after step 5. was
ended.
a Those characters, even if displayed nor-
mally, will change to a character other
than hyphen “–”after 30 seconds or above
elapsed.
The display may change to a character
other than “0” even within 30 seconds.
7. Turn the starting switch to START position for

about 3 to 5 seconds, and make sure that the
engine does not start.
a If the engine starts, re-execute the proce-
dure above from step 1.
a Do not return the starting switch to OFF
position.
8. Turn the starting switch from ACC position to

START position again, and make sure that the
engine starts.
9. Make sure that the KOMTRAX terminal's indi-

cator lamps are normally turned on.
a Move on to the next step if you can check
that the display is [Normal]. (It takes from
90 seconds to 15 minutes before the dis-
play turns normal.)
a If [GPS position data detection trouble] is
indicated, check if there is any abnormality
on the GPS antenna or cable. If there is
any abnormality, repair it and start from
procedure 1. again.
a If [Reception trouble] is indicated, check if
there is any abnormality on the appear-
ance of the communication antenna or
cable. If there is any abnormality, repair it
then repeat from procedure 1. again.
a If [GPS position data detection trouble and
reception trouble] is indicated, check if
there is any abnormality on the GPS
antenna/cable or communication antenna/
cable. If there is any abnormality, repair it
and start from procedure 1. again.
WA500-6R 5
a If [Network trouble] is indicated, check the 10. Turn the starting switch OFF.
display of [LED-C4] referring to “Lamp dis-
play of KOMTRAX terminal”. If the CAN is 11. Make sure that the 7-segment indicator lamp is
not recognized, check the CAN harness of displayed normally after 5 seconds elapsed.
the KOMTRAX terminal, and then if there a When [Normal] appears, station opening
is any abnormality, repair it and start from check is completed.
procedure 1. again. a If [Abnormal] appears, station opening
[A]: Normal check does not end normally, so you
[B]: GPS position data detection trouble should perform the procedure above from
[C]: Reception trouble step 1. again.
[D]: GPS position data detection trouble a If station opening check ends normally, it
and reception trouble should not be rechecked.
[E]: Network trouble
12. When station opening check ended normally, a

communication with the KOMTRAX server
starts automatically, and settings are stored in
KOMTRAX. (This requires about 25 minutes to
4 hours.)
a During this time, you may turn the starting
switch off and start the engine.
a During the communication and check
above, you should park the machine out-
side to enable a frequent communication
with the ORBCOMM satellite. The station
opening check may not be completed in
doors that cause radio waves from the
satellite to be intercepted.
6 WA500-6R
Application for the start of use

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

use a KOMTRAX client PC to register the
machine.
a Refer to “Manual for KOMTRAX opera-
tions administrator” for the procedure.
a For the procedure applied out of Japan,
refer to “Global KOMTRAX Web Refer-
ence Manual (For Key Person)”.
a Now the terminal is ready for use.
WA500-6R 7
Indicator lamps of KOMTRAX terminal 1

(if equipped)
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)
8 WA500-6R
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

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

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

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
WA500-6R 9
2. Contents of 7-segment and dot displays for CPU

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

Fast blink: Blinks in about 0.5-second cycle
Slow blink: Blinks in about 2.0-second cycle
*3: Supplementary explanation of GPS positioning status
One or more minute may be taken until GPS positioning is completed after the starting switch was
turned ON even in an outdoor service area.
GPS positioning will fail in a weak signal or non-service area.
10 WA500-6R
Machine monitor-based adjustment at replacement, disassembly and

assembly, and additional installation for each sensor and controller 1
1. Setting items that are necessary for replacement and disassembly and assembly as well as addi-
tional installation of sensors and controllers.
a When any of the following devices or parts was replaced, disassembled or assembled, the machine
monitor-based initialization of the sensors and solenoids is required.
Devices or optional parts being replaced, disassembled, assembled or added Adjustment item (order)
Machine monitor K, L, M, A, B, C
Transmission main body E, D, F
Transmission controller A, B, E. D, F
Transmission ECMV solenoid E, D, F
Lift arm angle sensor G, K, L, M
Work equipment control valve I
Work equipment EPC solenoid I
Work equipment electric lever H
Work equipment controller A, B, G, H, I
Work equipment bucket horizontal proximity switch J
Bucket J, K, L, M
Lift arm B, G, J, K, L, M
Adding and removing an optional device B
Adjustment item Contents of adjustment Section No.

A Selection of model 12 (*1)
B Selection of option 10 (*1)
C Machine serial number input 11 (*1)
D Adjustment of transmission ECMV current 7-1 (*1)
E Reset of transmission initial learning 7-2 (*1)
F Transmission initial learning 7-2 (*1)
G Adjustment of work equipment controller lift arm angle 7-4 (*1)
H Adjustment of work equipment EPC lever detent position 7-5, 7-6, 7-7 (*1)
I Adjustment of work equipment EPC starting current 7-5, 7-6, 7-7, 7-8 (*1)
J Adjustment of bucket positioner — (*2)
K Adjustment of load meter lift arm angle 7-17, 7-18 (*1)
L No load calibration of load meter — (*3)
M Loaded calibration of load meter — (*3)
*1: Section No. of “Service mode” in “Special functions of machine monitor (EMMS)”
*2: See “Testing and adjusting bucket positioner” and “Checking proximity switch operation indication
lamp”.
*3: See Attachment options, “Using load meter” of the Operation and maintenance manual.
WA500-6R 11
2. User needs-based adjustment

When user pointed out a trouble or requested solution for a trouble, the following setting change shall be
conducted by the machine monitor.
Contents of user's remarks or request Adjustment item

Want to change the display unit of the speedometer. N
Want to use the short ton for the load meter weight display unit. O
Want to turn off display of the economy lamp. P
Want to suppress hunting. Q
Want to change the gearshift travel speed in the auto shift. Q
Fine control is not available in the lift arm raise/lower operation or the response in this oper-
R
ation is poor.
Fine control is not available in the bucket tilt/dump operation or the shock dump effort is
S
weak.
Large shocks result at stopping the lift arm raise/lower or a substantial overrun occurs at
T
stopping.
Matching at loading to dump truck is poor. U
Travel speed indication is too fast/slow. V
Want to turn off the character display-based travel speed/engine speed indication. W
Want the power mode to turn on as the starting switch is turned on. (Power mode priority) X
Adjustment item Contents of adjustment Section No. (*)

N Optional setting and selection of speed unit 10
O Optional setting and selection of short ton switching 10
P Optional setting and selection of economy lamp display 10
Q Adjustment of sensor and adjustment of transmission L mode shift point 7-3
R Adjustment of sensor and change of lift arm lever pattern 7-13
S Adjustment of sensor and change of bucket lever pattern 7-14
T Adjustment of sensor and adjustment of lift arm lower stop modulation 7-15
Adjustment of sensor and adjustment of pump cut-off pressure in lift arm
U 7-16
raise
V Optional setting and change of tire size 10
Optional setting and change of travel speed/engine speed display on char-
W 10
acter display and normal screen
X Optional setting and change of power mode priority 10
*: Section No. of “Service mode” in “Special functions of machine monitor (EMMS)”

a Change of the display unit of the speed meter as well as the weight is not available when the specifica-
tion is prepared for a country where SI unit is employed.
12 WA500-6R
Special functions of machine monitor (EMMS) 1

Normal functions and special functions of machine monitor
The machine monitor (EMMS) is equipped with normal and special functions, and displays various types of
information to the character display at the center of the monitor section.
Some items are displayed automatically according to the internal setting of the machine monitor, and some
are displayed according to the operation of the machine monitor switches.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
a See the Operation and maintenance manual for details of the operator mode.
2) Special functions: Service mode

Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
No. of the No. of the

corresponding corresponding
Operator mode Service mode
section in this section in this
document document
Procedure for switching to Service
1
Service meter/clock display function mode and screen display
1
(*1) Electrical system failure history dis-
2
play function
Mechanical system failure history dis-
2 Load meter function (if equipped) (*1) 3
play function
3 Odometer display function 4 Real-time monitoring function
4 Maintenance monitoring function 5 Cylinder cut-out function
⇔
5 Phone No. input function 6 No injection cranking function
6 Language selection function 7 Adjustment function
7 Monitor brightness adjustment function 8 Maintenance monitoring function
8 Time adjustment function (*1) 9 Operation information display function
Travel speed/engine speed display
9 10 Optional device selecting function
selecting function
Character display: Travel speed/
10 engine speed display/non-display 11 Machine serial number input function
selecting function (*2)
11 Action code display function 12 Model selection function
12 Failure code display function 13 Initialize function
*1: This display is not available when the load meter function is turned off through OPT selection of service
mode.
*2: This display is not available when the travel speed and engine speed displays are turned off on the
character display by selecting OPT in the service mode.
WA500-6R 13
Functions and flow of the service mode
14 WA500-6R
WA500-6R 15
16 WA500-6R
Operator mode 3. Odometer display function

a Following overviews the operator mode. Press [U] switch from the ordinary service
a See the section “Structure, function and main- meter display screen to display the odometer.
tenance standard” or the Operation and main- When the load meter option is selected, dis-
tenance manual for details of the operator play the odometer as [<] switch is pressed suc-
mode. ceeding to display of the load meter function.
a For details, see the “Other functions of
1. Service meter/clock display function machine monitor” of the “Operation” sec-
Turning the starting switch ON display the ser- tion in the Operation and maintenance
vice meter in the upper space and the clock in manual.
the lower space.
4. Maintenance monitoring function

1) Filter, oil replacement time display (auto-
matic display)
2. Load meter function (if equipped) As the filter or oil replacement time draws
Press [U] switch from the ordinary service close, the machine monitor automatically
meter display screen to display the load meter displays its information to alert operator's
function. attention.
a For more information, see the section 2) Resetting replacement time (selection
Structure, function and maintenance stan- menu)
dard, “Load meter function”, and Attach- As maintenance operation for a filter or oil
ment options, “Using load meter” of the is completed, the machine monitor allows
Operation and maintenance manual. resetting the time interval through the
switch operation.
WA500-6R 17
5. Phone No. input function 7. Monitor brightness adjustment function

Telephone numbers are entered through the Brightness of the machine monitor is adjust-
switch operation. And modification or cancella- able in 7 levels through the switch operation.
tion of the phone numbers in the machine a Adjustment of brightness is available in
monitor is also available through the switch two approaches – adjustment of the moni-
operation. tor alone and separate adjustment of the
a When action code [E03] is displayed, a liquid crystal.
phone number is displayed along with a For details, see the “Other functions of
[CALL]. machine monitor” of the “Operation” sec-
a For details, see the “Other functions of tion in the Operation and maintenance
machine monitor” of the “Operation” sec- manual.
tion in the Operation and maintenance
manual.
6. Language selection function

Switch operation allows selecting a display lan-
guage of the machine monitor.
a The Service mode function is not included
in the display selection function, therefore
always displayed in English
a A desired language is selectable from
English, Japanese, German, French, Ital-
ian, Spanish and Swedish.
machine monitor” of the “Operation” sec- 8. Time adjustment function
tion in the Operation and maintenance The time indicated by the clock of the machine
manual. monitor is adjustable.
a This item can be changed only when the
optional load meter function is selected.
machine monitor” of the “Operation” sec-
manual.
18 WA500-6R
9. Travel speed/engine speed display selecting 11. Action code display function
function If a trouble occurs, the machine monitor dis-
A unit to be used for the machine monitor plays an action code corresponding to the seri-
speed display is selectable from km/h and ousness of the trouble to alert the operator for
MPH. It is also possible to display the travel appropriate actions.
speed and engine speed. a The figure below shows an example of the
a This function is available only when “RPM screen on which action code [E03] and
OPT” in the options is selected. [CALL + Telephone number] are alter-
a For details, see the “Other functions of nately displayed.
machine monitor” of the “Operation” sec- a When action code [E01] or [E02] is dis-
tion in the Operation and maintenance played, [CALL + Telephone number] is not
manual. displayed.
10. Character display: travel speed/engine speed

display/non-display selecting function
The travel speed or engine speed displayed on
the character display of machine monitor can
be turned ON and OFF.
a This function is available only when “RPM/
SPEED” in the options is selected.
a When the travel speed is displayed at the
center of the machine monitor, the engine
speed is displayed on the character dis-
play. When the engine speed is displayed
at the center of the machine monitor, the
travel speed is displayed on the character
display.
machine monitor” of the “Operation” sec-
manual.
WA500-6R 19
a Action codes and actions alerted to operator

CALL +
Action code Actions recommended to operator
Telephone number
• Do necessary testing and/or servicing as the current work is over or at
E01 Not displayed
shift of the operator.
• When an overrun-related item is displayed
Slow down the engine or machine speed.
E02 Not displayed
• When an overheat-related item is displayed
Stop the machine and run the engine at mid speed with no load.
E03 Displayed • Stop the engine and machine immediately and contact a serviceman.
12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code (location code + problem
failure code corresponding to the failure cur- code)
rently warned. B: Controller code
a The failure codes which have been MON : Machine monitor
detected in the past are separated into TM : Transmission controller
electrical and mechanical systems and WRK : Work equipment controller
recorded as failure history (refer to Ser- ENG : Engine controller
vice mode for a detail). C: The system where failure occurred
a When two or more failures are involved,
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display Screen
will be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 60 seconds,
the action code display screen is automat-
ically displayed.
a For details of a displayed failure code, see

Troubleshooting, “Failure code list”.
a If any switch operation is not done for 60
seconds or more on the failure code dis-
play screen, the action code display
screen is automatically turned on.
20 WA500-6R
Service mode (*1): When the cursor is located at the leftmost posi-
1. Procedure for switching to Service mode tion, pressing the switch restores the normal
and screen display screen (Operator mode).
When using Service mode, carry out the fol- When the cursor is at a location other than the
lowing special operation to switch the screen leftmost position, pressing the switch returns
display. the cursor to the leftmost position.
1-1. Checking screen display If any switch operation is not done for 60 sec-
Make sure that the machine monitor is set to onds or more from ID input screen, the normal
the operator mode and any of “Service meter”, screen is automatically turned on.
“Action code” or “Failure code” is displayed on
the screen.
1-2. Displaying ID input initial screen
Hold down [t] switch and [<] switch simulta-
neously for 5 seconds minimum to open ID
input initial screen.
a Holding down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the buttons.
1-4. Displaying menu initial screen

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

Operate the buttons to input the ID.
q ID: 6491
1) Cursor (C) is positioned at the highest-
order digit. Pressing [<] and [>] switches
changes the value of this digit in the range
of 0 – 9.
2) Press [U] switch when the intended value
appeared to specify it.
a The cursor moves to the 2nd digit.
3) Set the value in the same order and then
press [U] switch.
a When you have entered a wrong value to
a position except the highest-order digit,
move to the highest-order digit using [t]
switch to repeat the procedure from the
first. In this case, values that had been
entered remain as they are until modified.
When the cursor is at the highest-order
digit, it can move to the higher layer using
[t] switch. (*1).
WA500-6R 21
1-5. Selecting service mode menu 2) When ending an operation completely:

a Pressing [<] and [>] switches from the Turn the starting switch off from the cur-
menu screen displays Service mode rent state.
menus endlessly in the following order.
[1] ELECTRIC FAULT: Electrical system 2. Electrical system failure history display
failure history display function function (ELECTRIC FAULT)
[2] MACHINE FAULT: Mechanical sys- The machine monitor retains the data for prob-
tem failure history display function lems that occurred in the electrical system in
[3] REAL-TIME MONITOR: Real-time the past as failure codes. They can be dis-
monitoring function played as follows.
[4] CYLINDER CUT-OUT: Cylinder cut- 2-1. Selecting the menu
out function Select the ELECTRIC FAULT from the menu
[5] NO INJECTION: No injection crank- screen of Service mode.
ing function a [ ] field displays total number of the fail-
[6] TUNING: Adjustment function ure history currently recorded (up to 20
[7] MAINTENANCE MONITOR: Mainte- cases).
nance monitoring function
[8] OPERATION INFO: Operating infor-
mation display function
[9] OPTIONAL SELECT: Optional device
selecting function
[10] MACHINE No. SET: Machine serial
number input function
[11] MACHINE: Model selection function
[12] INITIALIZE: Initialize function (Func-
tion specialized for plant)
a The menus are displayed in the field indi-
cated with [*] mark.
2-2. Displaying failure history

Press [U] button while the menu is selected to
display the recorded failure history.
1-6. Completion of mode and function

Either of the following procedures ends a
mode or function independent of the function
being selected and the layer in which it is used.
1) When the operation is to be continued
using another mode or function: Press [t]
switch to return to the menu screen.
a Note, however, that [t] switch functions
as an execution key on [YES/NO] screen.
a When the normal screen (Operator mode)
was inadvertently turned on, repeat above
steps from 1) (input of the ID is not neces-
sary).
22 WA500-6R
2-3. Displayed trouble data a Information of the currently occurring fail-

The electric system trouble data display func- ure is not deletable.
tion displays the following information.
A: Record number
B: Failure code (Location code in 4 digits +
Problem code in 2 digits)
C: Number of occurrences (number of occur-
rences of same code in past)
D: Elapsed time 1 (Elapsed time on service
meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
a Note that part of the information displayed
2-6. Deleting all trouble data
from the electrical system trouble data dis-
1) Press [<] or [>] switch while the trouble
play function and the failure code display
data is on the screen to display the ALL
function is not identical.
CLEAR menu screen.
a When the requested failure history is not
recorded, [–] is indicated in the display
space.
2) Press [U] switch to display the ALL

CLEAR screen.
3) Select “YES” or “NO” using [<] or [>]
2-4. Switching failure history display
switch.
Pressing [<] or [>] switch while a set of failure
a The selected cursor will start flashing. If
history is on the screen displays another set of
"YES" is selected and [t] switch is
recorded failure history.
pressed, the information will be deleted. If
2-5. Deleting individual failure history
"NO" is selected and [t] switch is pressed,
1) Press [U] switch while the target failure
deletion is cancelled and the "Failure his-
history of deletion is on the screen to turn
tory information" screen is restored.
on CLEAR screen.
a By default, the cursor is set to NO (cancel)
2) Select “YES” or “NO” using [<] or [>]
to prevent resetting error.
switch.
a Information of the currently occurring fail-
ure is not deletable.
" YE S " i s se l e c t e d a n d [ t ] s w i t c h i s
"NO" is selected and [t] switch is pressed,
deletion is cancelled and the "Failure his-
tory information" screen is restored.
WA500-6R 23
3-3. Displayed failure history

The mechanical system failure history display
function displays the following information.
A: Record number
B: Failure code (Location code in 4 digits +
Problem code in 2 digits)
C: Number of occurrences (number of occur-
rences of same code in past)
D: Elapsed time 1 (Service meter reading at
first occurrence)
E: Elapsed time 2 (Service meter reading at
last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
3. Mechanical system failure history display
function (MACHINE FAULT)
a Note that part of the information displayed
The machine monitor retains the data for prob-
from the mechanical system failure history
lems that occurred in the mechanical system in
display function and the failure code dis-
the past as failure codes. They can be dis-
play function is not identical.
played as follows.
a When the requested failure history is not
3-1. Selecting the menu
recorded, [–] is indicated in the display
a Select MACHINE FAULT from the menu
space.
screen of Service mode.
a [ ] field displays total number of the fail-
ure history currently recorded.
3-4. Switching failure history display

Pressing [<] or [>] switch while a set of failure
3-2. Displaying failure history
history is on the screen displays another set of
Press [U] switch while the menu is selected to
recorded failure history.
display the recorded failure history.
3-5. Deleting failure history (Not available)
The failure history of the mechanical system is
not deletable.
24 WA500-6R
4. Real-time monitoring function 4-3. Selecting sub menu

(REAL-TIME MONITOR) a Press [<] or [>] switch from the sub menu
The machine monitor checks state of the screen to display the sub menus endlessly
machine on real-time basis referencing signals in the following order.
of the sensors being installed in various parts a The sub menus are displayed in the field
of the machine. indicated with [ ] mark.
The real-time monitoring function displays fol- [1] MONITOR PANEL:
lowing two types of information. Machine monitor system
q 1 item independent display (for each con- [2] TRANSMISSION:
troller) Transmission controller system
q 2 items simultaneous display (code input) [3] BOOM: Work equipment controller
4-1. Selecting the menu system
Select REAL-TIME MONITOR from the menu [4] ENGINE: Engine controller system
screen of Service mode. [5] 2 ITEMS: 2 items display
4-2. Displaying sub menu 4-4. Setting the 1 item individual monitoring
Press [U] switch while the menu is selected to 1) Select the target controller system of mon-
display the sub menu initial screen. itoring from the sub menu screen.
WA500-6R 25
4-5. Setting 2 items simultaneous monitoring

2) Press [U] switch while the sub menu is 1) Select 2 ITEMS on the sub menu screen.
selected to display the MONITOR PANEL 2) Press [U] switch while the sub menu is
screen. selected to display the monitoring code
3) Press [<] or [>] switch to select a monitor- input screen.
ing item.
a The monitoring items are scrolled accord-
ing to the internally set order.
a Holding down [U] switch turns on high-
speed scrolling.
a Holding and cancelling the monitoring
data: Pressing [U] switch while the moni-
toring is in progress holds the monitoring
data and [U] mark starts flashing. Press-
ing [U] switch again restores the active
state.
1] This cursor (C) is located at the high-

est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
value.
a The cursor moves to the 2nd position.
3] Set the value in the same order and
then press [U] switch.
a When you have entered a wrong
4) Display data for 1 item individual monitor- value to a position except the highest-
ing order digit, the cursor can move to the
The 1 item individual monitoring screen highest-order digit using [t] switch
displays the following information. and repeat the procedure from the
A: Item display first. In this case, values that had
B: Monitoring codes (5 digits) been entered remain as they are until
1: Monitoring data (including the unit modified. When the cursor is at the
used) highest-order digit, it can move to the
a See the “Real-time monitoring code list” higher layer using [t] switch.
for details.
26 WA500-6R
3) As both monitoring codes are settled, the

2 ITEMS screen will be turned on.
a Holding and cancelling the monitoring
data:
Pressing [U] switch while the monitoring
is in progress holds the monitoring data
and [U] mark starts flashing. Pressing [U]
switch again restores the active state.
4) Display data for 2 items simultaneous

monitoring
a The 2 items simultaneous monitoring
screen displays the following information.
A: Monitoring code 1
1: Monitoring data 1 (including the unit
used)
B: Monitoring code 2
2: Monitoring data 2 (including the unit
used)
a See the “Real-time monitoring code list”
for details.
WA500-6R 27
Real-time monitoring code list

MONITOR PANEL [Mechanical monitor system]
Monitoring items Display item Data display range
No. Monitoring codes
(*1) (*2) (*3)
1 20200 Part number of monitoring software VERSION Arabic numerals
2 20221 Application version VERSION (APP) Arabic numerals
3 20222 Data version VERSION (DATA) Arabic numerals
4 01001 Engine speed ENG SPEED 0 – 3000
5 40000 Travel speed SPEED 0 – 50
6 04202 Fuel level FUEL SENSOR 0 – 100
7 04207 Fuel level FUEL SENSOR 0.00 – 5.00
8 04103 Engine coolant temperature COOLANT TEMP –40 – 210
9 40100 Torque converter oil temperature TC OIL TEMP 24 – 131
10 40101 Torque converter oil temperature TC OIL TEMP 0.00 – 5.00
11 04401 Hydraulic oil temperature HYD TEMP 24 – 131
12 04404 Hydraulic oil temperature HYD TEMP 0.00 – 5.00
13 30202 Rear brake oil temperature R BRAKE OIL 24 – 131
14 30205 Rear brake oil temperature R BRAKE OIL 0.00 – 5.00
15 04302 Charge level ALTERNATOR R 0.00 – 30.00

16 40200 Small lamp voltage SMALL LAMP 0.00 – 30.00
17 40300 Battery electrolyte level A BATTERY A 0.00 – 30.00
18 40301 Battery electrolyte level B BATTERY B 0.00 – 30.00
19 06001 Lift arm angle BOOM ANG –90 – 90
20 06003 Lift arm angle BOOM ANG 0.00 – 5.00
21 40400 Lift arm bottom pressure BOOM BTM PRESS 0.00 – 50.00
22 40402 Lift arm bottom pressure BOOM BTM PRESS 0.00 – 5.00
28 WA500-6R

Unit Remarks
Display contents in normal state
(*4) (*5)
Depends on software part number Status display
Depends on application version Status display
Depends on data version Status display
Low idle: 800 ± 25 rpm
High idle: 2000 ± 50 rpm (P-mode)
1900 ± 50 rpm (E-mode)
rpm
Torque converter stall:
1800 ± 100 rpm (P-mode),
1730 ± 100 rpm (E-mode)
F1/R1: 6.7/7.3 km/h ±5% (P-mode, Torque converter)
km/h
0 – 100% %
Gauge FULL (100%, 10 z): 0.32 V
At disconnection or hot short in sensor:
Gauge 1/2 (50%, 32 z): 0.88 V
V Gauge EMPTY
Caution (61.3 z): 1.45 V
At grounding fault in sensor: Gauge FULL
Gauge EMPTY (0%, 85 z): 1.81 V
Coolant temperature Max. 100°C
Depends on machine status (°C) °C
Data acquired from engine controller
Depends on machine status (°C) °C Overheat 120°C
Start of gauge red zone (120°C): 1.62 V
V Gauge MIN
(80°C): 2.91 V
At grounding fault in sensor: Gauge MAX
Depends on machine status (°C) °C Oil temperature of hydraulic tank Max. 100°C
Start of gauge red zone (120°C): 1.62 V
V Gauge MIN
(80°C): 2.91 V
At grounding fault in sensor: Gauge MAX
Depends on machine status (°C) °C
(120°C): 1.62 V
V
(80°C): 2.91 V
Depends on machine status (0.0 to 30 V) V
Depends on machine status (0.0 to 30 V) V
Min. 2 V V Only for optional setting
— V Not used.
STD lift arm
Highest lift arm: 46.8 ± 2.0 deg
Lowest lift arm: –42.3 ± 3.0 deg
Degree (°)
Hi lift arm
STD lift arm
Highest lift arm: 3.80 ± 0.3 V
Lowest lift arm: 1.33 ± 0.5 V
V
Hi lift arm
Rated loading, high idle, lift arm control lever
Depends on machine status. MPa
full, arm horizontal: Approx. 18 MPa
0 MPa : 0.5 V
10 MPa: 1.3 V
V
20 MPa: 2.1 V
50 MPa: 4.5 V
WA500-6R 29

(*1) (*2) (*3)
23 40500 Lift arm head pressure BOOM HEAD PRESS 0.00 – 50.00
24 40501 Lift arm head pressure BOOM HEAD PRESS 0.00 – 5.00
25 40600 Calibration pressure CAL PRESS 0.00 – 50.00

26 40800 Load meter calculated weight MES LOAD 0.00 – 50.00
27 30802 Rotary switch setting state SW1, SW2, SW3 F, F, F
28 30904 DIP switch setting state SW5-1, SW5-2 ON/OFF, ON/OFF
32 40900 Input signal D_IN_0-7 D-IN--0------7 See attached table No.32-1
37 40925 Output signal D_OUT_0-3 D-OUT--0--3 See attached table No.37-1
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and
item name may be displayed on the machine monitor.
30 WA500-6R

Unit Remarks
(*4) (*5)
Only for optional setting of load meter
(Arm horizontal: Rated loading, high idle, lift
Depends on machine status. MPa
arm control lever full: Approx. 0.5 MPa {5.1 kg/
cm2})
0 MPa : 0.5 V
10 MPa: 1.3 V
V Only for optional setting of load meter
20 MPa: 2.1 V
50 MPa: 4.5 V
— MPa Not used.
Load weight (t) ton Only for optional setting of load meter
Status display Not used.
Status display
Status display
Status display
Status display
Status display
Status display
WA500-6R 31

Monitoring Input/Out- Description of ON/OFF switch
No. Display item
codes put signal (Display: when ON; 1, when OFF; 0)
D-IN-0 Head lamp Lighting of head lamp = ON (24 V)/OFF (OPEN)
D-IN-1 Starting motor ACC Starting switch Acc = ON (24 V)/OFF (OPEN)
D-IN-2 Starting switch C Starting switch START = ON (24 V)/OFF (OPEN)
D-IN-3 — —
Auto grease A D-IN-4 D-IN-5
32-1 40900 D-IN-4 (Applicable to a machine equipped
Operation OFF ON
with optional auto grease)
Failed OFF OFF
Auto grease B
Tank empty ON OFF
D-IN-5 (Applicable to a machine equipped
with optional auto grease) Failed ON ON
D-IN-6 — —
D-IN-7 — —
D-IN-8 — —
D-IN-9 — —
Load meter mode selector switch
(A/B)
D-IN-10 Pressing of switch = ON (24 V)/OFF (OPEN)
(Applicable to a machine equipped
with optional load meter)
Load meter mode selector switch
(+/–)
33-1 40901 D-IN-11 Pressing of switch = ON (24 V)/OFF (OPEN)
(Applicable to a machine equipped
with optional load meter)
Lighting of turn signal right lamp = ON (GND)/OFF
D-IN-12 Turn signal right
(OPEN)
Lighting of turn signal left lamp = ON (GND)/OFF
D-IN-13 Turn signal left
(OPEN)
D-IN-14 U switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-15 t switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-16 Brake oil pressure (front) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17 Brake oil pressure (rear) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-18 — —
D-IN-19 — —
34-1 40902 D-IN-20 Clogged air cleaner No clogging = ON (GND)/OFF (OPEN)

D-IN-21 — —
Parking brake emergency release
D-IN-22 Pressing of switch = ON (24 V)/OFF (OPEN)
switch
Load meter total weight display
D-IN-23 Pressing of switch = ON (GND)/OFF (OPEN)
selector switch
32 WA500-6R

Monitoring Input/Out- Description of ON/OFF switch
No. Display item
codes put signal (Display: when ON; 1, when OFF; 0)
D-IN-24 Transmission filter clogging No clogging = ON (GND)/OFF (OPEN)
D-IN-25 — —
Parking brake operation = ON (GND)/OFF
D-IN-26 Parking brake
(OPEN)
D-IN-27 Engine coolant level Normal coolant level = ON (GND)/OFF (OPEN)
35-1 40903 D-IN-28 — —

D-IN-29 Engine oil level Normal oil level = ON (GND)/OFF (OPEN)
Operation of emergency steering
motor (Applicable to a machine Emergency steering operation = ON (GND)/OFF
D-IN-30
equipped with the optional emer- (OPEN)
gency steering)
D-IN-31 — —
Load meter subtotal switch
(Load meter specifications)
Load meter cancel switch
(Load meter specifications)
D-IN-34 High beam (dimmer switch) High beam = ON (GND)/OFF (OPEN)
36-1 40904 D-IN-35 — —
D-IN-36 Service switch ON =ON(GND)/OFF(OPEN)
D-IN-37 > switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-38 < switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-39 — —
D-OUT-0 Alarm buzzer Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1 — —
37-1 40952
D-OUT-2 — —
D-OUT-3 — —
WA500-6R 33
TRANSMISSION [Transmission controller system]

(*1) (*2) (*3)
1 20201 Transmission controller ROM part number VERSION Arabic numerals
2 20223 Application version VERSION APP 20223
3 20224 Data version VERSION DATA 20224
4 41600 Selection of engine mode ENGINE MODE Arabic numerals
5 41400 Fan pump EPC current value (Command) FAN EPC DIR 0 – 1000
6 93400 Fan reverse switch input FAN REVERSE SW Arabic numerals
7 41501 Torque converter inlet oil temperature T/C IN OIL TEMP —

8 41502 Torque converter inlet oil temperature T/C IN OIL TEMP —
9 93500 Torque converter input shaft speed T/C SPEED:IN —
10 93501 Torque converter output shaft torque T/C TORQUE:OUT —
11 31200 Transmission input shaft speed T/M SPEED IN 0 – 32767
12 31400 Transmission output shaft speed T/M SPEED:OUT 0 – 32767
13 31404 Transmission output shaft speed 2 T/M SPEED:OUT2 —
14 41203 Transmission cut-off operation setting T/M CUT SET 0.00 – 5.00
15 41201 Transmission cut-off (left brake) pressure T/M CUT OFF P 0.00 – 5.00
16 41202 Transmission cut-off (left brake) pressure T/M CUT OFF P 0.00 – 5.00
17 93700 Torque converter speed ratio TC SPEED RATIO 0 – 100

18 93600 Transmission oil temperature T/M OIL TEMP 0 – 150
Transmission oil temperature sensor input volt-

19 93601 T/M OIL TEMP 0.00 – 5.00
age
20 92400 Modulation clutch oil pressure input MOD/C PRESS 0.00 – 50.00
21 92401 Modulation clutch oil pressure input voltage MOD/C PRESS 0.00 – 5.00
22 92500 Modulation clutch calorific value MOD/C Q 0 – 25.5
23 92501 Modulation clutch calorific rate MOD/C q 0 – 2.55
Throttle lock switch (press-up)
24 95500 THROT LOCK A Arabic numerals
(RPM set switch)
Throttle lock switch (pressed downward)
25 95501 THROT LOCK B Arabic numerals
(RPM set auto deceleration switch)
34 WA500-6R

Unit Remarks
(*4) (*5)
Depends on software part number Status display
Depends on software version Status display
Depends on software version Status display
0: Power mode
Status display
2: Economy mode
0 – 1000 [mA]
Engine speed below 500 rpm = 677 mA
During cranking (Terminal C operation) = 850 mA mA
During fan reverse switching = 850 mA
During fan reverse operation = 0 mA
1: ON (CLOSE)
Status display
0: OFF
— °C Not used in this machine.
— V Not used in this machine.
— rpm Not used in this machine.
— Nm Not used in this machine.
0 – 32767 [min-1] rpm
0 – 32767 [min-1]
0 km/h = 0 rpm
10 km/h = 788 rpm
rpm
20 km/h = 1376 rpm
30 km/h = 2063 rpm
40 km/h = 2751 rpm
— rpm Not used in this machine.
Cut-off set operation changes the displayed
0.00 – 5.00 [MPa] MPa
value.
As foot brake is released: 0.00 ± 0.1 MPa
0.00 – 5.00 [MPa] MPa Foot brake pressed: Brake pressing changes
the displayed value.
As foot brake is released: 1.00 ± 0.1 V
0.00 – 5.00 [V] MPa Foot brake pressed: Brake pressing changes
the displayed value.
0 – 100 [%] %
0 – 150 [°C] °C
0.00 – 5.00 [V]
4.72 V = 0°C
4.33 V = 30°C
V
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
— MPa Not used in this machine.
— 100 J/cm2 Not used in this machine.
2
— 0.1 kW/cm Not used in this machine.
0: PRM set switch OFF
Status display
1: PRM set switch ON
0: PRM set auto deceleration switch OFF
Status display
1: PRM set auto deceleration switch ON
WA500-6R 35

(*1) (*2) (*3)
26 95400 Throttle correction command output THROTTLE MOD –100 – 100
27 44200 Throttle opening upper limit output THROTTLE LIMIT UP 0 – 100.0
28 44201 Throttle opening lower limit output THROTTLE LIMIT LO 0 – 100.0
29 93801 Accelerator mode THROTTLE MODE Arabic numerals
30 94000 Traction setting input value TRACTION DIAL —

31 94001 Traction setting input voltage TRACTION DIAL —
32 95000 Lockup selector switch input signal LOCK UP SW Arabic numerals
33 31602 1st ECMV current value (Command) ECMV 1 DIR 0 – 1000

34 31603 2nd ECMV current value (Command) ECMV 2 DIR 0 – 1000
35 31604 3rd ECMV current value (Command) ECMV 3 DIR 0 – 1000
36 31605 4th ECMV current value (Command) ECMV 4 DIR 0 – 1000
37 31608 F (forward) ECMV current value (Command) ECMV F DIR 0 – 1000
38 31609 Lockup clutch ECMV current value (Command) ECMV LU DIR 0 – 1000
Modulation clutch ECMV current value
39 31640 ECMV MOD/C DIR —
(Command)
40 31606 R (reverse) ECMV current value (Command) ECMV R DIR 0 – 1000
ECSS (travel damper) solenoid valve current
41 93300 ECSS V DIR 0 – 1000
value (Command)
0 – 2.55
42 41802 1st fill time FILL TIME 1 (When fill is not
provided: 0)
0 – 2.55
43 41803 2nd fill time FILL TIME 2 (When fill is not
provided: 0)
0 – 2.55
44 41804 3rd fill time FILL TIME 3 (When fill is not
provided: 0)
0 – 2.55
45 41805 4th fill time FILL TIME 4 (When fill is not
provided: 0)
0 – 2.55
46 41808 F (forward) fill time FILL TIME F (When fill is not
provided: 0)
0 – 2.55
47 41806 R (reverse) fill time FILL TIME R (When fill is not
provided: 0)
49 40906 Input signal D_IN_8-15 D-IN--8-----15 See attached table No.49-1
50 40907 Input signal D_IN_16-23 D-IN-16-----23 See attached table No.50-1
53 40949 Output signal D_OUT_0-7 D-OUT-0------7 See attached table No.53-1
54 40950 Output signal D_OUT_8-15 D-OUT-8-----15 —
55 40951 Output signal D_OUT_16-23 D-OUT-16----23 —
56 94100 Clutch trigger initial learning flag TRIG FR1234 0/1 (ON/OFF)
36 WA500-6R

Unit Remarks
(*4) (*5)
–100 – 100 [%] %
0.0 – 100.0 [%] %
0.0 – 100.0 [%] %
Depends on accelerator pedal operation.
Accelerator pedal released = 0
Accelerator pedal partial pressing (release side) = 1 Status display
Accelerator pedal partial pressing (pressing side) = 2
Accelerator pedal full pressing = 3
— % Not used in this machine.
0: Lockup selector switch OFF
Status display
1: Lockup selector switch ON
0 – 1000 [mA] mA
0 – 1000 [mA] mA
0 – 1000 [mA] mA
0 – 1000 [mA] mA
0 – 1000 [mA] mA
0 – 1000 [mA] mA
— mA Not used in this machine.
0 – 1000 [mA] mA
0 – 1000 [mA] mA
0 – 2.55 [sec], When fill is not provided: 0 sec
Status display
Status display
Status display
Status display
Status display
Status display
Status display Not used in this machine.
0: ON
Status display
1: OFF
WA500-6R 37
model or option.
range.
38 WA500-6R
WA500-6R 39

Input/
Monitor- Description of ON/OFF switch
No. Output Display item
ing code (Display: when ON; 1, when OFF; 0)
signal
Engine mode selector switch
D-IN-0 Engine mode selector switch
(Power mode) = ON (GND)/OFF (OPEN)
Joystick shift-up switch = ON (GND)/OFF
D-IN-1 Joystick steering shift-up switch
(OPEN)
Joystick shift-down switch = ON (GND)/
D-IN-2 Joystick steering shift-down switch
OFF (OPEN)
Air conditioner compressor operation = ON
D-IN-3 Air conditioner compressor operation
48-1 40905 (GND)/OFF (OPEN)
D-IN-4 Shift mode L Shift mode Manual L H

D-IN-4 0 1 1
D-IN-5 Shift mode L D-IN-5 0 0 1
Joystick steering ON/OFF switch or right
Joystick steering ON/OFF switch or right FNR
D-IN-6 FNR ON/OFF switch
ON/OFF switch
= ON (24 V)/OFF (OPEN)
D-IN-7 Terminal C signal Starting switch = ON (24 V)/OFF (OPEN)
Pressing of switch = ON (GND)/OFF
D-IN-8 Transmission cut-off switch
(OPEN)
D-IN-9 Transmission cut-off set switch
(OPEN)
D-IN-10 Kick-down switch
(OPEN)
D-IN-11 Shift hold switch
49-1 40906 (OPEN)
D-IN-12 — —
D-IN-13 RPM set idle-up/down selector switch (idle-up)
(OPEN)
D-IN-14 RPM set idle-up/down switch (idle-down)
(OPEN)
Pressing left brake pedal = ON (GND)/OFF
D-IN-15 Throttle lock release left brake pedal switch
(OPEN)
• Gear shift lever 1st (1st speed)
D-IN-16 Gear shift lever 1st (1st speed)
• Gear shift lever 2nd (2nd speed)
D-IN-17 Gear shift lever 2nd (2nd speed)
• Gear shift lever 3rd (3rd speed)
D-IN-18 Gear shift lever 3rd (3rd speed)
• Gear shift lever 4th (4th speed)
D-IN-19 Gear shift lever 4th (4th speed)
50-1 40907
• FNR (directional) lever F (Forward)
D-IN-20 FNR (directional) lever F (Forward)
• FNR (directional) lever N (Neutral)
D-IN-21 FNR (directional) lever N (Neutral)
• FNR (directional) lever R (Reverse)
D-IN-22 FNR (directional) lever R (Reverse)
Parking brake ON (24 V) [Travel]
D-IN-23 Parking brake signal
OFF (OPEN) [Parking]
40 WA500-6R

Input/
Monitor- Description of ON/OFF switch
No. Output Display item
ing code (Display: when ON; 1, when OFF; 0)
signal
Joystick steering FNR (directional) switch F Joystick steering FNR (directional) switch F
D-IN-24 (forward) or right FNR (directional) switch F (forward) or right FNR (directional) switch F
(forward) (forward) = ON (GND)/OFF (OPEN)
ECMV fill switch F (forward) = ON (GND)/
D-IN-25 ECMV fill switch F (forward)
OFF (OPEN)
ECMV fill switch R (reverse)
D-IN-26 ECMV fill switch R (reverse)
= ON (GND)/OFF (OPEN)
ECMV fill switch 1st
D-IN-27 ECMV fill switch 1st
51-1 40908 ECMV fill switch 2nd
D-IN-28 ECMV fill switch 2nd
ECMV fill switch 3rd
D-IN-29 ECMV fill switch 3rd
ECMV fill switch 4th
D-IN-30 ECMV fill switch 4th
Joystick steering FNR (directional) switch
Joystick steering FNR (directional) switch R
R (reverse) or right FNR (directional)
D-IN-31 (reverse) or right FNR (directional) switch R
switch R (reverse) = ON (GND)/OFF
(reverse)
(OPEN)
Joystick steering FNR (directional) switch N Joystick steering FNR (directional) switch
D-IN-32 (neutral) or right FNR (directional) switch N N (neutral) or right FNR (directional) switch
(neutral) N (neutral) = ON (GND)/OFF (OPEN)
D-IN-33 — —
D-IN-34 — —
52-1 40942 D-IN-35 — —
D-IN-36 — —
D-IN-37 — —
D-IN-38 — —
D-IN-39 — —
D-OUT-0 — —
D-OUT-1 — —
D-OUT-2 — —
D-OUT-3 Fan reverse solenoid Output ON = ON (24 V)/OFF (OPEN)
53-1 40949
D-OUT-4 Fan neutral solenoid (if equipped) Output ON = ON (24 V)/OFF (OPEN)
D-OUT-5 Low temperature bypass solenoid (if equipped) Output ON = ON (24 V)/OFF (OPEN)
D-OUT-6 — —
D-OUT-7 — —
WA500-6R 41
WRK [Work equipment controller system]

(*1) (*2) (*3)
XXXXRYYY [3rd – 10th
digits of part No. are dis-
played]
1 20202 Work equipment controller software version VERSION
Example: When the
number is 7831-46-
R110 → “3146R110”
2 20225 Application version VERSION APP Arabic numerals
3 20226 Data version VERSION DATA Arabic numerals
4 94700 Loader pump pressure PUMP PRESS 0.00 – 50.00
5 94701 Loader pump pressure PUMP PRESS 0.00 – 5.00
6 94500 Loader pump EPC current (Command) PUMP EPC DIR 0 – 1000
7 94600 Pump delivery flow rate PUMP FLOW 0 – 264
8 06002 Lift arm angle BOOM ANG –180.0 – +180.0
9 06005 Lift arm angle BOOM ANG 0.00 – 5.00
10 94400 Frame angle FRAME ANGLE –180.0 – +180.0

0 – 256000
11 42100 Lift arm lever operation frequency BOOM LVR
(In a thousand of times)
12 42000 Lever potentiometer voltage lift arm 1 BOOM POT1 0.00 – 5.00
13 42001 Lever potentiometer voltage lift arm 2 BOOM POT2 0.00 – 5.00
0 – 256000
14 42101 Bucket lever operation frequency BUCKET LVR
15 42002 Lever potentiometer voltage bucket 1 BOOM POT1 0.00 – 5.00
16 42003 Lever potentiometer voltage bucket 2 BUCKET POT2 0.00 – 5.00
17 41900 Lift arm raise EPC current (Command) RAISE EPC DIR 0 – 1000
18 41901 Lift arm lower EPC current (Command) LOWER EPC DIR 0 – 1000
42 WA500-6R

Unit Remarks
(*4) (*5)
Depends on software part No. —
Depends on application version No. Status display

Depends on data version No. Status display
Work equipment neutral: 2.0 ± 2.0 MPa
MPa
Work equipment relieved: 34.0 ± 2.0 MPa
Work equipment neutral: 0.70 ± 0.2 V
V
Work equipment relieved: 3.22 ± 0.2 V
Low idle (800 rpm): 700 ± 30 mA
High idle (Min. 1,400 rpm): 200 ± 10 mA
mA
Work equipment relieved: 700 ± 10 mA
Engine stop (below 500 rpm): 900 ± 10 mA
Work equipment neutral: 170 CC/R
cc/r
Work equipment relieved: 23 ± 10 CC/R
STD lift arm
Degree (°)
Hi lift arm
STD lift arm
V
Hi lift arm
No relevant function in WA500-5 Degree (°)
Depends on lever operation frequency. —
Neutral 2.50 V ± 0.10 V

RAISE (Before detent) 3.89 V ± 0.25 V
RAISE (Detent position) 4.11 V ± 0.25 V V
LOWER (Before detent) 1.11 V ± 0.25 V
FLOAT (Detent position) 0.89 V ± 0.25 V
Neutral 2.50 V± 0.10 V
RAISE (Before detent) 1.11 V ± 0.25 V
RAISE (Detent position) 0.89 V ± 0.25 V V
LOWER (Before detent) 3.89 V ± 0.25 V
FLOAT (Detent position) 4.11 V ± 0.25 V
Neutral 2.50 V ± 0.10 V

TILT (Before detent) 3.89 V ± 0.25 V
V
TILT (Detent position) 4.11 V ± 0.25 V
Full dump 0.89 V ± 0.20 V
Neutral 2.50 V ± 0.10 V
TILT (Before detent) 1.11 V ± 0.25 V
V
TILT (Detent position) 0.89 V ± 0.25 V
Full dump 4.11 V ± 0.20 V
Neutral 0 ± 10 mA
mA
Max. 896 ± 10 mA
Neutral ± 10 mA
Before detent: 640 ± 10 mA mA
Float position: 1000 ± 10 mA
WA500-6R 43

(*1) (*2) (*3)
19 41902 Bucket tilt EPC current (Command) TILT EPC DIR 0 – 1000
20 41903 Bucket dump EPC current (Command) DUMP EPC DIR 0 – 1000
21 41908 AJSS EPC current (Command) AJSS EPC DIR —
22 41904 AJSS right EPC current (Command) J/S EPC DIR RH 0 – 1000
23 41905 AJSS left EPC current (Command) J/S EPC DIR LH 0 – 1000
24 42004 Lever potentiometer voltage AJSS 1 J/S POT1 0.00 – 5.00
25 42005 Lever potentiometer voltage AJSS 2 J/S POT2 0.00 – 5.00
3-spool valve 1, ECMV and current value

26 41906 3RD EPC1 DIR 0 – 1000
(Command)
3-spool valve 2, ECMV and current value
27 41907 3RD EPC2 DIR 0 – 1000
(Command)
0 – 256000
28 42102 3-spool valve lever operation frequency 3RD LVR
29 42006 Lever potentiometer voltage 3-spool valve 1 3RD POT1 0.00 – 5.00
30 42007 Lever potentiometer voltage 3-spool valve 2 3RD POT2 0.00 – 5.00
31 94300 AJSS lever operation angle AJSS LEVER —

32 94301 AJSS lever potentiometer voltage AJSS LEVER —
33 94401 AJSS frame potentiometer voltage FRAME ANGLE —
34 94800 AJSS steering deviation angle S/T DEFLECTION —
35 94900 Digging-in-progress flag WORK FLAG ON/OFF

37 40911 Input signal D_IN_8-15 D-IN--8-----15 See attached table No.37-1
40 40961 Input signal D_IN_32-39 D-IN-32-----39 —
41 40952 Output signal D_OUT_0-7 D-OUT-0------7 See attached table No.41-1
42 40953 Output signal D_OUT_8-15 D-OUT-8-----15 —
43 40954 Output signal D_OUT_16-23 D-OUT-16----23 See attached table No.43-1
44 WA500-6R

Unit Remarks
(*4) (*5)
Neutral 0 ± 10 mA
mA
Max. 930 ± 10 mA
Neutral 0 ± 10 mA
mA
Max. 848 ± 10 mA
— mA Not used in this machine.
Neutral 0 ± 10 mA
1 mA
Max. 850 ± 10 mA
Neutral 0 ± 10 mA
1 mA
Max. 850 ± 10 mA
Neutral 2.50 V ± 0.10 V
Full steering to right 1.34 V ± 0.25 V V
Full steering to left 3.66 V ± 0.25 V
Neutral 2.50 V ± 0.10 V
Full steering to right 1.34 V ± 0.25 V V
Full steering to left 3.66 V ± 0.25 V
Neutral 0 ± 10 mA
1 mA
Max. 960 ± 10 mA
Neutral 0 ± 10 mA
1 mA
Max. 960 ± 10 mA
Neutral: 2.50 V ± 0.10 V

Retract: 4.11 V ± 0.20 V 0.01 V
Extract: 0.89 V ± 0.20 V
Neutral: 2.50 V ± 0.10 V
Retract: 0.89 V ± 0.20 V 0.01 V
Extract: 4.11 V ± 0.20 V
— Degree (°) Not used in this machine.
— Degree (°) Not used in this machine.
Digging: ON
Status display
Others: OFF
Status display
Status display
Status display
Status display
Status display
Status display
model or option.
range.
WA500-6R 45

Monitoring Input/Out-
No. Display item Description of ON/OFF switch
codes put signal
Pressing of switch ON = ON (24 V)/OFF
D-IN-0 Semi-automatic digging lock mode switch
(OPEN)
D-IN-1 Semi-automatic digging loose mode switch
(OPEN)
D-IN-2 Joystick Hi/Lo selector switch
(OPEN)
36-1 40910
D-IN-3 — —
D-IN-4 — —
D-IN-5 — —
D-IN-6 — —
D-IN-7 — —
D-IN-8 Bucket full stroke proximity switch Bucket dump ON = ON (24 V)/OFF (OPEN)
Bucket horizontal ON = ON (24 V)/OFF
D-IN-9 Bucket tilt horizontal proximity switch
(OPEN)
Remote positioner bucket angle set switch Remote positioner bucket angle set switch
D-IN-10
(facing upward) (facing upward) = ON (GND)/OFF (OPEN)
37-1 40911 Remote positioner bucket angle set switch Remote positioner bucket angle set switch
D-IN-11
(facing downward) (facing upward) = ON (GND)/OFF (OPEN)
D-IN-12 — —
D-IN-13 — —
D-IN-14 — —
D-IN-15 — —
Work equipment neutral lock switch
D-IN-16 Work equipment neutral lock switch (Working position) ON = (24 V)/OFF
(OPEN)
D-IN-17 Starting motor C terminal signal Starting switch = ON (24 V)/OFF (OPEN)
D-IN-18 — —
38-1 40912 D-IN-19 — —
D-IN-20 — —
D-IN-21 — —
D-IN-22 — —
D-IN-23 — —
D-IN-24 — —
D-IN-25 — —
D-IN-26 — —
D-IN-27 — —
39-1 40913 Remote positioner raise/lower set switch Remote positioner raise/lower set switch
D-IN-28
(RAISE) (RAISE) = ON (GND)/OFF (OPEN)
Remote positioner raise/lower set switch Remote positioner raise/lower set switch
D-IN-29
(LOWER) (LOWER) = ON (GND)/OFF (OPEN)
D-IN-30 — —
D-IN-31 — —
46 WA500-6R

Monitoring Input/Out-
No. Display item Description of ON/OFF switch
codes put signal
D-OUT-0 Work equipment neutral lock solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1 Lift arm raise detent solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-2 Lift arm float detent solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-3 Bucket tilt detent solenoid Output ON = ON (24 V)/OFF (OPEN)
41-1 40952
D-OUT-4 — —
D-OUT-5 — —
D-OUT-6 — —
D-OUT-7 — —
D-OUT-16 — —
D-OUT-17 — —
D-OUT-18 Remote positioner top indicator ON Output ON = ON (24 V)/OFF (OPEN)
D-OUT-19 Remote positioner bottom indicator ON Output ON = ON (24 V)/OFF (OPEN)
43-1 40954
D-OUT-20 Safety relay operation Output ON = ON (24 V)/OFF (OPEN)
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —
WA500-6R 47
ENG [Engine controller system]

Monitoring Monitoring items Display item Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Status
1 20400 Hardware serial No. ECM S/N Arabic numerals
display
2 03200 Battery voltage POWER SUPPLY 0.0 – 480.0 V
3 01002 Engine speed ENG SPEED 0 – 4000 rpm
4 04104 Engine coolant temperature COOLANT TEMP –40 – 210 °C
Engine coolant temperature
5 04105 COOLANT TEMP 0.00 – 5.00 V
sensor voltage
6 37200 Engine oil pressure sensor ENG OIL PRESS –99.9 – 999.9 kPa
7 37201 Engine oil pressure sensor voltage ENG OIL PRESS 0.00 – 5.00 V
Not equipped on
8 42700 Engine oil temperature ENG OIL TEMP –40 – 210 °C WA500-6, always
displayed 100°C
Not equipped on
Engine oil temperature sensor
9 42702 ENG OIL TEMP 0.00 – 5.00 V WA500-6, always
voltage
displayed 0.00 V
10 36400 Common rail pressure RAIL PRESS 0 – 400 MPa
Common rail pressure sensor
11 36402 RAIL PRESS 0.00 – 5.00 V
voltage
12 37400 Atmospheric pressure AMBIENT PRESS –99.9 – 999.9 kPa
Atmospheric pressure sensor
13 37402 AMBIENT PRESS 0.00 – 5.00 V
voltage
Not equipped on
14 18400 Air intake temperature INTAKE TEMP –50 – 200 °C WA500-6, always
displayed 25°C
Not equipped on
Air intake temperature sensor
15 18401 INTAKE TEMP 0.00 – 5.00 V WA500-6, always
voltage
displayed 0.00 V
16 04204 Fuel temperature FUEL TEMP –40 – 210 °C
17 14201 Fuel temperature sensor voltage FUEL TEMP 0.00 – 5.00 V
18 18500 Boost temperature CHG TEMP –50 – 200 °C
19 18501 Boost temperature sensor voltage CHG TEMP 0.00 – 5.00 V
20 36500 Boost pressure CHG PRESS-A –99.9 – 999.9 kPa
21 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 – 5.00 V
Not equipped all
22 17900 EGR valve differential pressure EGR DIF PRESS –99.9 – 999.9 kPa models, always
displayed 0.0 kPa
Not equipped all
EGR valve differential pressure
23 17901 EGR DIF PRESS 0.00 – 5.00 V models, always
sensor voltage
displayed 0.00 V
24 18000 EGR valve inlet pressure EGR IN PRESS-A –99.9 – 999.9 kPa
EGR valve inlet pressure sensor
25 18002 EGR IN PRESS-A 0.00 – 5.00 V
voltage
26 18100 EGR valve position EGR VALVE POS 0.00 – 99.99 mm
27 18101 EGR valve position sensor voltage EGR VALVE POS 0.00 – 5.00 V
OUTPUT
28 18700 Engine output torque –24000 – 24000 Nm
TORQUE
29 36700 Equivalent torque TORQUE RATIO 0 – 100 %
FINAL
30 31706 Final accelerator position 0 – 100 %
THROTTLE
48 WA500-6R
ENG [Engine controller system]

Monitoring Monitoring items Display item Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
31 37300 Momentary fuel consumption FUEL RATE 0.0 – 999.9 l/h
Final injection volume command INJECT
32 18600 0 – 1000 mg
(in weight) COMMAND
Final injection timing command
33 36300 INJECT TIMING –180.0 – 180.0 CA
TFIN
34 31701 Position of accelerator pedal THROTTLE POS 0 – 100 %
35 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 – 5.00 V
36 18200 Bypass valve position BPS VALVE POS 0.00 – 99.99 mm
Bypass valve position sensor
37 18202 BPS VALVE POS 0.00 – 5.00 V
voltage
Status
38 18300 Idle validation signal IVS 1 ON/OFF
display
Status
39 18301 Idle validation signal IVS 2 ON/OFF
display
Engine controller internal
40 18900 ECM IN TEMP –40 – 210 °C
temperature
Final common rail pressure PRESS
41 36200 0 – 400 MPa
command PFIN COMMAND
PCV valve close timing
42 17201 PCV TIMING 180.0 – 180.0 CA
(BTDC standard)
Status
43 17500 Selection of engine mode POWER MODE 0–4
display
Incoming value is
Name of selected model displayed as is Status
44 00400 MACHINE ID (H)
(upper 8 digits) (Lower 8 digits of display
16 characters)
Incoming value is
Name of selected model (lower 8 displayed as is Status
45 00401 MACHINE ID (L)
digits) (Lower 8 digits of display
16 characters)
Incoming value is
Status
46 20216 Build version BUILD VER displayed as is
display
(8 characters)
Incoming value is
Status
47 20217 Calibration data version CAL VER displayed as is
display
(8 characters)
model or option.
range.
*5: An item that does not allow monitoring is indicated as “Not used” though its code and item name may be
displayed on the machine monitor.
WA500-6R 49
5. Cylinder cut-out function (CYLINDER CUT- 3) Selecting a cylinder to be reduced

OUT) Using [<] or [>] switch, select a cylinder to
The engine reduced-cylinder function denotes be reduced from No. 1 – No. 6 cylinders
setting the injector of a single cylinder or two or and then settle the selected cylinder using
more cylinders to electrically no injection state [U] switch.
and turns on the operation on reduced-cylinder a The cylinder to be reduced is selectable
condition. When any cylinders of the engine while the engine is run.
were suspected for abnormal output (combus- a Any number of cylinders can be reduced –
tion), this approach is used to single out the a single unit or two or more units.
failed cylinder. q [>] switch: Advances the cursor right-
1) Selecting menu ward
Display the CYLINDER CUT-OUT screen q [<] switch: Advances the cursor left-
from the menu screen of Service mode. ward
q [U] switch: Settles the cylinder to be
reduced (the cursor starts flashing
after the settlement)
q [t] switch: Restores the CYLINDER
CUT-OUT screen
2) Displaying sub menu

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

issued from the engine controller to the
cylinder to be reduced, the bottom of the
stopped cylinder number turns to black.
The cylinder No. and engine speed (N):

rpm are displayed on the upper line and
the specified injection rate (Q): mg/stroke
is displayed on the lower line.
50 WA500-6R
Judgment of abnormal cylinder 1) Selecting menu

q When a normal cylinder is cut out Display the NO INJECTION screen from
The value (Q) increases and that of (N) is menu screen of Service mode.
decreases by the quantity which is not
injected (They do not change, however, in
the constant engine speed control mode).
The quantity of change of (Q) and (N)
depends on the load condition.
q When an abnormal cylinder is cut out
The values of (Q) and (N) do not change
because the fuel has not been injected in
the cut-out cylinder since before it was cut
out.
4) Cancelling a reduced cylinder

Using [<] or [>] switch, select the currently
stopped cylinder and then press [U]
switch to cancel the reduced-cylinder
2) Pressing [U] switch sets up the no injec-
command from the engine controller. The
tion cranking.
black display will disappear.
a If the starting switch is turned to the
START position while this screen is dis-
played, no injection cranking starts.
a If this screen does not appear as [U]
switch is hit, a communication error should
be suspected.
6. No injection cranking function (NO INJEC-

TION)
The machine monitor is equipped with the
function capable of lubricating the engine
through no injection cranking. When a machine
has been stored for a long time, this function is
a If the no injection cranking is selected as
used to lubricate the engine prior to its restart
the engine is running, the engine stop
in order to prevent its wear or damages out of
instruction screen will appear.
oil.
a In such case, stop the engine once and
The no injection cranking must be set up while
then do the set up again.
the engine is stopped.
WA500-6R 51
SEN02929-02

© 2010 KOMATSU
All Rights Reserved
52
SEN02930-04
WA500-6R

WA500-6R 60001 and up

Special functions of machine monitor (EMMS) ............................................................................................... 2
Pm clinic inspection table.............................................................................................................................. 40
WA500-6R 1
Special functions of machine 7-1. Adjustment of transmission ECMV current

monitor (EMMS) 1 7-1-1. Preparations for transmission ECMV current
adjustment
7. Adjustment function (TUNING) 1) Display the REAL-TIME MONITOR from
The machine monitor implements initial setting the menu screen of Service mode.
after disassembly or replacement of the trans-
mission, or after replacement or addition of
sensor and EPC valve or controller. Through
the initial setting, the machine monitor corrects
and adjusts the installation error or manufac-
turing variations of individual parts.
a Adjustment function
No. Adjustment item

7-1 Adjustment of transmission ECMV current
7-2 Setting of transmission initial learning
Adjustment of transmission L-mode shift point
7-3
function
2) Press [U] switch to display the sub menu
Adjustment of lift arm angle sensor (Raise) and then select TRANSMISSION using [<]
7-4
(For EPC lever) function or [>] switch. (TRANSMISSION screen)
Adjustment of lift arm raise lever position just
7-5
before detent and variations in the dead zone
Adjustment of lift arm lower (float) lever and varia-
7-6
tions in the dead zone
Adjustment of bucket tilt lever position just before
7-7
detent and variations in the dead zone
7-8 Adjustment of bucket dump EPC starting current
Adjustment of 3-spool valve EPC cylinder extrac-
7-9 tion lever and variations in the dead zone of EPC
(*1)
Adjustment of the 3-spool valve EPC cylinder
7-10 retraction lever and variations in the dead zone of
EPC (*1)
Adjustment of joystick steering right lever and vari-
7-11
ations at EPC starting point (*1)
Adjustment of joystick steering left lever and varia-
7-12
tions at EPC starting point (*1)
7-13 Modification of lift arm lever pattern
7-14 Modification of bucket lever pattern
Adjustment of lift arm Raise/Lower stop modula-
7-15
tion
Adjustment of pump cut-off pressure in lift arm
7-16
raise
Adjustment of lift arm angle sensor (raise)
7-17
(Machine with load meter)
Adjustment of lift arm angle sensor (lower)
7-18
Modification of AJSS oil pressure command table
7-19
pattern (*1)
Adjustment of maximum travel speed limit (Lockup
7-20
clutch specification)
(*1): This item is not used.
2 WA500-6R
3) Press [U] switch to settle the real-time 7-1-2. Conformation of transmission oil temperature
monitoring of the transmission controller. control
a As the selection is settled, the application 1) Start the engine, press the brake pedal
program version of the transmission con- fully and then release the parking brake.
troller will be displayed. 2) Set the transmission shift mode to “Man-
q [20223] : ID number of display item ual”; set the FNR (directional) lever, joy-
q [ ]: Display of data (Program stick steering FNR (directional) switch or
version) right FNR (directional) switch to “F (for-
ward)”; and shift lever or switch to “4th”.
3) Make sure from “7-1-1 Preparations for
transmission ECMV current adjustment”
that the transmission controlled oil tem-
perature is 70 – 80°C. If it is out of the
range, stall the torque converter and
adjust the temperature to 70 – 80°C.
4) Return the FNR (directional) lever, joystick
steering FNR (directional) switch, or right
FNR (directional) to “N (neutral)” and
maintain it in that position. After 3 minutes,
make sure the oil temperature is still in the
70 – 80°C range.
5) Let the oil pervade in the transmission by
operating the FNR (directional) lever or
4) Using [<] or [>] switch, move the cursor to
joystick steering FNR (directional) switch,
the T/M OIL TEMP screen.
right FNR (directional) switch, or gear shift
q [93600] : ID number of transmission
lever or switch in the following table.
control oil temperature
q [ ]: Display of transmission Operating
control oil temperature 1 2 3 4
order
Gear speed N2 F2 F1 F2
Min. Min. Min. Min.
Holding time
2 sec. 2 sec. 2 sec. 2 sec.
Operating
5 6 7 8
order
Gear speed F3 F4 F3 F2
Min. Min. Min. Min.
Holding time
2 sec. 2 sec. 2 sec. 2 sec.
Operating
9 10 11
order
Gear speed N2 R2 N2
Min. Min. Min.
Holding time
2 sec. 2 sec. 2 sec.
a When executing the operation, the engine

shall be set to low idle, manual switch to
ON and lockup switch to OFF.
a Make sure the machine is normal (failure
is not detected).
a When stalling the torque converter, use
care it may not be overheated.
WA500-6R 3
7-1-3. Adjustment of transmission ECMV current 5) Using [<] or [>] switch from the sub menu,
a Targets of correction are 6 types – F (forward), select 02: ECMV TUNING.
R (reverse), 1st, 2nd, 3rd and 4th. As the
engine is started, correction of all of above
clutches is started automatically.
a Since the learning operation requires the spec-
ified oil temperature, the oil temperature must
be adjusted to 70 – 80°C range.
1) Turn on the starting switch (engine is not
started) and then display T/M OIL TEMP
referencing “7-1-1 Preparations for trans-
mission ECMV current adjustment”.
2) Make sure that the transmission controlled
oil temperature is in the 70 – 80°C range
when the engine is set to low idle; acceler-
ator pedal to OFF; FNR (directional) lever,
joystick steering FNR (directional) switch,
6) Press U switch to settle the adjustment
or right FNR (directional) switch to “N
item.
(neutral)”; and parking brake to ON.
7) Using [U] switch, select AUTO from the
3) Display the TUNING from the menu
automatic correction (AUTO) and manual
screen of Service mode.
correction (MANUAL) selection screen to
settle the automatic correction.
4) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.
a Selecting ECMV TUNING AUTO displays
IP in the character display, automatically
starting transmission ECMV current
adjustment.
4 WA500-6R
Operating
1 2 3 4
order
IP “IP F-1” “IP F-2” “IP F-3” “IP F-4”
ECMV/ F/2nd F/3rd F/4th
F/1st time
frequency time time time
Operating
5 6 7 8
order
IP “IP R-1” “IP R-2” “IP R-3” “IP R-4”
ECMV/ R/1st R/2nd R/3rd R/4th
frequency time time time time
Operating
9 10 11 12
order
IP “IP 1-1” “IP 1-2” “IP 1-3” “IP 1-4” a Codes for abnormal end
ECMV/ 1st/1st 1st/2nd 1st/3rd 1st/4th Reason CODE
frequency time time time time
Deviation from correction condition 1
Operating Absence of fill 2
13 14 15 16
order In excess of correction value 3
IP “IP 2-1” “IP 2-2” “IP 2-3” “IP 2-4”
ECMV/ 2nd/1st 2nd/2nd 2nd/3rd 2nd/4th a If abnormal end code “1” (NG1: Deviation
frequency time time time time from correction condition) was displayed,
set the condition again referencing “7-1-1
Operating Preparations for transmission ECMV cur-
17 18 19 20
order rent adjustment” and repeat the correc-
IP “IP 3-1” “IP 3-2” “IP 3-3” “IP 3-4” tion.
ECMV/ 3rd/1st 3rd/2nd 3rd/3rd 3rd/4th a If abnormal end code “2” (NG2: Absence
frequency time time time time of fill) was displayed, implement trouble-
shooting of the failure codes 15STLH and
Operating DXHTKA. If the state is normal, repeat the
21 22 23 24
order operation starting from “7-1-1 Prepara-
IP “IP 4-1” “IP 4-2” “IP 4-3” “IP 4-4” tions for transmission ECMV current
ECMV/ 4th/1st 4th/2nd 4th/3rd 4th/4th adjustment” and repeat the correction.
frequency time time time time (The value of T depends on the applica-
ble gear speed.)
8) As the correction is normally completed, a If the abnormal end code “3” (NG3: In
OK is displayed in the character display. excess of correction value) was displayed,
execute the troubleshooting of failure
code 15STL1. Then after making sure the
condition is normal, implement “7-1-1
Preparations for transmission ECMV cur-
rent adjustment” again. (The value of T
depends on the applicable gear speed.)
9) As the operation ended normally, turn the
starting switch off and the corrected value
will be stored on the transmission control-
ler after 3 seconds.
a When it is required to turn on the starting
switch immediately after the adjustment,
maintain the starting switch, just in case,
at off position for 10 seconds minimum
and then turn it on.
a If the correction is not normally ended, the
code for abnormal end will be indicated. (Fol-
lowing shows an example of the operation in
which the 1st time correction of the 3rd position
has ended abnormally).
WA500-6R 5
7-2. Setting of transmission initial learning 5) Press [U] switch to settle the adjustment
When initializing all the past initial trigger learn- item. As the item is settled, the initial
ing data stored on the transmission controller, learning reset screen appears.
employ the following procedure. a If the initial learning is not done, INITIAL
7-2-1. Reset of initial learning STATUS will be displayed.
1) Turn on the starting switch. (Engine does
not start)
2) Set the FNR (directional) lever, joystick
steering FNR (directional) switch, or right
FNR (directional) switch to “N (neutral)”.
3) Display the TUNING screen from the
menu screen of Service mode.
a When the initial learning is completed,

TUNED will be displayed.

1] When TUNED is displayed, press [U]

switch to display the initial learning
reset screen.
2] Press [<] or [>] switch from the initial
learning reset screen to move the cur-
sor to YES position and then press
[t] switch to reset the initial learning.
3] When suspending the reset opera-
tion, select NO from above 2] or press
[t] switch on TUNED screen.
6 WA500-6R
7-2-2. Preparations for transmission initial learning 4) Using [U] switch, settle 2 items display of
1) Display the REAL-TIME MONITOR from the transmission control oil temperature
the menu screen of Service mode. and the trigger learning display.
a Content of the trigger learning is displayed
for each of F, R, 1st, 2nd, 3rd and 4th
clutch in the figure.
q 0: Learning not done yet
q 1: Learning completed
2) Press [U] switch to display the sub menu,

select 2 ITEMS using [<] or [>] switch and
then settle the selection using [U] switch.
(SEL ITEMS 1,2 screen)
7-2-3. Implementation of transmission initial learn-

ing
a Before starting the transmission initial learning,
be sure to implement “7-1 Adjustment of trans-
mission ECMV current” and “7-2-1 Reset of ini-
tial learning”. Then start the initial learning
a Implement the gearshift operation using actual
travel, bench travel or while pressing the wheel
brake.
k When actual travel is employed for the
operation, be sure to choose a spacious
field while paying reasonable care to the
environment.
3) From the SEL ITEMS 1, 2 screen, enter ID
a When executing the operation, the engine shall
number 93600 of the transmission control
be set to low idle, manual switch to ON and
oil temperature and ID number 94100 for
lockup switch to OFF.
displaying the trigger learning.
1) Start the engine, press the brake pedal
a Referring to “4-5. Setting 2 items
fully and then release the parking brake.
simultaneous monitoring”.
2) Set the transmission shift mode to “Man-
ual”; set the FNR (directional) lever, joy-
stick steering FNR (directional) switch or
right FNR (directional) switch to “F (for-
ward)”; and shift lever or switch to “4th”.
3) Make sure from “7-2-2 Preparations for
transmission initial learning” that the trans-
mission control oil temperature is 70 –
80°C. If it is out of the range, stall the
torque converter and adjust the tempera-
ture to 70 – 80°C. (If the initial learning is
performed while the oil temperature is out
of the specified range, time lags and gear
shift shocks can result).
WA500-6R 7
4) Perform the initial learning by operating 7-3. Adjustment of transmission L mode shift
the FNR (directional) lever, joystick steer- point function
ing FNR (directional) switch, right FNR a This function is used for modifying the shift
(directional) switch, or gear shift lever or point when the shift mode switch is at L posi-
switch in the following manner. tion by adding a correction amount.
a The factory default setting of the correction
Operating amount shall be 0.
order
1 2 3 4 a The shift point depends on the engine mode.
When this function is used, however, the same
Gear
N2 F2 F1 F2 correction value is applied independent of the
speed
engine mode.
Holding Min. 6 Min. 6 Min. 6 Min. 4
a Some of the shift points being adjusted with
time sec. sec. sec. sec.
the shift point adjustment function may not
Operating include the following shift patterns.
5 6 7 8
order
Gear q The shift point that is used when the hunt-
F3 F4 F3 F2 ing prevention function is turned on.
speed
q The shift down point that is used when the
Holding Min. 4 Min. 4 Min. 4 Min. 4
accelerator is set to idle.
time sec. sec. sec. sec.
a After a shift point adjustment is done, confirma-
Operating tion on the machine must be done.
9 10 11
order
Gear 7-3-1. Clearing an adjusted shift point
N2 R2 N2 1) Display the TUNING screen from the
speed
Holding Min. 4 Min. 4 Min. 4
time sec. sec. sec.
a Hold the gear shift lever in each gear

speed for more than the specified time.
a If the gear shift lever is operated before
the specified time is reached, the initial
learning is not completed (TUNED is not
displayed).
7-2-4. Conformation of completion of transmission

initial learning
1) Referencing “7-2-2 Preparations for trans-
mission initial learning”, make sure 111111
is marked on ID number 94100, indicating
that the initial learning is completed. 2) Hold down [U] switch for 5 seconds mini-
2) Press [t] switch to end confirmation of the mum to display 01: TM TRIGGER screen.
initial learning.
8 WA500-6R
3) Using [<] or [>] switch, select 04: SHIFT <Gear shift pattern change procedure>
rpm screen from the sub menu. a As an example of a gear shift pattern change,
following describes the procedure for changing
the gear shift travel speed pattern from F2T/C
to F3T/C. (The same applies to other gear shift
patterns, too.)
1) Select 04: SHIFT rpm screen using [U]
switch and then select 01: F2T/C → F3T/C
using [<] or [>] switch.
4) Press [U] switch to settle the selection.

a As the selection is settled, 0: ALL
CLEAR will be displayed in the lower
space.
5) Press [U] switch to settle ALL CLEAR.
a As all the store values are deleted,
the set values are reset to the default
values and the screen returns to the
shift point adjustment items. 2) Press [U] switch to settle the selection.
a If [t] switch is pressed in place of [U] a As the selection is settled, the Shift
switch, the stored value is not cleared point adjusting value input screen will
and the screen returns to the adjust- appear.
ment items. a This screen displays the currently
entered shift point adjusting value.
7-3-2. Adjusting a shift point a Adjusting value input screen when
a This operation allows changing a gear shift Adjusting value = 0
travel speed when L auto-shift m ode is
selected.
a Gear shift patterns are changed as shown below.
No. Gear shift pattern to be changed

0 ALL CLEAR
1 F2T/C → F3T/C
2 F3 T/C → F4 T/C
3 F4T/C → F3T/C
4 F3 T/C → F2 T/C
5 F3L/U ON
6 F3L/U OFF
7 F4L/U ON 3) Press [<] or [>] switch to select a desired
8 F4L/U OFF adjusting value.
• T/C: Torque converter travel a When adjusting a shift point, 50 rpm
• L/U: Lockup travel of the transmission output shaft
(only for lockup specification) speed is used as a unit.
a Adjusting the transmission output shaft
speed by 50 rpm changes the travel
speed by approximately 0.759 km/h.
q Selecting +50 rpm increases the
q Selecting –50 rpm decreases the
WA500-6R 9
4) After selecting a desired setting data, 3) Using [<] or [>] switch, move the cursor to
press [t] switch to end the setup proce- item of 05: RAISE ANGLE.
dure.

7-4. Adjustment of lift arm angle sensor (Raise) a As the selection is settled, the RAISE
(for EPC lever) function ANGLE screen will be displayed.
Following procedure is employed for adjusting
lift arm angle of the work equipment.
5) Press [U] switch while the lift arm being

raised to the upper limit (cylinder stroke
end).
6) Two times of buzzer beep notify comple-
2) Hold down [U] switch for 5 seconds mini- tion of the setting.
mum to display 01: TM TRIGGER screen. 7) 1 second-long beep indicates that the set
lift arm angle voltage is not conforming to
the specified value. In this case, adjust-
ment does not start.
8) Press [t] switch to end the adjustment
mode.
a If [t] switch is pressed while the calibra-
tion is continued, the calibration currently
taking place will be stopped even if it is not
completed.
9) When the adjustment did not end suc-
cessfully, check the lift arm angle sensor
voltage from the real time monitor.
10) Adjust the lift arm angle sensor mounting
position so that the voltage displayed on
the real time monitor may fall within the
following range and then implement the
sensor adjustment again.
10 WA500-6R
a Lift arm length by lift arm specification 3) Using [<] or [>] switch, move the cursor to
item of 06: RAISE EPC.
Lift arm Voltage
Lift arm position
specification range
A Upper limit position 3.80 ± 0.3 V
(Stroke end of raised
B cylinder) 3.87 ± 0.3 V
a Lift arm length by machine model
Machine model A B
WA600-6 3850 mm 3990 mm
WA500-6 3250 mm 3636 mm
7-5. Adjustment of lift arm raise lever position

just before detent and variations in the
dead zone 4) Raise the lift arm EPC lever to a position
7-5-1. Adjusting variation correcting calibration of just before the raise detent position and
lift arm raise lever position just before detent maintain the lever at this position.
a Carry out this adjustment when the electric a Take care so that the raise detent opera-
(EPC) work equipment lever or the work equip- tion will not start.
ment controller was removed or replaced. 5) Pressing [U] switch turns on reading of
a Before starting the adjustment, lower the lift lever voltage and then stores the read
arm to the ground and stop the engine. voltage replacing the currently stored
1) Display the TUNING screen from the standard value.
a The setting is complete as 06: RAISE

2) Hold down [U] switch for 5 seconds mini- EPC screen was restored succeeding to
mum to display 01: TM TRIGGER screen. two times of buzzer beep.
a If the lever output voltage at this point is
below the standard value (off the design
range), pressing [U] switch sounds the
buzzer for 1 second and the screen
remains unchanged as U = SET like
shown in the above figure. In this case,
the adjustment is cancelled and 06:
RAISE EPC screen will be restored.
a If [t] switch is pressed at this point, cor-
rection of variations in the work equipment
EPC lever detent position is stopped even
if it is not completed.
WA500-6R 11
7-5-2. Adjusting lift arm raise EPC starting current 4) Lower the lift arm by dumping the bucket
a Start the engine prior to the setup opera- and then lift the front wheel.
tion. 5) Start raising the lift arm gradually while
1) Display the TUNING screen from the setting the engine to high idle (the
menu screen of Service mode. machine body is lowered).
6) Return the lever through fine operation. As
the lift arm is stopped, maintain the lever
at that position (front wheel is floated).
7) Pressing [U] switch turns on reading of
the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.

8) The setting is complete as 06: RAISE

EPC screen was restored succeeding to
two times of buzzer beep.
a If [U] switch is pressed when the lever is
at neutral, the adjusted value is cleared. In
this case, 06: RAISE EPC screen will be
restored succeeding to 2 times of buzzer
beep.

item of 06: RAISE EPC.
12 WA500-6R
7-6. Adjustment of lift arm lower (float) lever 3) Using [<] or [>] switch, move the cursor to
and variations in the dead zone item of 07: LOWER EPC.
7-6-1. Adjusting variation correcting calibration of
lift arm lower (float) EPC lever
a Carry out this adjustment when the electric
(EPC) work equipment lever or the work equip-
ment controller was removed or replaced.
a Before starting the adjustment, lower the lift
arm to the ground and stop the engine.
4) Stop the lift arm EPC lever in a position

just before the float detent position and
maintain the lever at this position.
a Take care so that float detent operation
may not turn on.
lever voltage and then stores the read
voltage replacing the currently stored
standard value.
a The setting is complete as 07: LOWER

EPC screen was restored after 2 times of
buzzer beep.
a If the lever output voltage at this point is
below the standard value (off the design
the adjustment is cancelled and 07:
LOWER EPC screen will be restored.
WA500-6R 13
7-6-2. Adjusting lift arm lower EPC starting current 4) Set the lift arm roughly horizontal without
a Start the engine prior to the setup opera- applying any load.
tion. 5) Start lowering the lift arm gradually while
1) Display the TUNING screen from the maintaining the engine at high idle.
menu screen of Service mode. 6) Return the lever through fine operation. As
the lift arm is stopped, maintain the lever
at that position.

8) The setting is complete as 07: LOWER

EPC screen was restored after 2 times of
buzzer beep.
this case, 07: LOWER EPC screen will be
restored after 2 times of buzzer beep.

item of 07: LOWER EPC.
14 WA500-6R
7-7. Adjustment of bucket tilt lever position just 4) Stop the bucket EPC tilt lever in a position
before detent and variations in the dead just before the tilt detent notch position
zone and maintain the lever at this position.
7-7-1. Adjusting variation correcting calibration of a Take care so that the tilt detent operation
bucket tilt lever position just before detent may not be turned on.
a Carry out this adjustment when the electric 5) Pressing [U] switch turns on reading of
(EPC) work equipment lever or the work equip- lever voltage and then stores the read
ment controller was removed or replaced. voltage replacing the currently stored
a Before starting the adjustment, lower the lift standard value.
arm to the ground and stop the engine.
a The setting is complete as 08: TILT EPC

screen was restored after 2 times of
buzzer beep.
2) Hold down [U] switch for 5 seconds mini- a If the lever output voltage at this point is
mum to display 01: TM TRIGGER screen. below the standard value (off the design
the adjustment is cancelled and 08: TILT
EPC screen will be restored.

item of 08: TILT EPC.
WA500-6R 15
7-7-2. Adjusting bucket tilt EPC starting current 4) Lower the lift arm by dumping the bucket
a Start the engine prior to the setup opera- and then lift the front wheel.
tion. 5) Start lowering the bucket gradually while
1) Display the TUNING screen from the maintaining the engine at high idle (the
menu screen of Service mode. machine body is lowered).
6) Return the lever through fine operation. As
the bucket is stopped, maintain the lever
at that position.

8) The setting is complete as 08: TILT EPC

buzzer beep.
this case, 08: TILT EPC screen will be

item of 08: TILT EPC.
16 WA500-6R
7-8. Adjustment of bucket dump EPC starting 4) Set the bucket roughly horizontal without
current applying any load.
a Start the engine prior to the setup opera- 5) Start dumping the bucket gradually while
tion. maintaining the engine at high idle.
1) Display the TUNING screen from the 6) Return the lever through fine operation. As
menu screen of Service mode. the bucket is stopped, maintain the lever
at that position.

8) The setting is complete as 09: DUMP EPC

buzzer beep.
this case, 09: DUMP EPC screen will be
7-9. Adjustment of 3-spool valve EPC cylinder

extraction lever and variations in the dead
zone of EPC
a This item is not used.
item of 09: DUMP EPC.
7-10. Adjustment of 3-spool valve EPC cylinder
retraction lever and variations in the dead
zone of EPC
7-11. Adjustment of joystick steering right lever

and variations at EPC starting point
7-12. Adjustment of joystick steering left lever

and variations at EPC starting point
WA500-6R 17
7-13. Modification of lift arm lever pattern

a This function is intended for modifying the fine-controllability and response of the lift arm by changing
the data on EPC output current to the lift arm lever stroke.
a Characteristics of tables 1 – 5 are summarized as shown in the table below. (Factory-set table: 3)
a Table No. and function

Table
Function General
No.
• In the lowering operation, the lift arm is lowered at approximately 70% of speed of the float-
Fine control
1 ing speed. (Floating speed remains the same)
priority
• In the raising operation, speed change becomes more drastic as the stroke grows bigger.
• In the lowering operation, the lift arm is lowered at approximately 85% of speed of the float-
Fine control
2 ing speed. (Floating speed remains the same)
priority
• In the raising operation, controllability at fewer strokes is enhanced.
• This table allows compatibility between controllability and response in both the raise and
3 Standard
lower operations.
Response
4 • Fewer and faster lever strokes enhance the response.
priority
• Response is further improved because of the lever strokes fewer and faster than that of No. 4.
Response
5 • This table allows a greater speed change at fewer strokes than others. Thus, if reasonable
priority
care is not exercised, substantial shocks can result at stopping.
a Normally, change to tables No. 2 to No. 4 is made. When selecting No. 1 or No. 5 table, therefore, thor-
ough preliminary performance check and operator evaluation are required.
a The maximum lowering speed is not available from the data of tables No. 1 and No. 2. Thus, when mea-
suring the lift arm lowering speed, tables No. 3 – No.5 must be used.
18 WA500-6R
1) Display the TUNING screen from the 4) Press [U] switch to settle the selection.
menu screen of Service mode. a As the selection is settled, the lift arm
lever table adjustment screen will be dis-
played.

5) Select a desired table from No. 1 – No. 5
by use of [<] or [>] switch.
6) Press [t] switch to settle the adjustment.

item of 14: BOOM TABLE.
WA500-6R 19
7-14. Modification of bucket lever pattern

a This function is intended for modifying the fine controllability, response and shock dump of the bucket by
changing the data on EPC output current to the bucket lever stroke.
a Characteristics of tables 1 – 3 are summarized as shown in the table below. (Factory-set table: 2)
a Table No. and function

Table
Function General
No.
Fine control
1 • In the dump and tilt operation, controllability at fewer strokes is enhanced.
priority
• This table allows compatibility between controllability and response in both the dump and tilt
2 Standard
operations.
• Fewer and faster lever strokes enhance the response.
Response
3 • This table makes it easier to dumping load by swinging the bucket as well as shock dump
priority
and leveling of load at the tilt end.
1) Display the TUNING screen from the 2) Hold down [U] switch for 5 seconds mini-
menu screen of Service mode. mum to display 01: TM TRIGGER screen.
20 WA500-6R
3) Using [<] or [>] switch, move the cursor to 7-15. Adjustment of lift arm Raise/Lower stop
item of 15: BUCKET TBL. modulation
a When the lift arm lever is operated for sudden
stop, this function modifies the speed reduction
rate of the stop modulation, which is prepared
for alleviating shocks resulting from stopping,
by applying the stop modulation to EPC output
current.
a The modulation used for an automatic stop
with the remote positioner or due to kickout
does not depend on this data.
a Before starting a modification of the modula-
tion by use of this function, “7-13 Adjustment of
lift arm lever pattern” and operator's evaluation
must be done first.
a The stop modulation function acts the same
way in both the raise and lower directions.
a The data at delivery is set to 100% of the stan-
a As the selection is settled, the bucket
dard.
lever adjustment screen will be displayed.
Modulation
State Remarks
quantity
The stop modulation
Stopping shocks can
is not activated. The
result if the operator
0% lift arm is stopped
does not pay reason-
without delaying to
able care.
the lever stroke.
It allows compatibility
between delay in
100% —
response at stop and
stopping shocks
The lift arm overruns
It alleviates stopping the target stop posi-
shocks that can result tion because its stop-
200%
from operator's sud- ping is delayed even
5) Select a desired table from No. 1 – No. 3 den stop operation. when the lever is set
by use of [<] or [>] switch. at neutral.

WA500-6R 21
2) Hold down [U] switch for 5 seconds mini- 7-16. Adjustment of pump cut-off pressure in lift
mum to display 01: TM TRIGGER screen. arm raise
a This function modifies matching of the travel
speed and work equipment speed at dump
approach and hopper charge by changing the
condition of the lift arm bottom pressure, which
is used as a pump flow rate restricting condi-
tion when lifting given load.
a The following lists the pump flow rate restrict-
ing conditions applicable to load lifting opera-
tion.
If the lift arm is operated under the following
initial conditions, its speed is restricted to
approximately 70% and the remaining torque
is used for the travel.
q Lift arm angle > 0° (Horizontal)
q Bucket tilt end detecting proximity switch
signal = Present (Tilt end detection avail-
item of 16: LOWER STOP.
able)
q Lift arm bottom pressure > 20 MPa
a Modifying the lift arm bottom pressure changes
the matching as shown in the table.
q The following data shows, when the
machine is loaded, the time required for
the lift arm to reach the lift arm top when
the raise operation was started simulta-
neously with start of the machine and the
travel distance at that time.
q Decreasing the currently set pressure acti-
vates the cut-off earlier, thereby lengthen-
ing the lift arm rising time as well as
extending the travel distance.
Lift arm F1 F2
4) Press [U] switch to settle the selection. bottom
a As the selection is settled, the LOWER Working pressure
STOP screen will appear. mode during ris- Distance Time Distance Time
ing (MPa (m) (sec.) (m) (sec.)
5) Select a desired table from 0, 100 and 200
by use of [<] or [>] switch. {kg/cm})
6) Press [t] switch to settle the adjustment. 10 {102] 16.5 11 25.1 11.2
Economy 20 {204] 15.5 10.7 24.7 10.7
25 {255] 15 10.2 24.5 10.6
10 {102] 17.8 10.7 26.7 11.1
Power 20 {204] 16.3 10.3 24.4 10.5
25 {255] 15.3 9.8 24.2 10.2
a The pressure at delivery is 20 MPa {204 kg/cm2}.

a Modifying the set value changes the lift arm ris-
ing time.
a When measuring the lift arm rising time for
troubleshooting purpose, be sure to return the
current setting to (20 MPa {204 kg/cm2}).
22 WA500-6R
1) Display the TUNING screen from the 4) Press [U] switch to settle the selection.
menu screen of Service mode. a As the selection is settled, the pump cutoff
pressure adjustment screen will be dis-
played.
5) Select a desired pressure in the range of 5
– 45 (Unit: MPa) by use of [<] or [>] switch.

7-17. Adjustment of lift arm angle sensor (raise)


item of 17: PUMP CUT.

WA500-6R 23
3) Using [<] or [>] switch, move the cursor to 8) When the adjustment did not end suc-
item of 18: RAISE ANGLE. cessfully, check the lift arm angle sensor
voltage from the real time monitoring.
a Adjust the lift arm angle sensor mounting
the real time monitoring may fall within the
Lift arm position Voltage range

Upper limit position
0.5 – 4.5 V
(Stroke end of raised cylinder)
7-18. Adjustment of lift arm angle sensor

(lower) (Machine with load meter)
4) Press [U] switch to settle the selection. 1) Display the TUNING screen from the
a As the selection is settled, the RAISE menu screen of Service mode.
ANGLE screen will appear.

5) Press [U] switch after raising the lift arm mum to display 01: TM TRIGGER screen.
to the upper limit position (cylinder stroke
end).
6) 2 times of buzzer beep notify completion
of the setting.
a 1 second-long beep indicates that the set
lift arm angle voltage is not conforming to
the specified value. In this case, adjust-
ment does not start.
7) Press [t] switch to end the adjustment
mode.
underway will be stopped even if it is not
completed.
24 WA500-6R
3) Using [<] or [>] switch, move the cursor to 8) When the adjustment did not end suc-
item of 19: LOWER ANGLE. cessfully, check the lift arm angle sensor
voltage from the real time monitoring.
a Adjust the lift arm angle sensor mounting
the real time monitoring may fall within the
Lift arm position Voltage range
Lower limit position
0.5 – 4.5 V
(Stroke end of lowered cylinder)
7-19. Modification of AJSS oil pressure com-

mand table pattern
a As the selection is settled, the LOWER 7-20. Adjustment of maximum travel speed limit
ANGLE screen will appear. (Lockup clutch specification)
a The maximum travel speed limit adjusting
function is used to enhance fuel consumption
in the forward 4th lockup travel.
a First select the maximum travel speed
(selected from three levels). Then set the
upper limit of the throttle opening for F (for-
ward), 4th and L/U (lockup) to limit the maxi-
mum travel speed.
a The throttle opening is limited to 90%, when
delivered.
a Select a restricted throttle opening from 80%,
90% and 100% (no restriction).
a The state in which F (forward), 4th and L/U
(lockup) are selected is, in other words, the
5) Press [U] switch after lowering the lift arm state in which F4 gear shift is completed and
to the lower limit position (cylinder stroke L/U is at the holding pressure.
end). a When gear shift to a speed other than F4 is
6) 2 times of buzzer beep notify completion started or when L/U is cancelled, the upper
of the setting. limit value of this control becomes 100% (no
a 1 second-long beep indicates that the set restriction).
lift arm angle voltage is not conforming to a Setting at delivery is 90%.
the specified value. In this case, adjust- 1) Display the TUNING screen from the
ment does not start. menu screen of Service mode.
7) Press [t] switch twice to end the adjust-
ment mode.
underway will be stopped even if it is not
completed.
WA500-6R 25
2) Hold down [U] switch for 5 seconds mini- 8. Maintenance monitoring function (MAINTE-
mum to display 01: TM TRIGGER screen. NANCE MONITOR)
The maintenance function offers the following
capabilities in the maintenance of filters and oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.

item of 22: SPEED LIMIT.
2) Press [U] switch to display 41: FUEL P

FILT screen.
a The lower left side space indicates the
time remained up to the replacement.
a The lower right side space indicates the
cumulative replacement frequencies.
a As the selection is settled, the maximum
3) Using [<] or [>] switch, select the item for
speed limit adjustment screen will be dis-
which the maintenance interval is to be
played.
changed from the following.
5) Select a "throttle level (80%, 90% or
100%)" with [<] or [>] switch and then
press [U] switch to settle the setting
change.
26 WA500-6R
List of maintenance items
Indication of items on the Replacement

Item ID No.
character display interval time (H)
Fuel pre-filter 41 FUEL P FILT 500
Engine oil 01 ENG OIL 500
Engine oil filter 02 ENG OIL FILTER 500
Transmission oil filter 13 TRANSM FILTER 500
Fuel filter 03 FUEL FILT 1000
Transmission oil 12 TRANSM OIL 1000
Corrosion resistor 06 CORR-RESISTER 1000
Hydraulic tank breather element 05 HYD BREATHER 2000
Axle oil 15 AXLE OIL 2000
Hydraulic oil filter 04 HYD FILT 2000
Hydraulic oil 10 HYD OIL 2000
4) Settle the target items of interval change a The shortest interval time value is 50 h.
by use of [U] switch. a When you have entered a wrong value to
a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.
5) Maintenance interval time change proce-

dure
1] This cursor (C) is located at the high-
est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
value.
a The cursor moves to the 2nd digit.
3] Set the values up to the lowest-order
digit in the same order and then press
[U] switch.
q When the input interval time is within
the setting range: The screen
changes to the check screen.
q When the entered interval time is out
of the setting range: The entered
interval time does not replace the cur-
rent value and the input screen will be
restored.
WA500-6R 27
6) Select “YES” or “NO” using [<] or [>] a When “Timer by item” is disabled, the
switch. order of display becomes OFF → ON.
a The selected cursor will start flashing. a The default display is ON.
If “YES” is selected and [t] switch is
pressed, the information will be deleted.
If “NO” is selected and [t] switch is
pressed, deletion is cancelled and the
maintenance interval change item screen
is restored.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If “Timer by item” is disabled, OFF will be
displayed in the upper column.
8-2. Selection between enabling or disabling timer

by item
1) Pressing [<] or [>] switch from 8-1-4) Inter-
val time change screen displays the
a If “Timer by item” is enabled, ON will be
“Selection between enabling or disabling
displayed in the upper column.
timer by item” screen.
a When “Timer by item” is enabled, the
order of display is ON → OFF.
28 WA500-6R
3) Select “YES” or “NO” using [<] or [>] a The selected cursor will start flashing.
switch. If “YES” is selected and [t] switch is
a The selected cursor will start flashing. pressed, the change will be enabled.
If “YES” is selected and [t] switch is If “NO” is selected and [t] switch is
pressed, the information will be deleted. pressed, the change will not be imple-
If “NO” is selected and [t] switch is mented and the maintenance monitoring
pressed, deletion is cancelled and the screen will be restored.
is restored.
a If the timer which has been stopped is set
effective, the interval time set before the
timer was stopped is applied.
The timer remaining time is reset. The
number of resets before the timer was
stopped is applied.
8-3. Changing set default value

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

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

enable by item
1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
3) Press [U] switch from this state.

4) Select “YES” or “NO” using [<] or [>] switch.
WA500-6R 29
2) Using [<] or [>] switch, select the ALL 5) Press [U] switch from the ALL ITEMS →
ITEMS OFF OR ON screen from the fol- OFF screen or the ALL ITEMS → ON
lowing table. screen.
a When [U] switch is pressed from the ALL
ITEMS → OFF screen, OFF will be dis-
played in the upper space.
3) Press [U] switch to display the ALL

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

ITEMS → ON screen, ON will be dis-
played in the upper space.
6) Select “YES” or “NO” using [<] or [>] switch.
a The selected cursor will start flashing.
If “YES” is selected and [ t ] switch is
pressed, the information will be deleted.
If “NO” is selected and [ t ] switch is
pressed, deletion is cancelled and the
is restored.
4) Press [<] or [>] switch when selecting the

ALL ITEMS → ON.
30 WA500-6R
7) As the timer stop for all items is executed: 2) Press [U] switch to display the fuel con-
a The timer function for all items is stopped sumption ratio and average fuel consump-
a n d t h e M A I N T E N A N C E M O N I TO R tion screen.
screen is restored. 3) Using [<] or [>] switch, select the item to
a Setting for individual items is also dis- be displayed from 1] – 4] on the fuel con-
abled. sumption ratio and average fuel consump-
a If cancelled: The operation is cancelled tion screen.
a n d t h e M A I N T E N A N C E M O N I TO R 1] Fuel consumption ratio and average
screen is restored. fuel consumption screen
8) When timer enable for all items is exe- a The upper column displays fuel con-
cuted: sumption [L/km or L/mile] per 1 km (or
a Interval time being set for all items is exe- 1 mile) from the last resetting.
cuted to the set value before disabled q Above value is computed from the
independent of whether or not it is fuel consumption ratio and travel dis-
enabled or disabled for a specific item. tance (odometer distance).
a The timer remaining time is reset. (The q The counting is stopped at 99999.9,
reset frequency remains the same as the upper limit.
before the resetting.) a The lower column displays the aver-
a The MAINTENANCE MONITOR screen is age fuel consumption [L/h] from the
restored. last resetting.
a Setting for individual items is also q The counting is stopped at 99999.9,
enabled. the upper limit.
a If cancelled: The operation is cancelled a Calculation is done only for the dura-
a n d t h e M A I N T E N A N C E M O N I TO R tion in which the engine is run.
screen is restored.
9. Operation information display function

(OPERATION INFO)
It is a fuel consumption-related function and
displays the following information.
q Fuel consumption ratio and average fuel
consumption
q Cumulative fuel consumption and travel
distance
q Cumulative fuel consumption and elapsed
time
q Loaded volume and loading frequency
(This display is available only when the
load meter is installed.)
1) Selecting menu
Display the OPERATION INFO screen
from the menu screen of Service mode.
WA500-6R 31
2] Cumulative fuel consumption and

travel distance
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
q The counting is stopped at 99999.9,
the upper limit.
a The lower column displays the travel
distance [km or mile] from the last
resetting.
q The unit km or mile shall be selected
depending on that used on the odom-
eter.
the upper limit.
4] Loaded volume and loading fre-
quency screen
a Calculation is done only for the dura-
a The upper column displays the
tion in which the engine is run.
loaded volume [ton] from the last
resetting.
q Upper limit: Counting is stopped at
999999.9.
q Short ton or metric ton depends on
optional setting.
a The lower column displays the load-
ing frequency from the last resetting.
q Upper limit: Counting starts stopped
at 65000.
tion in which the engine is run and the
optional device is used.
3] Cumulative fuel consumption and

elapsed time
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit.
a The lower column displays the
elapsed time [h] from the last reset-
ting.
the upper limit.
tion in which the engine is run.
32 WA500-6R
4) Deleting display data 7] Press [U] switch when the intended

a Data on screens 5) – 8) allow deletion. value appeared to specify it as the set
a Select a desired item and then delete it value.
using [U] switch. a The cursor moves to the 2nd digit.
a Use [t] switch when canceling deletion of 8] Set the values up to the lowest digit in
data. the same order as above and then
press [U] switch to settle.
a As the selection is settled, the pre-
ceding screen is restored.
a If [t] switch is pressed before finish-
ing entering, the cursor moves to the
[+] and [–] position. In this case, the
value remains unchanged. Pressing
[t] switch again restores the preced-
ing screen.
a If the value is not in the –50.0 to
+50.0 range, pressing [U] switch at
the lowest digit just moves the cursor
the [+] and [–] position and the value
remains as it is.
5) Setting gain correction
a Gain correction denotes the function of
correcting cumulative fuel.
a Gain correction is available only from the
fuel consumption ratio and average fuel
consumption screen.
1] After deleting data (RESET screen),
press [<] or [>] switch to display the
current set value.
2] Pressing [U] switch displays the cor-

rection screen.
a Default value: 0.0%
a This setting allows correcting the
cumulative fuel consumption in the
range of –50.0 to +50.0.
3] Move the cursor to [+] or [–].
4] Pressing [<] or [>] switch alternately
displays [+] and [–].
5] Press [U] switch to settle [+] or [–].
a The cursor moves to the highest-
order digit of the set value.
6] Pressing [<] or [>] switch changes the
value of this digit in the range of 0 – 9.
WA500-6R 33
10. Optional device selecting function (OPTIONAL SELECT)

a When enabling optional setting, turn the starting switch off once after changing the current setting and
then turn on the starting switch again after respective controller power supplies have been completely
turned off (it takes approximately 15 seconds).
a Before performing the optional setting, make sure that the model is selected.
(Model selection shall be performed before the optional setting.)
a List of installed optional devices and their setting

Display in Item
Item Default Description of selection
English No.
Select A or B according to the lift arm specifica-
tions.
Lift arm model LIFT BOOM 1 A
• Lift arm length = 3,250 mm: A
• Lift arm length = 3,636 mm: B
AUTO
Auto grease 2 None When an option is provided, select ADD.
GREASE
Battery electrolyte level sensor BAT LIQUID 3 None When an option is provided, select ADD.
Transmission filter clogging TRANSM
4 None When an option is provided, select ADD.
sensor CLOG
Printer PRINTER 5 None When an option is provided, select ADD.
Normally, 0% shall be maintained without modify-
Tire size TIRE SIZE 6 0
ing current setting.
Only in specification which can display in mile,
SHORT
Selection of weight unit 7 None select ADD to display in short ton and select NO to
TON
display in metric ton.
SPEED Only in specification which can display in mile,
Travel speed unit 8 MPH
(UNIT) MPH and km/h are selectable.
Engine speed or travel speed
RPM/ Normally, ADD shall be maintained without modify-
display on character display and 10 Provided
SPEED ing current setting.
normal screen
LOAD
Load meter 11 None When an option is provided, select ADD.
METER
Emergency steering EMERG S/T 13 Provided When an option is not provided, select NO ADD.
When joystick steering or right FNR switch is
installed, the setting applicable to each shall be
Joystick steering or right FNR implemented.
(directional) switch, or both are J/S-FNR SW 14 NON • Set “NON” only for steering wheel.
absent • Set J/S for joystick steering.
• Set FNR SW for the right FNR (directional)
switch.
Normally, ADD shall be maintained without modify-
Selection of ECO display ECO LAMP Provided
ing current setting.
ECSS (Travel damper) E.C.S.S. 20 None When an option is provided, select ADD.
AUTO RE
Automatic reversing fan 21 None Set NO ADD and never change.
FAN
Torque converter lockup LOCK UP 22 None When an option is provided, select ADD.
FORBID Normally, NO ADD shall be maintained without
4th gear prohibition 23 None
4TH modifying current setting.
THROT
RPM set 24 None When an option is provided, select ADD.
LOCK
When an option is provided, select ADD.
P-MODE
Power mode priority 25 None (Setting available: Power mode is introduced as
PRI
starting switch is turned on)
COLD
Very cold region specification 26 None NO ADD, which must not be changed.
SPEC
EPC 3-spool lever EPC 3RD 31 None When an option is provided, select ADD.
EPC lever EPC LEVER 32 Provided When an option is provided, select ADD.
34 WA500-6R
1) Display the OPTIONAL SELECT screen

from the menu screen of Service mode.
2) Hold down [U] switch for 5 seconds or

longer.
3) The 1: LIFT BOOM screen will appear.
a Pressing [t] switch again restores the
OPTIONAL SELECT screen.
a For optional setting, be sure to change or

select the relevant items from the 1: LIFT
BOOM screen, and also set each item
sequentially on the next 2: AUTO
GREASE screen and after.
WA500-6R 35
36 WA500-6R
10-1. Changing or settling lift arm model option 10-3. Setting tire deflection option
selection a Select the tire deflection option from the list of
a Pressing [U] switch from the 1: LIFT installed optional devices and their setting.
BOOM screen interchanges A and B. a Pressing [U] switch sequentially displays
a As A and B are interchanged, the sound [@@]% in the following order.
(beep) indicating acceptance of the opera- a The display progresses from +00 through –12.
tion will be generated. Pressing [U] switch at this point returns the
a Select the lift arm length for A and B from display to +00.
the following.
Machine model A B Order No.1 No.2 No.3 No.4 No.5 No.6 No.7
WA600-6 3850 mm 3990 mm @@ +00 +02 +04 +06 +08 +10 +12
WA500-6 3250 mm 3636 mm Order No.8 No.9 No.10 No.11 No.12 No.13 No.14
@@ –02 –04 –06 –08 –10 –12 +00
10-2. Option setting/not setting selection

a As the display is switched, the sound (beep)
a Among the items included in the list of
indicating acceptance of the operation will be
installed optional devices and their setting,
generated.
the option setting/not setting selection
applies to the following items.
a If the options are not selected, the option
non-selection screen is displayed.
10-4. Storing option selection

1) When the option selection was changed,
turn off the starting switch once to stop the
controller operation completely. (After
a If the options are selected, the option
turning off the starting switch, wait for 15
selected screen is displayed.
seconds without doing any switch opera-
tion.)
2) The specified option selection is enabled
as the starting switch is turned on.
a Whenever an option selection is made,
turn off the starting switch once and then
turn it on again in approximately 15 sec-
onds.
a [U] switch allows alternately displaying

the option non-selection screen and the
option-selected screen.
WA500-6R 37
11. Machine serial number input function 12. Model selection function (MACHINE WA500)
(MACHINE No. SET) a The model selection function enables a
1) Display the MACHINE No. SET screen change of machine monitor model setting.
from the menu screen of Service mode. a Select a model first after initializing the
machine monitor.
a Selecting a model resets the optional set-
ting. If a model is selected, perform all the
optional settings in sequence from the
beginning.
12-1. Implementing the model change

1) Display the MACHINE screen from the
a If WA600-6 is selected, “WA600” will be
displayed on the screen.
a In the case of WA500-6, the display will be
“WA500”.
2) Press [U] switch to display the MACHINE

No. screen.
3) Enter the serial number according to the
a The cursor is positioned at the high-
est-order digit.
1] Pressing [<] or [>] switch increases or
decreases the value at the cursor
position. Select a desired value using
these switches.
2] Press [U] switch to settle the selection.
a The cursor moves to the digit situated
immediately on the right hand.
3] Set the values up to the lowest digit in 2) Hold down [U] switch for 5 seconds to
the same order as above and then display the model selection screen.
press [U] switch to settle.
a As the selection is settled, the imme-
diately preceding screen is restored.
a Pressing [t] switch while entry is tak-
ing place will move the cursor the
highest-order digit. In this case,
repeat entry from the highest-order
digit.
a If [t] switch is pressed while the cur-
sor is at the highest-order digit, the
immediately preceding screen will be
restored.
38 WA500-6R
3) Using [<] or [>], replace “WA600” with 13. Initialize function (INITIALIZE)
“WA500”. This function is used only in the factory. It is,
a Press [t] switch when stopping the model therefore, not used for a service purpose.
selection.
a As the operation is stopped, the sound
(beep) indicating cancellation of the oper-
ation acceptance will be generated,
restoring the MACHINE screen.
4) Settle the selected model by use of [U]
switch.
a As the selection is settled, the sound
(beep) indicating completion of the opera-
tion acceptance will be generated, restor-
ing the MACHINE screen.
a Make sure the model on the MACHINE
screen is the target model.
12-2. Storing model change

1) When the model change was done, turn
off the starting switch once to stop the
controller operation completely. (After
turning off the starting switch, wait for 15
seconds without doing any switch opera-
tion.)
2) The model being selected as the starting
switch is turned on again is validated.
a Whenever a model change was done, turn
off the starting switch once and then turn it
on again after approximately 15 seconds
lapsed.
WA500-6R 39
Pm clinic inspection table 1

WA500-6R Serial No. 60001 and up Machine serial No. #
Engine serial No.

hour inspection SAA6D140E-5 #
Work instruction No. Date of execution Service meter Inspector

Year: Month: Day: hours
Interview with operator and walk-around check

Is there abnormality before starting inspection? Outside temperature
Max. °C
Min. °C
Altitude m
Maximum coolant temperature (overheated)? Maximum torque converter oil temperature

(During operation) (overheated)? (During operation)
a If machine is cold, warm it up.

a Working mode: P-mode
Standard
Service limit Measurement
Item Condition Unit value for new Good Bad
value result
machine
765 – 815 765 – 815
Engine at low idle
(*1: 675 – 725) (*1: 675 – 725)
Engine at high idle 2,070 – 2,170 2,070 – 2,170
Engine at high idle and torque converter
1,740 – 1,940 1,640 – 2,040
Engine speed stalled rpm
Engine at high idle and work equipment
2,000 – 2,200 1,900 – 2,300
relieved
Torque converter stalled + Work equipment
1,700 – 1,900 1,500 – 2,100
relieved
Engine
Engine at high idle and torque converter kPa Max. 2.94 3.92
Blow-by pressure
stalled {mmH2O} {Max. 300} {400}
SAE0W30EOS Min. 0.34 0.21
Engine at high idle
SAE5W40EOS MPa {Min. 3.5} {2.1}
Lubricating oil
SAE10W30DH
pressure {kg/cm2} Min. 0.10 0.08
SAE15W40DH
Engine at low idle
SAE30DH {Min. 1.0} {0.8}
Engine at high idle and torque converter kPa Min. 89 76
Boost pressure
stalled {mmHg} {Min. 670} {570}
Exhaust Engine at high idle and toque converter stalled
°C Max. 670 720
temperature Outside temperature: 20°C
a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
Engine at low idle 3.19 – 3.48 3.19 – 3.48
Main relief (*1) {32.5 – 35.5} {32.5 – 35.5}
pressure 3.49 – 3.79 3.49 – 3.79
Engine at high idle • Torque converter oil
pressure: {35.6 – 38.6} {35.6 – 38.6}
Torque converter Within operating range 0.44 – 0.84 0.44 – 0.84
Engine at high idle • Transmission: Neutral
inlet pressure {4.5 – 8.5} {4.5 – 8.5}
Torque converter 0.29 – 0.49 0.29 – 0.49
Engine at high idle
outlet pressure {3.0 – 5.0} {3.0 – 5.0}
Transmission valve
3.04 – 3.44 3.04 – 3.44

1st
{31 – 35} {31 – 35}
MPa 3.08 – 3.48 3.08 – 3.48
2nd
{kg/cm2} {31.5 – 35.5} {31.5 – 35.5}
3.08 – 3.48 3.08 – 3.48
3rd • Torque converter oil {31.5 – 35.5} {31.5 – 35.5}
pressure:
ECMV output 2.99 – 3.39 2.99 – 3.39
4th Within operating range
(clutch) pressure {30.5 – 34.5} {30.5 – 34.5}
• Engine at high idle
• Manual switch: ON 1.71 – 2.01 1.71 – 2.01
Lockup
{17.5 – 20.5} {17.5 – 20.5}
3.18 – 3.58 3.18 – 3.58
F
{32.5 – 36.5} {32.5 – 36.5}
3.14 – 3.54 3.14 – 3.54
R
{32 – 36} {32 – 36}
40 WA500-6R
Pm clinic inspection table

WA500-6R Serial No. 60001 and up
Standard
value result
machine
Secure frame with frame lock bar.
Steering
Steering relief MPa 24.01 – 25.68 23.03 – 25.68

Engine at high idle
pressure {kg/cm2} {245 – 262} {235 – 262}
Torque converter oil 3.38 – 3.68 3.38 – 3.68

As brake is released
Parking brake temperature: Within MPa {34.5 – 37.5} {34.5 – 37.5}
inlet pressure operating range {kg/cm2} Min. 0.14 Min. 0.14
Engine at low idle When brake operated
{Min. 1.4} {Min. 1.4}
Tire inflation pressure: Specified pressure
Parking brake Holds in Holds in
Test on flat and dry paved slope of 1/5 (11° 20'). —
performance position position
Set machine in operating state.
Parking brake
mm 3.1 – 3.3 2.77
disc thickness
Measure when brake
Charge cut-in 5.88 – 6.37 5.39 – 6.86
Hydraulic oil tempera- oil pressure warning
pressure (60 – 65) {55 – 70}
ture: Within operating lamp goes off.
range Measure when brake
Charge cut-out Engine at low idle MPa 9.8 – 10.78 9.31 – 11.27
oil pressure starts
{kg/cm2}
Brake
pressure {100 – 110} {95 – 115}

lowering after rising.
Hydraulic oil temperature: Within operating
4.9 – 5.59 4.7 – 5.78
Brake oil pressure range
{50 – 57} {48 – 59}
Engine at low idle
Engine: Stopped
Drop in brake Measure lowering of oil pressure from 4.9 MPa kPa Max. 0.49 Max. 0.49
pressure {kg/cm2} {Max. 5} {Max. 5}
{50 kg/cm2} in 5 minutes.
Tire inflation pressure: Specified pressure
Test on flat, level, straight, and dry paved road.
Braking initial speed: 20 km/h, Delay in press-
Wheel brake
ing pedal: Max 0.1 sec m Max. 4 Max. 4
performance
Brake pedal pressing force:
Specified force, 294 ± 29.4 Nm {30 ± 3 kg}
Measure braking distance.
Wear of wheel
Measure with disc wear indicator. mm 0 Max. 4.0
brake disc
Work equipment
32.8 – 34.8 31.8 – 34.8
valve relief Bucket circuit relieved
{335 – 355} {325 – 355}
pressure MPa
Work equipment P-mode {kg/cm2}
Work equipment control 1.27 – 1.47 1.17 – 1.57
valve LS differen- Hydraulic oil tem-
lever moved halfway {13 – 15} {12 – 16}
Work equipment
tial pressure perature: Within

operating range Rising time 6.7 – 7.5 Max. 8.9
Lift arm speed Engine at high idle
Lowering time 3.7 – 4.7 Max. 5.4
Sec
Bucket tilt back Bucket full stroke time 2.2 – 2.8 Max. 3.4
speed Bucket at level time 1.5 – 2.1 Max. 2.6
Hydraulic oil tem- Bucket cylinder Max. 20 Max. 20
Hydraulic drift of perature: Within mm/
work equipment operating range Lift cylinder 15 min. Max. 40 Max. 40
Engine: Stopped
WA500-6R 41
Standard
value result
machine
• Engine coolant temperature: Min. 95°C
Max. fan speed • Hydraulic oil temperature: Min. 95°C 1,055 ± 50 1,055 ± 100
• Torque converter oil temperature: Min.
105°C
• Engine speed: Low idle (*1) rpm
• Engine coolant temperature: Max. 75°C
• Hydraulic oil temperature: Max. 75°C
Hydraulic drive fan
Min. fan speed 170 ± 30 170 ± 50

• Torque converter oil temperature: Max.
85°C
• Air conditioner OFF
• Engine coolant temperature: Min. 95°C
Fan drive pres- 17.7 ± 2.5 17.7 ± 2.5
• Hydraulic oil temperature: Min. 95°C
sure {180 ± 25} {180 ± 25}
• Torque converter oil temperature: Min.
105°C MPa
• Engine speed: High idle {kg/cm2}
Fan reverse sole- • Engine coolant temperature: Min. 95°C
19.6 ± 2.5 19.6 ± 2.5
noid output pres- • Hydraulic oil temperature: Min. 95°C
{200 ± 25} {200 ± 25}
sure • Torque converter oil temperature: Min.
105°C
Visual check of Front axle
There must not be excessive
Axle
differential drain —
Rear axle metal powder.
plug
*1: Denotes the low idle speed when the engine speed was decreased to the minimum speed with the RPM idle-up/down selector switch.
Memo
42 WA500-6R
WA500-6R 43
SEN02930-04

© 2011 KOMATSU
All Rights Reserved
44
SEN02931-02
WA500-6R

WA500-6R 60001 and up
40 Troubleshooting 1
Failure codes list and fuse locations
Failure codes list ............................................................................................................................................. 2
Fuse locations............................................................................................................................................... 13
WA500-6R 1
SEN02931-02 40 Troubleshooting
Failure codes list 1
Failure Action Category of Reference

Troubled part Trouble Controller
code code record document No.
TORQFLOW Electrical
1500L0 Double meshing TM E03
transmission system
Mechanical
15B0NX Transmission filter Clogging MON E01
system
When command current is Electrical
15SAL1 ECMV F clutch TM E03
OFF, fill signal is ON system
15SALH ECMV F clutch TM E01
ON, fill signal is OFF system
15SBL1 ECMV R clutch TM E03
15SBLH ECMV R clutch TM E01
15SEL1 ECMV 1st clutch TM E03
Troubleshoot-
When command current is Electrical ing by failure
15SELH ECMV 1st clutch TM E01
ON, fill signal is OFF system code (Display
When command current is Electrical of code),
15SFL1 ECMV 2nd clutch TM E03 Part 1
SEN02933-**
15SFLH ECMV 2nd clutch TM E01
15SGL1 ECMV 3rd clutch TM E03
15SGLH ECMV 3rd clutch TM E01
15SHL1 ECMV 4th clutch TM E03
15SHLH ECMV 4th clutch TM E01
Electrical
2F00MA Parking brake Malfunction MON E03
system
Mechanical
2G42ZG Front accumulator Low oil pressure MON E03
system
Mechanical
2G43ZG Rear accumulator Low oil pressure MON E03
system
Electrical
44K0L4 Bucket positioner ON/OFF signals disagree WRK E01
system
Mechanical
AA1ANX Air cleaner Clogging MON E01
system
Signal does not match Troubleshoot-
Electrical ing by failure
AB00L6 Alternator engine running or stopped MON E03
system code (Display
state
of code),
Mechanical Part 2
AB00MA Alternator Malfunction MON E03
system SEN02934-**
Mechanical
B@BAZG Engine oil Low oil pressure ENG E03
system
Mechanical
B@BAZK Engine oil Low level MON E01
system
Mechanical
B@BCNS Coolant Overheating ENG E02
system
2 WA500-6R

Mechanical
B@BCZK Coolant Low level MON E01
system
Mechanical
b@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@GAZK Battery electrolyte Low level MON E01
system
Mechanical
B@HANS Hydraulic oil Overheating MON E02
system
Abnormality in engine Electrical
CA111 — ENG E03
controller system
Engine Ne or Bkup speed Electrical
CA115 — ENG E03
sensor error system
Charge pressure sensor Electrical
CA122 — ENG E03
high error system
Charge pressure sensor Electrical
CA123 — ENG E03
low error system
Electrical Troubleshoot-
CA131 Throttle sensor high error — ENG E03
system ing by failure
Electrical code (Display
CA132 Throttle sensor low error — ENG E03
system of code),
Engine oil pressure Electrical Part 2
CA135 — ENG E01 SEN02934-**
sensor high error system
Engine oil pressure Electrical
CA141 — ENG E01
sensor low error system
Coolant temperature Electrical
CA144 — ENG E01
Coolant temperature Electrical
CA145 — ENG E01
Charge temperature Electrical
CA153 — ENG E01
Charge temperature Electrical
CA154 — ENG E01
Sensor power supply 2 Electrical
CA187 — ENG E03
voltage low error system
Atmospheric pressure Electrical
CA221 — ENG E01
Atmospheric pressure Electrical
CA222 — ENG E01
Sensor power supply 2 Electrical
CA227 — ENG E03
voltage high error system
Mechanical
CA234 Engine overspeed — ENG E02
system
Troubleshoot-
Ne speed sensor power Electrical ing by failure
CA238 — ENG E03
supply error system code (Display
Fuel temperature sensor Electrical of code),
CA263 — ENG E01 Part 3
high error system
SEN02935-**
Fuel temperature sensor Electrical
CA265 — ENG E01
low error system
WA500-6R 3

Electrical
CA271 PCV1 short circuit — ENG E03
system
Electrical
CA272 PCV1 disconnection — ENG E03
system
Electrical
CA273 PCV2 short circuit — ENG E03
system
Electrical
CA274 PCV2 disconnection — ENG E03
system
Injector #1 open/short Electrical
CA322 — ENG E03
error system
CA323 — ENG E03
error system
CA324 — ENG E03
error system
CA325 — ENG E03
error system
CA331 — ENG E03
error system
CA332 — ENG E03
error system
Engine controller data Electrical
CA342 — ENG E03
inconsistency system
Electrical
CA351 Injector drive circuit error — ENG E03
system
Troubleshoot-
Sensor power supply 1 Electrical ing by failure
CA352 — ENG E03
low error system code (Display
Sensor power supply 1 Electrical of code),
CA386 — ENG E03 Part 3
high error system
SEN02935-**
Electrical
CA431 Idle validation switch error — ENG E01
system
Electrical
CA432 Idle validation action error — ENG E03
system
Electrical
CA441 Battery voltage low error — ENG E03
system
Electrical
CA442 Battery voltage high error — ENG E03
system
Common rail pressure Electrical
CA449 — ENG E03
high error 2 system
CA451 — ENG E03
CA452 — ENG E03
CA553 — ENG E03
high error 1 system
CA554 — ENG E03
sensor in-range error system
Supply pump pressure Electrical
CA559 — ENG E03
very low error 1 system
Engine Ne speed sensor Electrical
CA689 — ENG E03
error system
Engine Bkup speed Electrical
CA731 — ENG E03
sensor phase error system
4 WA500-6R

All continuous data lost Electrical Troubleshoot-
CA757 — ENG E03
error system ing by failure
Engine Bkup speed Electrical code (Display
CA778 — ENG E03
sensor error system of code),
KOMNET datalink timeout Electrical Part 3
CA1633 — ENG E03 SEN02935-**
error system
Throttle sensor supply Electrical
CA2185 — ENG E03
voltage high error system
Throttle sensor power Electrical
CA2186 — ENG E03
supply low error system
Supply pump pressure Electrical
CA2249 — ENG E03
very low error 2 system
Intake heater relay Electrical
CA2555 — ENG E01
disconnection error system
Intake heater relay short Electrical
CA2556 — ENG E01
circuit error system
Disconnection or short Electrical
D160KZ Backup lamp relay TM E01
circuit system
Joystick steering neutral Electrical
D191KA Disconnection WRK E01
safety relay system
Joystick steering neutral Electrical
D191KB Short circuit WRK E01
safety relay system
ECSS (travel damper) Electrical
D192KA Disconnection TM E01
solenoid system
ECSS (travel damper) Electrical
D192KB Short circuit TM E01
solenoid system
ECSS (travel damper) Short circuit with power Electrical Troubleshoot-
D192KY TM E01
solenoid supply line system ing by failure
Joystick steering solenoid Electrical code (Display
D193KA Disconnection WRK E03 of code),
cut relay system
Part 4
Joystick steering solenoid Electrical
D193KB Short circuit WRK E03 SEN02936-**
cut relay system
Joystick steering solenoid Short circuit with power Electrical
D193KY WRK E03
cut relay supply line system
Electrical
D5ZHKA Terminal C signal Disconnection TM E01
system
Electrical
D5ZHKB Terminal C signal Short circuit TM E01
system
Disconnection or short Electrical
D5ZHKZ Terminal C signal WRK E01
circuit system
Signal does not match
Electrical
D5ZHL6 Terminal C signal engine running or stopped MON E01
system
state
Electrical
DA80L4 Auto grease controller ON/OFF signals disagree MON —
system
Low source voltage Electrical
DAF3KK Machine monitor MON E03
(input) system
Electrical
DAF5KP Machine monitor Low output voltage MON E01
system
Defective communication
CAN communication with Electrical
DAFRKR (Abnormality in target TM E03
machine monitor system
component system)
WA500-6R 5

Electrical
DAQ0KK Transmission controller Low source voltage TM E03
system
Troubleshoot-
DAQ0KT Transmission controller Abnormality in controller TM E01
Transmission controller Low source voltage Electrical of code),
DAQ2KK TM E03 Part 4
load power supply line (input) system
SEN02936-**
Transmission controller Disagreement of model
DAQ9KQ MON E03 —
model selection selection signals
DAQRKR (Abnormality in target MON E03
transmission controller system
component system)
Transmission controller
DAQRMA Malfunction MON E03 —
option setting
DB2RKR (Abnormality in target TM E03
engine controller system
component system)
Low source voltage Electrical
DB90KK Work equipment controller WRK E03
(input) system
Electrical
DB90KT Work equipment controller Abnormality in controller WRK E01
system
Work equipment controller Low source voltage Electrical
DB92KK WRK E03
load power supply line (input) system
Work equipment controller Electrical
DB95KX Out of input signal range WRK E03
power supply output system
Work equipment controller Disagreement of model
DB99KQ MON E03 —
model selection selection signals
DB9RKR (Abnormality in target TM E03 Troubleshoot-
work equipment controller system
component system) ing by failure
Work equipment controller code (Display
DB9RMA Malfunction MON E03 — of code),
option setting
Part 5
CAN communication with Electrical SEN02937-**
DB9RMC Defective operation WRK E03
transmission controller system
Switch is kept pressed for Electrical
DD15LD t switch (Panel switch 1) MON E01
long time system
DD16LD U switch (Panel switch 2) MON E01
long time system
DD17LD < switch (Panel switch 3) MON E01
long time system
DD18LD > switch (Panel switch 4) MON E01
long time system
Remote positioner raise/ Switch is kept pressed for Electrical
DD1ALD WRK E01
lower set switch (RAISE) long time system
Remote positioner raise/ Switch is kept pressed for Electrical
DD1BLD WRK E01
lower set switch (LOWER) long time system
Load meter subtotal Switch is kept pressed for Electrical
DD1CLD MON E01
switch long time system
Load meter mode selector Switch is kept pressed for Electrical
DD1FLD MON E01
switch (A/B) long time system
Load meter mode selector Switch is kept pressed for Electrical
DD1GLD MON E01
switch (+/–) long time system
6 WA500-6R

Load meter display Switch is kept pressed for Electrical
DD1HLD MON E01
selector switch long time system
DDA7L4 RPM set ON/OFF switch ON/OFF signals disagree TM E01
RPM set idle-up/down Electrical code (Display
DDA8KB Short circuit TM E01
switch (idle-up) system of code),
RPM set idle-up/down Electrical Part 5
DDA9KB Short circuit TM E01 SEN02937-**
switch (idle-down) system
Parking brake switch Electrical
DDB6L4 ON/OFF signals disagree TM E03
(Neutralizer) system
Remote positioner bucket Switch is kept pressed for Electrical
DDD1LD WRK E01
angle set switch long time system
Emergency steering drive Electrical
DDE5MA Malfunction MON E01
switch system
Electrical
DDK3KA Right FNR switch Disconnection TM E03
system
Electrical
DDK3KB Right FNR switch Short circuit TM E03
system
Joystick steering FNR Electrical
DDK4KA Disconnection TM E03
switch system
Joystick steering FNR Electrical
DDK4KB Short circuit TM E03
switch system
Joystick steering shift-up/ Electrical
DDK5L4 ON/OFF signals disagree TM E01
down switch system
Electrical
DDK6KA FNR lever switch Disconnection TM E03
system
Electrical
DDK6KB FNR lever switch Short circuit TM E03
system
Troubleshoot-
DDT0L4 Shift mode selector switch ON/OFF signals disagree TM E01
Transmission cut-off set Switch is kept pressed for Electrical of code),
DDT4LD TM E01 Part 6
switch long time system
SEN02938-**
DDW9LD Kick-down switch TM E01
long time system
DDWLLD Hold switch TM E01
long time system
DDY0LD Load meter cancel switch MON E01
long time system
Transmission shift lever Electrical
DF10KA Disconnection TM E01
switch system
Transmission shift lever Electrical
DF10KB Short circuit TM E01
switch system
Transmission oil Electrical
DGF1KA Disconnection TM E01
temperature sensor system
Transmission oil Electrical
DGF1KB Short circuit TM E01
Hydraulic oil temperature Electrical
DGH2KX Out of input signal range MON E01
sensor system
Rear brake oil Electrical
DGR2KA Disconnection MON E01
WA500-6R 7

Rear brake oil Electrical Troubleshoot-
DGR2KX Out of input signal range MON E01
temperature sensor system ing by failure
Torque converter oil Electrical code (Display
DGT1KX Out of input signal range MON E01
temperature sensor system of code),
Oil pressure sensor of Electrical Part 6
DH21KA Disconnection WRK E01 SEN02938-**
work equipment pump system
Oil pressure sensor of Electrical
DH21KB Short circuit WRK E01
work equipment pump system
Lift arm cylinder bottom Electrical
DHPCKX Out of input signal range MON E01
pressure sensor system
Lift arm cylinder head Electrical
DHPDKX Out of input signal range MON E01
pressure sensor system
Left brake pressure Electrical
DHT1KX Out of input signal range TM E01
sensor system
Signal does not match
Transmission filter Electrical
DHT2L6 engine running or stopped MON E01
clogging sensor system
state
Lift arm EPC lever Electrical
DK59KA Disconnection WRK E03
potentiometer (Main) system
Lift arm EPC lever Short circuit with power Electrical
DK59KY WRK E03
potentiometer (Main) supply line system
DK59L8 Analog signals disagree WRK E03
DK5AKA Disconnection WRK E03
potentiometer (Sub) system
Troubleshoot-
Lift arm EPC lever Short circuit with power Electrical
DK5AKY WRK E03 ing by failure
potentiometer (Sub) supply line system
code (Display
Bucket EPC lever Electrical of code),
DK5BKA Disconnection WRK E03
potentiometer (Main) system Part 7
Bucket EPC lever Short circuit with power Electrical SEN02939-**
DK5BKY WRK E03
potentiometer (Main) supply line system
Bucket EPC lever Electrical
DK5BL8 Analog signals disagree WRK E03
Bucket EPC lever Electrical
DK5CKA Disconnection WRK E03
potentiometer (Sub) system
Bucket EPC lever Short circuit with power Electrical
DK5CKY WRK E03
potentiometer (Sub) supply line system
3rd valve (attachment)
Electrical
DK5DKA EPC lever potentiometer Disconnection WRK E03
system
(Main)
Short circuit with power Electrical
DK5DKY EPC lever potentiometer WRK E03
supply line system
(Main)
Electrical
DK5DL8 EPC lever potentiometer Analog signals disagree WRK E03
system
(Main)
Electrical
DK5EKA EPC lever potentiometer Disconnection WRK E03
system
(Sub)
8 WA500-6R

DK5EKY EPC lever potentiometer WRK E03
supply line system
(Sub)
Joystick steering EPC Electrical
DK5FKA Disconnection WRK E03
lever potentiometer (Main) system
Joystick steering EPC Short circuit with power Electrical
DK5FKY WRK E03
lever potentiometer (Main) supply line system
DK5GKA Disconnection WRK E03
lever potentiometer (Sub) system
Joystick steering EPC Short circuit with power Electrical
DK5GKY WRK E03
lever potentiometer (Sub) supply line system
DK5FL8 Analog signals disagree WRK E03
lever potentiometer (Main) system
Electrical
DKA0KA Lift arm angle sensor Disconnection WRK E01
system
Electrical
DKA0KX Lift arm angle sensor Out of input signal range MON E01
system
DKA0KY Lift arm angle sensor WRK E01
supply line system
Electrical
DKA0L0 Lift arm angle sensor Double meshing WRK E01
system
Transmission input shaft Electrical
DLF1KA Disconnection TM E01
speed sensor system Troubleshoot-
Transmission input shaft Electrical ing by failure
DLF1LC Speed signals disagree TM E01 code (Display
speed sensor system
of code),
Transmission output shaft Electrical Part 8
DLT4KB Short circuit TM E03
speed sensor system SEN02940-**
Transmission output shaft Electrical
DLT4KX Out of input signal range TM E03
speed sensor system
Transmission cut-off Electrical
DT20KB Short circuit TM E01
indicator lamp system
Remote positioner raise
DUM1KB Short circuit WRK — —
set indicator lamp
Remote positioner lower
DUM2KB Short circuit WRK — —
set indicator lamp
Electrical
DV00KB Alarm buzzer Short circuit MON E01
system
Lift arm raise EPC Electrical
DW4PKA Disconnection WRK E03
solenoid system
Lift arm raise EPC Electrical
DW4PKB Short circuit WRK E03
solenoid system
Lift arm raise EPC Short circuit with power Electrical
DW4PKY WRK E03
solenoid supply line system
Lift arm lower EPC Electrical
DW4QKA Disconnection WRK E03
solenoid system
Lift arm lower EPC Electrical
DW4QKB Short circuit WRK E03
solenoid system
Lift arm lower EPC Short circuit with power Electrical
DW4QKY WRK E03
WA500-6R 9

DW4RKA Bucket tilt EPC solenoid Disconnection WRK E03
Electrical code (Display
DW4RKB Bucket tilt EPC solenoid Short circuit WRK E03
system of code),
Short circuit with power Electrical Part 8
DW4RKY Bucket tilt EPC solenoid WRK E03 SEN02940-**
supply line system
Bucket dump EPC Electrical
DW4SKA Disconnection WRK E03
solenoid system
Bucket dump EPC Electrical
DW4SKB Short circuit WRK E03
solenoid system
Bucket dump EPC Short circuit with power Electrical
DW4SKY WRK E03
Electrical
DW7BKA Fan reverse solenoid Disconnection TM E01
system
Electrical
DW7BKB Fan reverse solenoid Short circuit TM E01
system
DW7BKY Fan reverse solenoid TM E01
supply line system
Hydraulic drive fan neutral Electrical
DW7DKA Disconnection TM E01
solenoid system
Hydraulic drive fan neutral Electrical
DW7DKB Short circuit TM E01
solenoid system
Hydraulic drive fan neutral Short circuit with power Electrical
DW7DKY TM E01
Work equipment neutral Electrical
DWM1KA Disconnection WRK E01
lock EPC solenoid system
Work equipment neutral Electrical Troubleshoot-
DWM1KB Short circuit WRK E01
lock EPC solenoid system ing by failure
Work equipment neutral Short circuit with power Electrical code (Display
DWM1KY WRK E01
lock EPC solenoid supply line system of code),
Lift arm raise magnet Electrical Part 9
DWN6KA Disconnection WRK E01 SEN02941-**
detent solenoid system
Lift arm raise magnet Electrical
DWN6KB Short circuit WRK E01
Lift arm raise magnet Short circuit with power Electrical
DWN6KY WRK E01
detent solenoid supply line system
Lift arm float magnet Electrical
DWN7KA Disconnection WRK E01
Lift arm float magnet Electrical
Lift arm float magnet Short circuit with power Electrical
DWN7KY WRK E01
detent solenoid supply line system
Bucket tilt magnet detent Electrical
DWN8KA Disconnection WRK E01
solenoid system
Bucket tilt magnet detent Electrical
solenoid system
Bucket tilt magnet detent Short circuit with power Electrical
DWN8KY WRK E01
Electrical
DX16KA Fan pump EPC solenoid Disconnection TM E01
system
Electrical
DX16KB Fan pump EPC solenoid Short circuit TM E01
system
10 WA500-6R

DX16KY Fan pump EPC solenoid TM E01
supply line system
Electrical
DXA1KA Pump PC-EPC solenoid Disconnection WRK E01
system
Electrical
DXA1KB Pump PC-EPC solenoid Short circuit WRK E01
system
Troubleshoot-
DXH1KA Lockup ECMV solenoid Disconnection TM E01
Electrical of code),
DXH1KB Lockup ECMV solenoid Short circuit TM E01 Part 9
system
SEN02941-**
DXH1KY Lockup ECMV solenoid TM E03
supply line system
Electrical
DXH4KA 1st clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH4KB 1st clutch ECMV solenoid Short circuit TM E03
system
DXH4KY 1st clutch ECMV solenoid TM E03
supply line system
2nd clutch ECMV Electrical
DXH5KA Disconnection TM E03
solenoid system
2nd clutch ECMV Electrical
DXH5KB Short circuit TM E03
solenoid system
2nd clutch ECMV Short circuit with power Electrical
DXH5KY TM E03
Electrical
DXH6KA 3rd clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH6KB 3rd clutch ECMV solenoid Short circuit TM E03
system
DXH6KY 3rd clutch ECMV solenoid TM E03
supply line system
Electrical
DXH7KA R clutch ECMV solenoid Disconnection TM E03
system
Troubleshoot-
DXH7KB R clutch ECMV solenoid Short circuit TM E03
Short circuit with power Electrical of code),
DXH7KY R clutch ECMV solenoid TM E03 Part 10
supply line system
SEN02942-**
Electrical
DXH8KA F clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH8KB F clutch ECMV solenoid Short circuit TM E03
system
DXH8KY F clutch ECMV solenoid TM E03
supply line system
Electrical
DXHHKA 4th clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXHHKB 4th clutch ECMV solenoid Short circuit TM E03
system
DXHHKY 4th clutch ECMV solenoid TM E03
supply line system
3rd valve extract EPC Electrical
DXHJKA Disconnection WRK E03
solenoid system
3rd valve extract EPC Electrical
DXHJKB Short circuit WRK E03
solenoid system
WA500-6R 11

3rd valve extract EPC Short circuit with power Electrical
DXHJKY WRK E03
3rd valve retract EPC Electrical
DXHKKA Disconnection WRK E03
solenoid system
3rd valve retract EPC Electrical
DXHKKB Short circuit WRK E03
solenoid system
3rd valve retract EPC Short circuit with power Electrical
DXHKKY WRK E03
Troubleshoot-
Joystick steering right Electrical ing by failure
DXHLKA Disconnection WRK E03
EPC solenoid system code (Display
Joystick steering right Electrical of code),
DXHLKB Short circuit WRK E03 Part 10
EPC solenoid system
SEN02942-**
Joystick steering right Short circuit with power Electrical
DXHLKY WRK E03
EPC solenoid supply line system
Joystick steering left EPC Electrical
DXHMKA Disconnection WRK E03
solenoid system
Joystick steering left EPC Electrical
DXHMKB Short circuit WRK E03
solenoid system
Joystick steering left EPC Short circuit with power Electrical
DXHMKY WRK E03
a Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified.
12 WA500-6R
Fuse locations 1
Connection table of fuse box and slow blow fuse
a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is
supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
slow blow fuse to see if the power is supplied normally.
Fuse box A
Type of power supply Fuse No. Capacity of fuse Destination of power

Switch power supply
1 5A Engine controller circuit
Starting switch ACC
2 10 A Starting switch terminal B circuit
3 30 A Engine controller cut circuit
Constant power supply 4 10 A Hazard lamp circuit

slow blow fuse SBF1 5 10 A Radio, auto grease circuit
(50 A) 6 10 A Transmission controller (B) circuit
7 10 A Work equipment controller (B) circuit
8 10 A Machine monitor (B) circuit
9 10 A Horn circuit
10 20 A Air conditioner circuit
Switch power supply 11 5A Air conditioner compressor circuit

slow blow fuse CBF2 12 20 A Rear glass heater circuit
(80 A) 13 10 A Radio, auto grease circuit
14 20 A Air suspension seat, 12 V converter circuit
15 10 A KOMTRAX circuit
Fuse box B
Type of power supply Fuse No. Capacity of fuse Destination of power

1 10 A Turn signal lamp circuit
2 10 A Back-up lamp and brake lamp circuit
3 20 A Front working lamp circuit
4 20 A Rear working lamp circuit
Switch power supply 5 10 A Transmission controller (A) circuit

slow blow fuse SBF2 6 10 A Parking brake circuit
(120 A) 7 10 A Work equipment controller (A) circuit
8 10 A Machine monitor (A) circuit
9 20 A Wiper and washer circuit
10 10 A Spare
11 20 A Main lamp circuit
Switch power supply 12 10 A Clearance lamp (right) circuit
lamp switch 13 10 A Clearance lamp (left) circuit
Switch power supply 14 10 A Headlamp (right) circuit
head lamp relay 15 10 A Headlamp (left) circuit
WA500-6R 13
Slow blow fuse
Slow blow fuse

Type of power supply Capacity of fuse Destination of power
No.
Starting switch B terminal circuit, engine controller cut cir-
cuit, hazard lamp circuit, radio, auto grease circuit, trans-
Constant power supply SBF1 50 A
mission controller (B) circuit, work equipment controller
(B) circuit, machine monitor (B) circuit
Horn circuit, air conditioner circuit, air conditioner com-
pressor circuit, rear glass heater circuit, radio, auto
80 A
grease circuit, air suspension seat, 12 V converter circuit,
KOMTRAX circuit
SBF2 Turn signal lamp circuit, back-up lamp, brake lamp circuit,
Switch power supply
front working lamp circuit, rear working lamp circuit,
120 A transmission controller (A) circuit, parking brake circuit,
work equipment controller (A) circuit, machine monitor (A)
circuit, wiper, washer circuit, spare, main lamp circuit
SBF3 250 A Heater relay circuit
Locations and numbers of fuse boxes and slow blow fuse
14 WA500-6R
WA500-6R 15
SEN02931-02


© 2017 KOMATSU
All Rights Reserved
16
SEN02932-02
WA500-6R

WA500-6R 60001 and up
General information on troubleshooting
Points to remember when performing troubleshooting ................................................................................... 2
How to proceed in troubleshooting ................................................................................................................. 4
Testing before troubleshooting........................................................................................................................ 6
Classification and procedures of troubleshooting ........................................................................................... 7
Information in troubleshooting table...............................................................................................................11
Troubleshooting method for disconnecting wiring harness of pressure sensor system................................ 13
Phenomena looking like troubles and troubleshooting Nos. ......................................................................... 16
Connection table for connector pin numbers ................................................................................................ 18
T- branch box and T- branch adapter table ................................................................................................... 54
WA500-6R 1
Points to remember when performing troubleshooting 1

(Rev. 2014/11)
k Stop the machine on a level place and make sure that the frame lock pin, chocks, parking brake,
etc. are applied normally.
k When performing the operation with 2 or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before disconnecting wiring, etc., be sure to remove the starting switch key and disconnect the
battery ground cable.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
k Before starting inspection or replacement of the coolant temperature sensor, be sure to drain
about 10 l of coolant because the coolant can spout out through the temperature sensor mount-
ing port even if the radiator cap has been removed.
k When inspecting or replacing the engine oil pressure sensor (switch), open the engine oil filler
port and make sure the engine oil temperature has dropped enough to avoid burning.
k When checking or replacing an oil temperature sensor or oil pressure sensor, loosen the oil filler
cap of hydraulic tank to release the pressure inside the hydraulic tank and release the remaining
pressure in the hydraulic circuit. For details, see "Releasing remaining pressure in hydraulic cir-
cuit" in Testing and adjusting. Use the monitoring function to display the hydraulic oil tempera-
ture on the machine monitor and check that it is 40°C or below to prevent burn injury.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to
prevent reoccurrence of the failure.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how identifying rough causes of the given undesirable symptom through the interview
with the operator concerned can facilitate the troubleshooting.
1. When performing troubleshooting, do not hurry to disassemble the machine. 
If the machine is disassembled immediately after any failure occurs,
q Parts that have no connection with the failure or other unnecessary parts are disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of staff-hours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting corresponding to the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything unusual about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Does the machine have abnormal symptoms?
2) Check "Check before starting" items.
3) Check other check items.
4) Check other maintenance matters which can be checked externally and are considered to be necessary.
4. Checking failure
Check the extent of the failure yourself, and judge whether it is a real failure or a problem of the method
of operation, etc.
a When operating the machine to reproduce the failure symptom, do not perform any investigation or
measurement that may make the problem worse.
2 WA500-6R
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure,
then use the troubleshooting flowchart or troubleshooting flow (matrix) to locate the position of the failure
exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur
again. To prevent this, you must locate and eliminate the primary cause behind the given failure.
WA500-6R 3
How to proceed in troubleshooting 1

(Rev. 2011/09)
4 WA500-6R
WA500-6R 5
Testing before troubleshooting 1
Item Criteria Remedy

1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel — Clean or drain
3. Check of level and type of oil in engine oil pan Between H and L Add oil
Between FULL and
4. Check of coolant level Add coolant
LOW
Lubricating oil 5. Check of air cleaner for clogging No red Clean or replace
and coolant 6. Check of level and type of hydraulic oil Between H and L Add oil
In upper range of site
7. Check of level and type of transmission oil Add oil
gauge
8. Check of engine oil filter for clogging — Replace
9. Check of hydraulic oil filter for clogging — Replace
10. Check of transmission oil filter for clogging — Replace
11. Check of battery terminal cables for looseness
— Retighten or replace
and corrosion
12. Check of alternator terminal cables for
Electrical — Retighten or replace
looseness and corrosion
parts
13. Check of starting motor terminal cables for
— Retighten or replace
looseness and corrosion
14. Check of operation of instruments — Repair or replace
15. Check for abnormal noise and smell — Repair
Hydraulic and 16. Check for oil leakage — Repair
mechanical
equipment 17. Bleeding air — Bleed air
18. Check of effect of brake — Repair or adjust
19. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
20. Check of battery electrolyte level Between U.L and L.L Add or replace
21. Check wires for discoloration, burn, and removal
— Replace
of cover
22. Check for removed wire clamp and drooping
— Repair
wire
Electrical 23. Check wiring for wetting with water (Check

Disconnect and dry
equipment connectors and terminals for wetting with water, —
connectors
in particular)
24. Check of slow-blow fuses and fuses for
— Replace
disconnection and corrosion
25. Check of alternator voltage (with engine at After several-minute
Repair or replace
medium speed or higher) operation: 27.5 – 29.5 V
26. Check of operating sound of battery relay
— Replace
(Starting switch OFF  ON)
6 WA500-6R
Classification and procedures of troubleshooting 1

Classification of troubleshooting
Mode Content
Code display Troubleshooting by failure code (code display)
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical systems
S-mode Troubleshooting of the engine unit
Troubleshooting procedure
If a failure symptom appears on the machine, select an appropriate troubleshooting No. according to the
following procedure, and go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when an action level is displayed on machine monitor:
If an action level appears on the machine monitor, display the failure code by using the abnormality record
display function (for electrical and mechanical systems) of the machine monitor (EMMS). (See [*1].)
Perform the corresponding troubleshooting classified in [Code display] mode according to the displayed
failure code.
a Each failure code appears "flashing" when the problem corresponding to it is detected. Even if a failure
code appears "lighting up" with the starting switch in ON, the problem corresponding to that failure code
has not necessarily been repaired (some problems can be detected by simply turning the starting
switch to ON position).
a If any failure code is recorded, be sure to perform the operation for reproducing it to see whether the
problem corresponding to it still remains as a problem or has been repaired (for the method of
reproducing the failure code, see the troubleshooting in [Code display]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If no action level appears on the machine monitor, display the failure code by using the abnormality record
display function (for electrical and mechanical systems) of the machine monitor (EMMS). (See [*2].)
1) If a failure code is recorded, perform the corresponding troubleshooting classified in [Code display]
mode according to that failure code.
a Each failure code appears "flashing" when the problem corresponding to it is detected. Even if a
failure code appears "lighting up" with the starting switch in ON, the problem corresponding to that
failure code has not necessarily been repaired (some problems can be detected by simply turning
the starting switch to ON position).
a If any failure code is recorded, be sure to perform the operation for reproducing it to see whether
the problem corresponding to it still remains as a problem or has been repaired (for the method of
reproducing the failure code, see the troubleshooting in [Code display]). (See [*1].)
a A failure code of the mechanical system cannot be deleted.
2) If a failure code is not recorded in the machine monitor (EMMS), a problem that the machine cannot
find out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the failure symptom again to select the same symptom from the table of "Failure
symptom and troubleshooting No.", and then perform the troubleshooting related to that symptom in
the "E mode", "H mode", or "S mode".
3. Action to take after failure is eliminated

Clear all the failure codes in the electrical system abnormality record, referring to [*2].
WA500-6R 7
[*1] a Holding down the two switches for 5

Failure code display function seconds or more makes the entire screen
While an action level appears on the machine blank. As this state is recognized, release
monitor, press [>] switch once to display the the buttons.
failure code of currently unsolved failure.
a The failure codes detected in the past are
classified into failures of the electrical sys-
tem and the mechanical system and are
recorded as abnormality records. (For
details, see "Service mode".)
a When two or more failures are involved,
pressing [>] switch displays further codes.
a After [>] switch is pressed to display all fail-
ure codes of currently unsolved failures, if
[>] switch is pressed again, the service
meter display screen will be restored.
Pressing [>] switch one more time displays
the failure codes from the first.
If no switch is touched for 30 seconds, the
action level display screen is automatically
3) Inputting and accepting ID
displayed.
Operate the buttons to input the ID.
q ID: "6491"
1] With cursor (C) located at the highest-order
digit, press "<" or ">" switch to change the
value of this digit in the range of "0" to "9".
2] If a desired numerical number is displayed,
press "U" switch to accept it.
a The cursor moves to the 2nd digit
position.
3] Similarly set remaining 3 digits and press
"U" switch.
a If you have entered a wrong value, you
can move to the highest-order digit by
using t switch except when the cursor is
located at a position other than the
[*2] highest-order digit allowing to repeat the
1. Procedure for switching to service mode and procedure from the first. In this case, the
operation on screen value that had been entered remains as
When using the service mode, perform following they are until modified. When the cursor
special operation to switch the screen display. is at the highest-order digit, you can move
Reference: The language displayed in the to the higher layer by using t switch.
service mode is English When the cursor is located at the leftmost
irrespective of the language position, pressing the switch restores the
selected in the operator mode. standard screen (operator mode).
1) Checking screen display When the cursor is located at a position
Check that the machine monitor is in the other than the leftmost position, pressing
operator mode and any of the "Service the switch returns the cursor to the
meter", "Action level", or "Failure code" is leftmost position.
displayed on the screen. If no switch operation is performed for 60
seconds or longer in the ID input screen,
2) Displaying ID input initial screen
the screen automatically changes to the
Hold down "t" switch and "<" switch
standard screen.
simultaneously for 5 seconds minimum to
open the ID input initial screen.
8 WA500-6R
2. Electrical system abnormality record display

function (ELECTRIC FAULT)
For the failure code list, see Troubleshooting,
"Failure code list".
The machine monitor records the past failures in
the electrical system as the failure codes. The
failure codes are displayed from the following
operations.
1) Selecting a menu
Select the ELECTRIC FAULT (Electrical
system abnormality record display function)
from the service mode menu screen.
a [**] field displays total number of
abnormality records currently stored (up
to 20 records).
4) Displaying menu initial screen
a After accepting 4-digit ID, display the
menu initial screen in the service mode.
a Once you enter and accept an ID, it is
effective until the starting switch is turned
to OFF position.
2) Displaying abnormality record

With the menu item being selected, press
[U] button to display stored abnormality
record information.
5) Selecting menu in service mode

a Pressing [<] or [>] switch displays each
service mode menu item in the following
order.
[1] ELECTRIC FAULT: Electrical system
abnormality
record display
function
[2] MACHINE FAULT: Mechanical system
abnormality record
display function
While menu items [3] to [12] are provided,
they are not described in this section.
3) Clearing abnormality record information
With abnormality record information being
displayed, Press [<] or [>] switch to display
the ALL CLEAR menu screen.
WA500-6R 9
3. Mechanical system abnormality record

display function (MACHINE FAULT)
For the failure code list, see Troubleshooting,
"Failure code list".
The machine monitor records the past failures in
the mechanical as the failure codes. The failure
codes are displayed from the following
operations.
1) Selecting a menu
a Select "MACHINE FAULT" (mechanical
system abnormality record display
function) from the service mode menu
screen.
a "**" displays the number of abnormality
records currently recorded.
Press [U] switch to display the ALL CLEAR
screen. 
Select "YES" or "NO" by using [<] or [>]
switch.
"YES" is selected and [t] switch is
"NO" is selected, deletion is cancelled
and "Abnormality record information"
screen is restored.
a By default, the cursor is set to "NO"
(cancel) to prevent resetting error.
a The currently unsolved failure information
(blinking) cannot be cleared.
2) Displaying abnormality record

With the menu item being selected, press
[U] switch to display stored abnormality
record information.
3) Clearing abnormality record (not allowed)

Abnormality record information of the
mechanical system cannot be deleted.
10 WA500-6R
Information in troubleshooting table 1

(Rev. 2010/03)
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before performing troubleshooting, understand that information fully.
User code Failure code
Display on Failure name displayed on the Abnormality Record screen of the
Display on machine Failure
machine moni- machine monitor
monitor
tor
Detail of failure Description of the failure detected by the machine monitor or controller
Action of
Action to be taken to protect the system and equipment when the machine monitor or controller detects
machine moni-
a trouble
tor or controller
Problem on
Problem that appears on machine as result of action (above) taken by machine monitor or controller
machine
Related infor-
Information related to detected failure or troubleshooting
mation
Cause Procedure, measuring location, criteria and remarks
<Details of description>
q Procedure
1 Defective component
q Measuring location
a "Between A and B" means the measurement of voltage, resistance or oth-
ers between terminals A and B.
q Criteria to judge probable causes (normal value)
q Remarks for judgment
Open or short circuit in wiring <How to use troubleshooting sheet>
2 q Perform troubleshooting procedures in numerical order.
harness
q If the check result does not meet the criteria, the probable cause described
on the left column is the actual cause of the failure.
q If the check result shows no abnormality, and unless otherwise specified, pro-
ceed to the next step (next cause item).
Open circuit in wiring harness q Check that the failure is fixed after a failure was found and repaired.
3 (wire breakage or defective con- <Failures in wiring harness>
tact of connector) q Open circuit in wiring
The connector connection is defective or the wire is broken.
q Ground fault
A harness not connected to ground circuit contacts the ground wiring or ma-
chine.
Ground fault in wiring harness
4 q Hot short circuit
(contact with ground circuit)
A harness not connected to the power circuit (24 V) contacts with the power
circuit.
q Short circuit
An independent wire in the harness contacts with other wire.
(poor insulation at connector and others)
Hot short circuit <Precautions for troubleshooting>
5
(contact with 24 V circuit) (1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless otherwise
specified.
q When "male" or "female" is not indicated with a connector number, dis-
connect the connector, and insert T-adapter between the male and fe-
6 Short circuit in wiring harness male connectors.
q When "male" or "female" is indicated with a connector number, discon-
nect the connector, and connect T-adapter only to either male or femae
connector.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as shown
below unless otherwise specified.
7 Defective controller
q Connect the positive (+) lead to pin or wire indicated first.
q Connect the negative (-) lead to a pin or wire indicated second.
WA500-6R 11
Related circuit diagram
This is the excerpted circuit diagram related to troubleshoot-

ing
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed
12 WA500-6R
Troubleshooting method for disconnecting wiring harness of pressure

sensor system 1
a Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may
have the differences among the resistances measured and its own polarities. So troubleshooting must be
performed carefully.
Failure codes applicable to this diagnosis

q CA122: Charge Air Pressure Sensor High Error
q CA123: Charge Air Pressure Sensor Low Error
q CA221: Ambient Pressure Sensor High Error
q CA222: Ambient Pressure Sensor Low Error
q CA451: Common rail pressure sensor high error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore, when
measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and
2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each oth-
er and record the finite value obtained as a measured value.
a Since measured values may be different from each other, take several measurements. Cause of
the differences appears to be that the sensor may be charged by the tester. Take several measure-
ment in both steps 1 and 2. Take the fact into consideration this differences when determining
whether the wiring harness is disconnected in step 3.
2. Measure and record resistance with wiring harness between pressure sensor and engine controller
connected
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor
connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and
connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
WA500-6R 13
3. Judging open circuit

If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is disconnected".
a "Apparent difference" means a difference of 10 or more times.
List of pressure sensor measuring locations and reference values

Indide of sensor
Measuring location at Measured internal resistance of
Sensor Remarks
sensor pin sensor
(reference)
Charge pressure R2: Between (1) and (3) Appoximately 2.9kz
sensor R1: Between (2) and (3) Appoximately 4.3kz
Sensor is common to engine mod-
R2: Between (1) and (3) Appoximately 3.2kz
els 95, 125, 140, 170 and 12V140.
Ambient pressure R1: Between (2) (+) and
Appoximately 4.6kz
sensor (1) (-) If polarities are reversed, resistance
R1: Between (1) (+) and value changes.
Appoximately 2.9kz
(2) (-)
R2: Between (3) and (1) Appoximately 23kz
Common rail pres- It the polarity is reversed, the resis-
sure sensor R1: Between (1) (+) and tance becomes infinite.
Appoximately 10Mz
(2) (-)
*: The following lists the connector to be disconnected when measuring R2’. (See related circuit diagram listed
in troubleshooting section of each failure code.)
q When measuring R2' of charge pressure sensor (CA123):
Connectors of resistance RES, engine oil pressure sensor, and G sensor
q When measuring R2' of ambient pressure sensor (CA222):
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, and G sensor
q When measuring R2' of common rail pressure sensor (CA451):
Since 5 V power supply is used independently, there is no connector to be disconnected.
14 WA500-6R
Measurement record (For measuring locations, see related circuit diagram listed in troublshooting section of
each failure code)
Sensor with wiring harness con-
Sensor unit
Measuring nected Measuring value
Sensor (Measuring location at
value (Measuring location on harness
sensor pin)
connector of engine controller)
Charge pressure R2: Between (1) and (3) R2’: Between (37) and (47) (*)
sensor R1: Between (2) and (3) R1’: Between (44) and (47)
R2: Between (1) and (3) R2’: Between (37) and (38) (*)
Ambient pressure R1: Between (2) (+) and
R1’: Between (3) (+) and (38) (-)
sensor (1) (-)
R1: Between (1) (+) and
R1’: Between (38) (+) and (3) (-)
(2) (-)
R2: Between (3) and (1) R2: Between (37) and (47) (*)
Common rail pres-
sure sensor R1: Between (1) (+) and
R1: Between (47) (+) and (25) (-)
(2) (-)
WA500-6R 15
Phenomena looking like troubles and troubleshooting Nos. 1

Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Engine does not start easily. E-1 S-1
4 Engine does not crank E-1 S-2 a)
Engine cranks but exhaust smoke does not comes
5 Engine does S-2 b)
out
not start.
Exhaust smoke comes out but engine does not start
6 S-2 c)
(Fuel is injected)
7 Engine does not pick up smoothly. S-3
8 Engine stops during operation H-2 S-4
9 Engine rotation is abnormal (Engine hunts) S-5
10 Output is insufficient (Power is low) S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Engine oil becomes contaminated quickly S-9
14 Fuel is consumed much S-10
15 Coolant contains oil (blows back or reduces) S-11
16 Engine oil pressure drops S-12
17 Engine oil level rises (Water or fuel is mixed in oil) S-13
18 Coolant temperature is too high (Overheating) S-14
19 Abnormal sound comes out S-15
20 Vibration is excessive S-16
21 Air cannot be bled from fuel circuit S-17
Phenomena related to power train
22 Machine does not start H-1
Torque converter lockup is not switched (engine stalls) 
23 H-2
[machine with lockup clutch (it equipped)]
Torque converter lockup is not switched 
24 H-3
[machine with lockup clutch (it equipped)]
Travel speed is slow, the thrusting force is weal, the uphill traveling
25 H-4
power is weak, and the gear is not shifted
26 Shocks are large at the times of starting and shifting gear H-5
27 Time lag is large at the times of starting and shifting gear H-6
28 Torque converter oil temperature is high H-7
Phenomena related to steering
29 Machine cannot be steered H-8
30 Machine cannot be steered [machine with joystick steering (it equipped)] H-9
31 Steering response is low H-10
Turning, response of steering is poor 
32 H-11
[machine with joystick steering (it equipped)]
33 Steering is heavy H-12
34 When machine turns, it shakes or makes large shocks H-13
16 WA500-6R
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
When machine turns, it shakes or makes large shocks 
35 H-14
[machine with joystick steering (if equipped)]
Phenomena related to brake
36 The wheel brake does not work or does not work well H-15
37 The wheel brake is not released or it drags H-16
38 The parking brake does not work or does not work well H-17
Parking brake cannot be reset or it drags (including emergency
39 H-18
release system)
Phenomena related to work equipment
40 Lift arm does not rise H-19
41 Lift arm speed is low or rising force of lift arm is insufficient H-20
42 When rising, the lift arm comes to move slowly at specific height H-21
43 Bucket cannot be held with lift arm cylinder (Bucket floats) H-22
44 Hydraulic drifts of the lift arm occur often H-23
45 The lift arm wobbles during operation H-24
46 Bucket does not tilt back H-25
47 Bucket speed is low or tilting back force is insufficient H-26
48 The bucket comes to operate slowly in the midst of tilting-back H-27
49 The bucket cylinder cannot hold down the bucket H-28
50 Hydraulic drifts of the bucket occur often H-29
The bucket wobbles during travel with cargo (The work equipment
51 H-30
valve is set to “HOLD”)
Engine speed lowers remarkably or engine stalls during work equip-
52 H-31
ment control
53 Large shocks are made when work equipment starts and stops H-32
When work equipment circuit is relieved singly, other work equipment
54 H-33
moves
55 ECSS does not operate, and pitching or bouncing occurs H-34
Others
56 Wiper does not operate E-2
57 Windshield washer does not operate E-3
Headlamp, clearance lamp, tail lamp, and license plate lamp do not
58 E-4
light up or go off
59 Working lamp does not light up or go off E-5
60 Turn signal lamp and hazard lamp do not light up or go off E-6
61 Brake lamp does not light or it keeps lighting up E-7
62 Backup lamp does not light or it keeps lighting up E-8
63 Backup buzzer does not sound or it keeps sounding E-9
64 Horn does not sound or it keeps sounding E-10
65 Alarm buzzer does not sound or it keeps sounding E-11
66 Air conditioner does not operate or stop. E-12
67 KOMTRAX system does not work properly. E-13
Electric priming pump does not operate or does not stop automati-
68 E-14
cally
WA500-6R 17
Connection table for connector pin numbers (Rev. 2007.12)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
18 WA500-6R
WA500-6R 19
20 WA500-6R
WA500-6R 21
22 WA500-6R
WA500-6R 23
24 WA500-6R
WA500-6R 25
26 WA500-6R
WA500-6R 27
28 WA500-6R
WA500-6R 29
30 WA500-6R
WA500-6R 31
32 WA500-6R
WA500-6R 33
34 WA500-6R
WA500-6R 35
36 WA500-6R
WA500-6R 37
38 WA500-6R
WA500-6R 39
40 WA500-6R
WA500-6R 41
42 WA500-6R
WA500-6R 43
44 WA500-6R
WA500-6R 45
46 WA500-6R
WA500-6R 47
48 WA500-6R
WA500-6R 49
50 WA500-6R
WA500-6R 51
52 WA500-6R
WA500-6R 53
T- branch box and T- branch adapter table 1

(Rev. 2007.12)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
54 WA500-6R
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
WA500-6R 55
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3) 
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for 
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“ * ” Shows not T-adapter but socket.
56 WA500-6R
WA500-6R 57
SEN02932-02


© 2017 KOMATSU
All Rights Reserved
58
SEN02933-00
WA500-6R

WA500-6R 60001 and up
Troubleshooting by failure code
(Display of code), Part 1
Failure code [1500L0] (TORQFLOW transmission : Double meshing) ................................................ 3
Failure code [15B0NX] (Transmission filter: Clogged) ......................................................................... 4
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)................. 6
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)................ 8
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) .............. 10
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) ............. 12
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) ............ 14
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) ........... 16
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) ........... 18
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) .......... 20
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) ........... 22
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) .......... 24
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)............ 26
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)........... 28
WA500-6R 1
Failure code [2F00MA] (Parking brake: Malfunction) ......................................................................... 30

Failure code [2G42ZG] (Front accumulator: Low oil pressure) .......................................................... 32
2 WA500-6R
Failure code [1500L0] (TORQFLOW transmission : Double meshing) 1
Action code Failure code TORQFLOW transmission: Double meshing

Trouble
E03 1500L0 (Transmission controller system)
Contents of
• A combination for double meshing is input as a fill signal.
trouble
Action of • Turns the centralized warning lamp and warning buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The transmission may be broken.
appears on
• The machine can not travel.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 See failure codes [15SAL1], [15SBL1], [15SEL1], [15SFL1], [15SGL1] and [15SHL1].
state
WA500-6R 3
Failure code [15B0NX] (Transmission filter: Clogged) 1
Action code Failure code Transmission filter: Clogging

Trouble
E01 15B0NX (Machine monitor system)
• Transmission filter clogging sensor circuit is OPEN. (When torque converter oil temperature is above
Contents of
50°C, engine is running, and option is set)
trouble
Trouble detected while engine is stopped is maintained even after engine is started.
Action of • Turns the transmission filter clogging caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The transmission filter clogging caution lamp lights on.
appears on
• The transmission may be broken.
machine
• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the mon-
Related
itoring function (Code: 40903, D-IN-24).
information
• Method of reproducing failure code: Start engine.
Cause Standard value in normal state/Remarks on troubleshooting

1 Transmission filter clogging The transmission filter may be clogged. Check it directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission clog- • Disconnect connector R12
2 ging sensor (Internal discon- R12 (male) Transmission oil filter Resistance
nection or short circuit)
Normal Max. 1 z
Between (1) and (2)
Clogging Min. 1 Mz
Disconnection in wiring har- without turning starting switch ON.
Possible causes
ness (Disconnection or Wiring harness between L53 (female) (5) – Resis-
and standard 3 Max. 1 z
defective contact of connec- R12 (female) (1) tance
value in normal
tor) Wiring harness between R12 (male) (2) – Resis-
state Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting.
4
(Contact with 24 V circuit) Wiring harness between L53 (female) (5) –
Voltage Max. 1 V
R12 (female) (1) and chassis ground
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
5 Defective machine monitor L53 (female) Transmission oil filter Resistance
Between (5) – Normal Max. 1 z
chassis ground Clogging Min. 1 Mz
4 WA500-6R
Circuit diagram related to transmission clogging sensor
WA500-6R 5
Failure code [15SAL1] (ECMV F clutch: When command current is OFF,

fill signal is ON) 1
Action code Failure code ECMV F clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SAL1 (Transmission controller system)
Contents of • When F ECMV solenoid output is turned OFF, F ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the F ECMV fill switch signal is turned ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to “N (Neutral)”.
Problem that
appears on • F travel is enabled, but R travel is disabled.
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31608, ECMV F DIR).
Related
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-25).

Abnormal F (forward) clutch
1 oil pressure (There is resid- There is no pressure in position other than F.
ual pressure)
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective F ECMV fill switch FNR (directional)
2 lever, joystick steer-
(Internal short circuit)
F.SW (male) ing FNR (directional) Resistance
switch, or right FNR
(directional) switch
Between (1) – F (Forward) Max. 1 z
Possible causes
and standard chassis ground Other than above Min. 1 Mz
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring without turning starting switch ON.
3 harness (Contact with
ground circuit) Wiring harness between L03 (female) (27) – Resis-
Min. 1 Mz
F.SW (female) (1) and chassis ground tance
troubleshooting.
Defective transmission FNR (directional)
controller
L03 ing FNR (directional) Voltage
Between (27) – F (Forward) Max. 1 V
chassis ground Other than above 8 – 10 V
6 WA500-6R
Circuit diagram related to transmission F clutch
WA500-6R 7
Failure code [15SALH] (ECMV F clutch: When command current is ON,

fill signal is OFF) 1
Action code Failure code ECMV F clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SALH (Transmission controller system)
Contents of
• When F ECMV solenoid output is turned ON, F ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the F ECMV fill switch signal is turned OFF.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31608, ECMV F DIR).
Related
40908, D-IN-25).
information
40908, D-IN-25).
• Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch F (forward)

Abnormal F (forward) clutch
oil pressure (There is no
1 Oil pressure is normal in F.
pressure while command is
ON)
troubleshooting.
Defective F ECMV fill switch FNR (directional)
(Internal disconnection)
F.SW (male) ing FNR (directional) Resistance
Possible causes Between (1) – F (Forward) Max. 1 z
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
3 harness (Disconnection or
defective contact of connector) Wiring harness between L03 (female) (27) – Resis-
Max. 1 z
F.SW (female) (1) tance
troubleshooting.
controller
Between (27) – F (Forward) Max. 1 V
8 WA500-6R
Circuit diagram related to transmission F clutch
WA500-6R 9
Failure code [15SBL1] (ECMV R clutch: When command current is OFF,

fill signal is ON) 1
Action code Failure code ECMV R clutch When command current is OFF, fill signal is ON
Trouble
E03 15SBL1 (Transmission controller system)
Contents of • When R ECMV solenoid output is turned OFF, R ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the R ECMV fill switch signal is turned ON.
controller • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
Problem that
appears on • The machine can travel in the R position, but cannot travel in the F position.
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the moni-
toring function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-26).

Abnormal R (reverse) clutch
1 oil pressure (There is resid- There is no pressure in position other than R.
ual pressure)
troubleshooting.
Defective R ECMV fill switch FNR (directional)
R.SW (male) ing FNR (directional) Resistance
Between (1) – R (Reverse) Max. 1 z
Possible causes
3 harness (Contact with
ground circuit) Wiring harness between L03 (female) (17) – Resis-
Min. 1 Mz
R.SW (female) (1) and chassis ground tance
troubleshooting.
controller
Between (17) – R (Reverse) Max. 1 V
10 WA500-6R
Circuit diagram related to transmission R clutch
WA500-6R 11
Failure code [15SBLH] (ECMV R clutch: When command current is ON,

Action code Failure code ECMV R clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SBLH (Transmission controller system)
Contents of • When R ECMV solenoid output is turned ON, R ECMV fill switch signal ON is not input.
trouble • Engine speed is below 500 rpm, and clutch does not mesh.
Action of • Judges that the R ECMV fill switch signal is turned OFF.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
toring function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-26).
• Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch R (reverse)

Abnormal R (reverse) clutch
oil pressure (There is no
1 Oil pressure is normal in R.
pressure while command is
ON)
troubleshooting.
Defective R ECMV fill switch FNR (directional)
R.SW (male) ing FNR (directional) Resistance
Possible causes Between (1) – R (Reverse) Max. 1 z
value in normal
state Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness (Disconnection or without turning starting switch ON.
3
defective contact of connec- Wiring harness between L03 (female) (17) – Resis-
tor) Max. 1 z
R.SW (female) (1) tance
troubleshooting.
controller
Between (17) – R (Reverse) Max. 1 V
12 WA500-6R
Circuit diagram related to transmission R clutch
WA500-6R 13
Failure code [15SEL1] (ECMV 1st clutch: When command current is

OFF, fill signal is ON) 1
Action code Failure code ECMV 1st clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SEL1 (Transmission controller system)
Contents of • When 1st ECMV solenoid output is turned OFF, 1st ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the 1st ECMV fill switch signal is turned ON.
• Holds 2nd, 3rd, and 4th proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
Problem that
appears on • The machine can travel at 1st, but not at 2nd, 3rd, and 4th.
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31602, ECMV 1 DIR).
Related
• The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-27).

Abnormal 1st clutch oil pres-
1 sure (There is residual pres- There is no pressure in position other than 1st.
sure)
troubleshooting.
Defective 1st ECMV fill
2 • Keep pressing brake pedal to prevent machine from traveling.
switch (Internal short circuit)
1.SW (male) Shift lever Resistance
Between (1) – 1st (1st speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard 3 harness (Contact with
value in normal ground circuit) Wiring harness between L03 (female) (7) – Resis-
Min. 1 Mz
state 1.SW (female) (1) and chassis ground tance
troubleshooting.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
4
controller • Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R
(reverse).
L03 Shift lever Voltage
Between (7) – 1st (1st speed) Max. 1 V
14 WA500-6R
Circuit diagram related to transmission 1st clutch
WA500-6R 15
Failure code [15SELH] (ECMV 1st clutch: When command current is ON,
Action code Failure code ECMV 1st clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SELH (Transmission controller system)
Contents of
• When 1st ECMV solenoid output is turned ON, 1st ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 1st ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 1st.
appears on
• When the 1st gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring func-
Related • The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-27).
• Method of reproducing failure code: Engine started + Manual/auto shift selector switch to MANUAL +
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to
F (forward) or R (reverse) + Shift lever 1st

Abnormal 1st clutch oil pres-
1 sure (There is no pressure Oil pressure is normal in 1st.
while command is ON)
troubleshooting.
Defective 1st ECMV fill • Turn parking brake switch OFF.
2 switch (Internal disconnec- • Keep pressing brake pedal to prevent machine from traveling.
tion) 1.SW (male) Shift lever Resistance
Between (1) – 1st (1st speed) Max. 1 z
Possible causes Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
and standard ness (Disconnection or without turning starting switch ON.
3
value in normal defective contact of connec- Wiring harness between L03 (female) (7) – Resis-
tor) Max. 1 z
state 1.SW (female) (1) tance
troubleshooting.
4
(reverse).
Between (7) – 1st (1st speed) Max. 1 V
16 WA500-6R
Circuit diagram related to transmission 1st clutch
WA500-6R 17
Failure code [15SFL1] (ECMV 2nd clutch: When command current is

Action code Failure code ECMV 2nd clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SFL1 (Transmission controller system)
Contents of • When 2nd ECMV solenoid output is turned OFF, 2nd ECMV fill switch signal ON is input, and clutch
trouble is not released.
• Judges that the 2nd ECMV fill switch signal is turned ON.
Action of
• Holds 1st, 3rd, and 4th proportional solenoid outputs OFF.
controller
Problem that
appears on • The machine can travel at 2nd, but not at 1st, 3rd, and 4th.
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
Related
• The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-28).

Abnormal 2nd clutch oil pres-
1 sure (There is residual pres- There is no pressure in position other than 2nd.
sure)
troubleshooting.
Defective 2nd ECMV fill
Between (1) – 2nd (2nd speed) Max. 1 z
Min. 1 Mz
troubleshooting.
4
(reverse).
Between (13) – 2nd (2nd speed) Max. 1 V
18 WA500-6R
Circuit diagram related to transmission 2nd clutch
WA500-6R 19
Failure code [15SFLH] (ECMV 2nd clutch: When command current is

ON, fill signal is OFF) 1
Action code Failure code ECMV 2nd clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SFLH (Transmission controller system)
Contents of
• When 2nd ECMV solenoid output is turned ON, 2nd ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 2nd ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 2nd.
appears on
• When the 2nd gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
Related • The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
F (forward) or R (reverse) + Shift lever 2nd

Abnormal 2nd clutch oil pres-
1 sure (There is no pressure Oil pressure is normal in 2nd.
troubleshooting.
Defective 2nd ECMV fill switch
Between (1) – 2nd (2nd speed) Max. 1 z
and standard 3 harness (Disconnection or
value in normal Wiring harness between L03 (female) (13) – Resis-
defective contact of connector) Max. 1 z
troubleshooting.
4
(reverse).
Between (13) – 2nd (2nd speed) Max. 1 V
20 WA500-6R
Circuit diagram related to transmission 2nd clutch
WA500-6R 21
Failure code [15SGL1] (ECMV 3rd clutch: When command current is

Action code Failure code ECMV 3rd: When command current is OFF, fill signal is ON
Trouble
E03 15SGL1 (Transmission controller system)
Contents of • When 3rd ECMV solenoid output is turned OFF, 3rd ECMV fill switch signal ON is input, and clutch is
• Judges that the 3rd ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 4th proportional solenoid outputs OFF.
Action of
controller
Problem that
appears on • The machine can travel at 3rd, but not at 1st, 2nd, and 4th.
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring func-
Related
• The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-29).

Abnormal 3rd clutch oil pres-
1 sure (There is residual pres- There is no pressure in position other than 3rd.
sure)
troubleshooting.
Defective 3rd ECMV fill
Between (1) – 3rd (3rd speed) Max. 1 z
Min. 1 Mz
troubleshooting.
4
(reverse).
Between (3) – 3rd (3rd speed) Max. 1 V
22 WA500-6R
Circuit diagram related to transmission 3rd clutch
WA500-6R 23
Failure code [15SGLH] (ECMV 3rd clutch: When command current is

Action code Failure code ECMV 3rd clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SGLH (Transmission controller system)
Contents of • When 3rd ECMV solenoid output is turned ON, 3rd ECMV fill switch signal ON is not input.
trouble • Engine speed is below 500 rpm and clutch does not mesh.
Action of • Judges that the 3rd ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 3rd.
appears on
• When the 3rd gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring func-
Related • The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
F (forward) or R (reverse) + Shift lever 3rd

Abnormal 3rd clutch oil pres-
1 sure (There is no pressure Oil pressure is normal in 3rd.
troubleshooting.
Defective 3rd ECMV fill switch
Between (1) – 3rd (3rd speed) Max. 1 z
troubleshooting.
4
(reverse).
Between (3) – 3rd (3rd speed) Max. 1 V
24 WA500-6R
Circuit diagram related to transmission 3rd clutch
WA500-6R 25
Failure code [15SHL1] (ECMV 4th clutch: When command current is

Action code Failure code ECMV 4th: When command current is OFF, fill signal is ON
Trouble
E03 15SHL1 (Transmission controller system)
Contents of • When 4th ECMV solenoid output is turned OFF, 4th ECMV fill switch signal ON is input, and clutch is
• Judges that the 4th ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 3rd proportional solenoid outputs OFF.
Action of
controller
Problem that
appears on • The machine can travel at 4th, but not at 1st, 2nd, and 3rd.
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
Related
• The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-30).

Abnormal 4th clutch oil pres-
1 sure (There is residual pres- There is no pressure in position other than 4th.
sure)
troubleshooting.
Defective 4th ECMV fill
Between (1) – 4th (4th speed) Max. 1 z
Min. 1 Mz
troubleshooting.
4
(reverse).
Between (2) – 4th (4th speed) Max. 1 V
26 WA500-6R
Circuit diagram related to transmission 4th clutch
WA500-6R 27
Failure code [15SHLH] (ECMV 4th clutch: When command current is

Action code Failure code ECMV 4th: When command current is ON, fill signal is OFF
Trouble
E01 15SHLH (Transmission controller system)
Contents of
• When 4th ECMV solenoid output is turned ON, 4th ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 4th ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 4th.
appears on
• When the 4th gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31605, ECMV 4).
Related • The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
F (forward) or R (reverse) + Shift lever 4th

Abnormal 4th clutch oil pres-
1 sure (There is no pressure Oil pressure is normal in 4th.
troubleshooting.
Defective 4th ECMV fill switch
Between (1) – 4th (4th speed) Max. 1 z
troubleshooting.
4
(reverse).
Between (2) – 4th (4th speed) Max. 1 V
28 WA500-6R
Circuit diagram related to transmission 4th clutch
WA500-6R 29
Failure code [2F00MA] (Parking brake: Malfunction) 1
Action code Failure code Parking brake: Malfunction

Trouble
E03 2F00MA (Machine monitor system)
Contents of
• While the F or R clutch is operated, the parking brake operation sensor circuit is OPEN.
trouble
Problem that
appears on • While parking brake lamp is lighting up, actual gear speed is not neutral.
machine
• The input state (ON/OFF) from the parking indicator switch can be checked with the monitoring func-
Related tion (Code: 40903 D-IN-26).
information • Method of reproducing failure code: Turn starting switch ON, turn parking brake switch OFF, and
perform forward or reverse travel operation.

troubleshooting.
Defective parking brake indi- • Disconnect connector PB.SW.
1 cator switch (Internal discon- PB.SW (male) Parking brake Resistance
nection)
Released Max. 1 z
Between (1) and (2)
Operates Min. 1 Mz
Possible causes without turning starting switch ON.
and standard Disconnection in wiring
Wiring harness between L54 (female) (1) – Resis-
value in normal 2 harness (Disconnection or Max. 1 z
state PB.SW (female) (1) tance
defective contact)
Wiring harness between PB.SW (female) (2) Resis-
Max. 1 z
– chassis ground tance
troubleshooting.
Parking brake oil
3 Defective machine monitor L54 Voltage
pressure
Between (1) – Released Max. 1 V
chassis ground Operates 20 – 30 V
30 WA500-6R
Circuit diagram related to parking brake
WA500-6R 31
Failure code [2G42ZG] (Front accumulator: Low oil pressure) 1
Action code Failure code Front accumulator: Low oil pressure

Trouble
E03 2G42ZG (Machine monitor system)
Contents of • After engine is started, pressure increases to set pressure and then front brake accumulator pres-
trouble sure sensor circuit is OPEN.
Problem that
• The front brake accumulator oil pressure lowers.
appears on
• The brake may not work.
machine
• The input state (ON/OFF) from the front brake oil pressure sensor can be checked with the monitor-
Related
ing function (Code: 40902, D-IN-16).
information
• Method of reproducing failure code: Turn starting switch ON.

The front brake accumulator Check the front brake accumulator oil pressure.
1
oil pressure lowers. (See Testing and adjusting.)
and carry out troubleshooting.
Front brake accumu-
B05 (male) Resistance
lator oil pressure
Defective front brake oil Normal brake
2 pressure sensor (Internal pressure
disconnection) Max. 1 z
Min. 5.88 MPa
Between (1) and (2) {Min. 60 kg/cm2}
Low brake pressure
Max. 3.92 MPa Min. 1 Mz
{Max. 40 kg/cm2}
Possible causes
and standard
value in normal Disconnection in wiring
state Wiring harness between L53 (female) (1) – Resis-
3 harness (Disconnection or Max. 1 z
B05 (female) (1) tance
defective contact)
Wiring harness between B05 (female) (2) – Resis-
Max. 1 z
GND tance
Front brake accumu-
L53 (female) Resistance
lator oil pressure
Normal brake
4 Defective machine monitor pressure
Max. 1 z
Wiring harness Min. 5.88 MPa
between (1) – {Min. 60 kg/cm2}
chassis ground Low brake pressure
Max. 3.92 MPa Min. 1 Mz
{Max. 40 kg/cm2}
32 WA500-6R
Circuit diagram related to front brake accumulator
WA500-6R 33
SEN02933-00

© 2007 KOMATSU
All Rights Reserved
34
SEN02934-01
WA500-6R

WA500-6R 60001 and up
Failure code [2G43ZG] Rear accumulator: Low oil pressure.......................................................................... 4
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree.............................................................. 6
Failure code [AA1ANX] Air cleaner: Clogging............................................................................................... 10
Failure code [AB00L6] Alternator: Signal disagrees with operating state of engine ..................................... 12
Failure code [AB00MA] Alternator: Malfunction ............................................................................................ 14
Failure code [B@BAZG] Low engine oil pressure ........................................................................................ 16
Failure code [B@BAZK] Engine oil: Low level .............................................................................................. 18
Failure code [B@BCNS] Coolant: Overheating ............................................................................................ 20
Failure code [B@BCZK] Coolant: Low level ................................................................................................. 22
Failure code [b@CENS] Torque converter oil: Overheating ......................................................................... 24
Failure code [B@CENS] Torque converter oil: Overheating ......................................................................... 25
Failure code [B@GAZK] Battery electrolyte: Low level................................................................................. 26
Failure code [B@HANS] Hydraulic oil: Overheating ..................................................................................... 27
Failure code [CA111] Abnormality in engine controller ................................................................................. 28
WA500-6R 1
Troubleshooting by failure code (Display of code), Part 2
SEN02934-01
Failure code [CA115] Engine Ne or Bkup speed sensor error ...................................................................... 31

Failure code [CA122] Charge (boost) pressure sensor high error ................................................................ 32
Failure code [CA123] Charge (boost) pressure sensor low error.................................................................. 34
Failure code [CA131] Throttle sensor high error ........................................................................................... 36
Failure code [CA132] Throttle sensor low error ............................................................................................ 39
Failure code [CA135] Engine oil pressure sensor high error ........................................................................ 42
Failure code [CA141] Engine oil pressure sensor low error.......................................................................... 44
Failure code [CA144] Coolant temperature sensor high error ...................................................................... 46
Failure code [CA145] Coolant temperature sensor low error........................................................................ 48
Failure code [CA153] Charge (boost) temperature sensor high error........................................................... 50
Failure code [CA154] Charge (boost) temperature sensor low error ............................................................ 52
Failure code [CA187] Sensor power supply 2 low error................................................................................ 54
Failure code [CA221] Atmospheric pressure sensor high error .................................................................... 56
Failure code [CA222] Atmospheric pressure sensor low error...................................................................... 58
Failure code [CA227] Sensor power supply 2 high error .............................................................................. 60
2 WA500-6R
SEN02934-01
WA500-6R 3
SEN02934-01 Failure code [2G43ZG] Rear accumulator: Low oil pressure
Failure code [2G43ZG] Rear accumulator: Low oil pressure 1
Action code Failure code Rear accumulator: Low oil pressure

Trouble
E03 2G43ZG (Machine monitor system)
Contents of • After engine is started, pressure increases to set pressure and then rear brake accumulator pressure
trouble sensor circuit is OPEN.
Problem that
• Low rear brake accumulator oil pressure
appears on
• The brake may not work.
machine
• The input state (ON/OFF) from the rear brake oil pressure sensor can be checked with the monitor-
Related
ing function (Code: 40902, D-IN-17).
information

Low rear brake accumulator Check the rear brake accumulator oil pressure.
1
oil pressure (See Testing and adjusting.)
1. Turn starting switch to OFF position.
2. Disconnect connector B04, and connect T-adapter to male side.
3. Depress brake pedal 10 times, then perform troubleshooting.
4. Start engine.
Rear brake
Defective rear brake oil pres- accumulator oil pres-
2 sure sensor (Internal discon- sure: Normal pres- Resis-
Max. 1 Ω
nection) sure tance
Min. 5.88 MPa
Possible causes Between B04 (male) {Min. 60kg/cm2}
and standard (1) and (2)
Rear brake
value in normal accumulator oil pres-
state Resis-
sure: Low pressure Min. 1 MΩ
tance
Max. 3.92 MPa
{Max. 40kg/cm2}
2. Disconnect connectors L53 and B04 and connect T-adapters to
Disconnection in wiring  each female side.
3 harness (Disconnection or Between L53 (female) (7) and B04 (female) Resis-
Max. 1 z
defective contact) (1) tance
Resis-
Between B04 (female) (2) and GND Max. 1 z
tance
If no failure is found by above checks, machine monitor is defective.
4 Defective machine monitor (Since this is an internal defect, troubleshooting cannot be
performed.)
4 WA500-6R
Failure code [2G43ZG] Rear accumulator: Low oil pressure SEN02934-01
Circuit diagram related to rear brake accumulator
WA500-6R 5
SEN02934-01 Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree 1
Action code Failure code Bucket positioner: ON/OFF signals disagree

Trouble
E01 44K0L4 (Work equipment controller system)
• The signals input from the bucket proximity switch are combined impossibly.
• After bucket level-over signal ON and full stroke signal OFF were continued for 3 seconds, full stroke
Contents of signal ON was detected for one second.
trouble • After bucket level-over signal ON and full stroke signal OFF were continued for 3 seconds, bucket
level-over signal OFF was detected for one second.
• If cause of failure disappears, system resets itself.
Action of
• Judged to be below bucket level.
controller
Problem that
appears on • Bucket leveler does not function.
machine
• The input state (ON/OFF) from the bucket cylinder full stroke proximity switch can be checked with
the monitoring function (Code: 40911, D-IN-8).
Related
• The input state (ON/OFF) from the bucket cylinder level proximity switch can be checked with the
information
monitoring function (Code: 40911, D-IN-9).
• Method of reproducing failure code: Start engine + Slowly full-tilt bucket io Full dump

2. Disconnect connectors F11 and F12, and connect T-adapters to
each female side.
3. Turn starting switch to ON position.
Defective 24 V power supply a If power supply voltage is abnormal, go to cause 2, if normal, go
1 to cause 3 and after.
system
Between F11 (female) (A) and Power
Voltage 20 – 30 V
(C) supply
Between F12 (female) (A) and Power
Voltage 20 – 30 V
Possible causes (C) supply
and standard • Power sypply and GND line
value in normal 1. Turn starting switch to OFF position.
state 2. Disconnect connectors F11 and F12, and connect T-adapters to
each female side.
3. Disconnect No.7 fuse in fuse box B.
Between fuse box B - No.7 fuse and F11 Resis-
Max. 1 z
2 Disconnection of harness 1 (female) (A) tance
Between F11 (female) (C) and chassis Resis-
Max. 1 z
ground tance
Between fuse box B - No.7 fuse and F12 Resis-
Max. 1 z
(female) (A) tance
Between F12 (female) (C) and chassis Resis-
Max. 1 z
ground tance
6 WA500-6R
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree SEN02934-01

2. Insert T-adapter into connector F11.
3. Start engine.
4. After operating bucket, stop engine. (Starting switch in ON posi-
tion)
Defective bucket cylinder
level proximity switch (Inter- Position of bucket:
3 Voltage Max. 1 V
nal disconnection or short Between F11 (B) and Below horizontal
circuit) (C) Position of bucket:
Voltage 8 – 10 V
Above horizontal
Since the harness is connected to measure the sensor voltage, if
the voltage is not normal, troubleshoot the harness and confirm that
there is no other cause of failure.
2. Insert T-adapter into connector F12.
3. Start engine.
tion)
Defective bucket cylinder full Position of bucket: Tilt
stroke proximity switch Voltage 8 – 10 V
4 full stroke
(Internal disconnection or Between F12 (B) and
short circuit) (C) Position of bucket:
Other than tilt full Voltage Max. 1 V
stroke
Since the harness is connected to measure the sensor voltage, if
the voltage is not normal, troubleshoot the harness and confirm that
there is no other cause of failure.
Possible causes
and standard 1. Turn starting switch to OFF position.
value in normal 2. Disconnect connectors F11 and F12, and connect T-adapters to
state Disconnection in wiring  each female side.
5 harness (Disconnection or Between F11 (female) (B) and L07 (female) Resis-
Max. 1 z
defective contact of connector) (20) tance
Between F12 (female) (B) and L07 (female) Resis-
Max. 1 z
(10) tance
2. Disconnect connectors L07, F11 and F12, and connect T-
Grounding fault in wiring  adapter to either female side.
6 harness (Contact with Between F11 (female) (B) or L07 (female) Resis-
Min. 1 Mz
ground circuit) (20) and chassis ground tance
Between F12 (female) (B) or L07 (female) Resis-
Min. 1 Mz
(20) and chassis ground tance
2. Insert T-adapter to connector L07.
3. Start engine.
tion)
Position of bucket:
Voltage Max. 1 V
Defective work equipment Between L07 (20) Below horizontal
7 and chassis ground
controller Position of bucket:
Voltage 8 – 10 V
Above horizontal
Position of bucket:
Voltage 8 – 10 V
Tilt full stroke
Between L07 (10)
and chassis ground Position of bucket:
Other than tilt full Voltage Max. 1 V
stroke
WA500-6R 7
SEN02934-01 Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree
Circuit diagram related to bucket proximity switch
8 WA500-6R
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree SEN02934-01
WA500-6R 9
SEN02934-01 Failure code [AA1ANX] Air cleaner: Clogging
Failure code [AA1ANX] Air cleaner: Clogging 1
Action code Failure code Air cleaner: Clogging

Trouble
E01 AA1ANX (Machine monitor system)
Contents of
• The air cleaner clogging sensor circuit is OPEN. (at engine running)
trouble
Action of • Turns the air cleaner clogging caution lamp ON.
Problem that
• The engine does not start or pick up easily, its output is insufficient, and its exhaust gas color is
appears on
black.
machine
• The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring
Related
function (Code: 40902, D-IN-20).
information

1 Clogged air cleaner The air cleaner may be clogged. Check it.
2. Disconnect connector E15.
Defective dust indicator 3. Start engine.
2
If failure code [AA1ANX] is not displayed, dust indicator is
defective.
a Be ready with starting switch at OFF, then perform trouble-
shooting without turning starting switch to ON position.
Resis- 200 to
Between L107 (male) (1) and (2)
tance 400 Ω
Defective dust indicator relay
3 (L107) (Internal disconnec- 1. Turn starting switch to OFF position.
tion or short circuit) 2. Disconnect connector L107, and replace dust indicator relay
with another relay of same model.
3. Start engine.
Possible causes If failure code [AA1ANX] is not displayed, original dust indicator
and standard relay is defective.
value in normal
state
2. Disconnect connectors L107, L53, and E15 and connect T-
adapters to female side.
3. Remove fuse No. 8 in fuse box B.
Between L53 (female) (3) and L107 Resis-
Disconnection in wiring  Max. 1 Ω
(female) (3) tance
Resis-
defective contact of connector) Between L107 (female) (6) and ground Max. 1 Ω
tance
Between L107 (female) (2) and E15 Resis-
Max. 1 Ω
(female) (1) tance
Resis-
Between E15 (female) (2) and ground Max. 1 Ω
tance
Grounding fault in wiring  2. Disconnect connectors L107 and E15, and connect T-adapter
5 harness (Contact with to either female side.
ground circuit) Between ground and L107 (female) (2) or Resis-
Min. 1 MΩ
E15 (female) (1) tance
10 WA500-6R
Failure code [AA1ANX] Air cleaner: Clogging SEN02934-01

2. Insert T-adapter into connector L53.
Possible causes 3. Turn starting switch to ON position.
and standard
Dust indicator: Nor-
value in normal 6 Defective machine monitor mal (Air cleaner is Voltage 20 to 30V
state Between L53 (3) normal)
and ground Dust indicator: Defec-
tive (Air cleaner is Voltage Max. 1 V
clogged)
Circuit diagram related to dust indicator
WA500-6R 11
SEN02934-01 Failure code [AB00L6] Alternator: Signal disagrees with operating state of
Failure code [AB00L6] Alternator: Signal disagrees with operating state

of engine 1
Action code Failure code Alternator: Signal does not match engine running or stopped state
Trouble
E03 AB00L6 (Machine monitor system)
Contents of
• When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
Action of
• Turns charge circuit abnormality caution lamp ON.
controller
Problem that
• After engine start operation, after the starting switch is simply turned ON, the service meter
appears on
advances.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information

2. Disconnect alternator terminal R.
3. Start engine.
Defective alternator (Internal
1 Between alternator Engine running
defect) 27.5 to
terminal R (alternator (Throttle at 1/2 or Voltage
29.5V
side) (E03) and higher)
ground Engine stopped Voltage Max. 1 V
Possible causes 1. Turn starting switch to OFF position.
and standard 2. Disconnect alternator terminal R.
value in normal Hot short in wiring harness 3. Turn starting switch to ON position.
2
state (Contact with 24 V circuit)
Between alternator terminal R (harness side)
Voltage Max. 1 V
(E03) and ground
3. Start engine.
3 Defective machine monitor Engine running
27.5 to
Between L52 (18) (Throttle at 1/2 or Voltage
29.5V
and ground higher)
Engine stopped Voltage Max. 1 V
12 WA500-6R
Failure code [AB00L6] Alternator: Signal disagrees with operating state of SEN02934-01
Circuit diagram related to alternator
WA500-6R 13
SEN02934-01 Failure code [AB00MA] Alternator: Malfunction
Failure code [AB00MA] Alternator: Malfunction 1
Action code Failure code Alternator: Malfunction

Trouble
E03 AB00MA (Machine monitor system)
Contents of
• While the engine is running, the alternator terminal R input voltage is below 5 V.
trouble
Action of
• Turns charge circuit abnormality caution lamp ON.
controller
Problem that
appears on • Deteriorated battery, lack of charge.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information

1 Deteriorated battery The battery may be deteriorated. Check it.
3. Start engine.
Defective alternator (Internal
2 Between alternator Engine running
defect) 27.5 to
terminal R (alternator (Throttle at 1/2 or Voltage
29.5V
side) (E03) and higher)
ground Engine stopped Voltage Max. 1 V
Disconnection in wiring  3. Disconnect connector L52, and connect T-adapter to female
3 harness (Disconnection or side.
Possible causes defective contact of connector)
and standard Between alternator terminal R (E03) and L52 Resis-
Max. 1 Ω
value in normal (female) (18) tance
state 1. Turn starting switch to OFF position.
Grounding fault in wiring  3. Disconnect connectors L52, D02, and K0M, and connect T-
4 harness (Contact with adapter to female side of L52.
ground circuit) Between ground and alternator R terminal
Resis-
wiring harness side (E03) or L52 (female) Min. 1 MΩ
tance
(18)
3. Start engine.
5 Defective machine monitor Engine running
27.5 to
Between L52 (18) (Throttle at 1/2 or Voltage
29.5V
and ground higher)
Engine stopped Voltage Max. 1 V
14 WA500-6R
Failure code [AB00MA] Alternator: Malfunction SEN02934-01
WA500-6R 15
SEN02934-01 Failure code [B@BAZG] Low engine oil pressure
Failure code [B@BAZG] Low engine oil pressure 1
Action code Failure code Low engine oil pressure

Trouble
E03 B@BAZG (Engine controller system)
Contents of • When engine speed was below 500 rpm for 15 seconds or more, engine oil pressure became lower
trouble than operating range.
Action of • Limits output for travel (Limit injection rate and engine speed).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200 ENG OIL PRESS).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
function (Code: 37201 ENG OIL PRESS).

Possible causes Since engine oil pressure may become excessively low, check it
1 Low engine oil pressure
and standard and repair the trouble.
value in normal If cause 1 is not a cause of the trouble, engine oil pressure sensor
state Defective engine oil pressure
2 system may be defective.
sensor system
Carry out troubleshooting for failure codes [CA135] and [CA141].
16 WA500-6R
Failure code [B@BAZG] Low engine oil pressure SEN02934-01
WA500-6R 17
SEN02934-01 Failure code [B@BAZK] Engine oil: Low level
Failure code [B@BAZK] Engine oil: Low level 1
Action code Failure code Engine oil: Low level

Trouble
E01 B@BAZK (Machine monitor system)
• The engine oil level sensor circuit OPEN was detected min. 2 seconds. (at engine stopped)
Contents of
(However, no error is detected for 5 minutes after the engine stopped.)
trouble
• Error detected while engine is stopped is maintained until it is reset even after engine is started.
Action of • Turns the engine oil level caution lamp ON.
Problem that
appears on —
machine
• The engine oil level sensor is connected between the target pin and chassis ground of the machine
monitor without installed in WA500-6.
Related
• The input state (ON/OFF) from target pin – ground circuit of the machine monitor can be checked
information
with the monitoring function (Code: 40903, D-IN-29).

Disconnection in wiring  without turning starting switch ON.
Possible causes defective contact) Max. 1 z
and standard
state without turning starting switch ON.
2 Defective machine monitor
Wiring harness Normal Max. 1 z
between (11) –
chassis ground Disconnection Min. 1 Mz
18 WA500-6R
Failure code [B@BAZK] Engine oil: Low level SEN02934-01
Circuit diagram related to engine oil level sensor
WA500-6R 19
SEN02934-01 Failure code [B@BCNS] Coolant: Overheating
Failure code [B@BCNS] Coolant: Overheating 1
Action code Failure code Coolant: Overheating

Trouble
E02 B@BCNS (Engine controller system)
Contents of • When engine speed was below 500 rpm for 3 seconds or more, coolant temperature exceeded oper-
trouble ating range.
Action of • Limits output and continues operation.
Problem that
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the monitor-
ing function (Code: 04104 COOLANT TEMP).
Related
• The input state (voltage) from the coolant temperature sensor can be checked with the monitoring
information
function (Code: 04105 COOLANT TEMP).

Possible causes Overheating of engine Since engine coolant temperature may become overheat, check it
1
and standard coolant temperature and repair the trouble.
value in normal If cause 1 is not a cause of the trouble, engine coolant temperature
state Defective engine coolant
2 sensor system may be defective.
Carry out troubleshooting for failure codes [CA144] and [CA145].
20 WA500-6R
Failure code [B@BCNS] Coolant: Overheating SEN02934-01
WA500-6R 21
SEN02934-01 Failure code [B@BCZK] Coolant: Low level
Failure code [B@BCZK] Coolant: Low level 1
Action code Failure code Coolant: Low level

Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• The coolant level sensor circuit is OPEN. (Detected time 30 sec.)
trouble
Action of • Turns the coolant level caution lamp ON.
Problem that
appears on • The coolant level is low. The engine overheats (The engine may be broken).
machine
• The input state (ON/OFF) from the coolant level sensor can be checked with the monitoring function
Related
(Code: 40903, D-IN-27).
information

1 Low coolant level The coolant level may be low. Check it directly.
Defective coolant level relay 2. Disconnect connector L116, and replace coolant level relay with
(L116) another relay of same model.
2 3. Turn starting switch to ON position.
(Internal open or short
circuit) If failure code [B@BCZK] is not displayed, original coolant level
relay is defective.
2. Disconnect connector R13, and connect T-adapter to male side.
Defective coolant level sen- Radiator coolant level Resis-
3 Max. 1 z
sor (Internal ground fault) Between R13 (male) is normal tance
(1) and (2) Lowered radiator cool- Resis- Min. 1
ant level tance Mz
Possible causes
2. Disconnect connectors L54 and R13 and connect T-adapters to
and standard
Disconnection in wiring  each female side.
value in normal
state 4 harness (Disconnection or Between L54 (female) (10) and R13 (female) Resis-
Max. 1 z
defective contact) (2) tance
Between L54 (female) (10) and chassis Resis-
Max. 1 z
ground tance
Grounding fault in wiring 2. Disconnect connectors L116 and R13 and connect T-adapter to
5 harness (Contact with either female side.
ground circuit) Between L116 (female) (2) and R13 (female) Resis-
Min. 1 Mz
(1) tance
6 Defective machine monitor Radiator coolant level
Voltage Max. 1 V
Between L54 (10) is normal
and chassis ground Lowered radiator
Voltage Min. 7 V
coolant level
22 WA500-6R
Failure code [B@BCZK] Coolant: Low level SEN02934-01
Circuit diagram related to coolant level sensor
WA500-6R 23
SEN02934-01 Failure code [b@CENS] Torque converter oil: Overheating
Failure code [b@CENS] Torque converter oil: Overheating 1
Action code Failure code Torque converter oil: Overheating

Trouble
E02 b@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 120°C.
trouble
Action of • If cause of failure disappears, system resets itself. (120°C and below was detected continuously for 1
controller second.)
Problem that
• The torque converter oil temperature caution lamp is turned ON (If the machine is used as it is, the
appears on
torque converter may be broken).
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100 TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101 TC OIL TEMP).

Torque converter oil may overheat due to torque converter stall, etc.
Possible causes Overheating of torque 
1 (See Troubleshooting of hydraulic and mechanical system (H-
and standard converter oil
mode).)
value in normal
state Defective torque converter
2 oil temperature sensor Perform troubleshooting for failure code [DGT1KX].
system
24 WA500-6R
Failure code [B@CENS] Torque converter oil: Overheating SEN02934-01
Failure code [B@CENS] Torque converter oil: Overheating 1
Action code Failure code Torque converter oil: Overheating

Trouble
E02 B@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 130°C.
trouble
Action of
• If cause of failure disappears, system resets itself. (130°C and below was detected continuously for 1
controller
second.)
Problem that
• The torque converter oil temperature caution lamp is turned ON (If the machine is used as it is, the
appears on
torque converter may be broken).
machine
Related
information

Torque converter oil may overheat due to torque converter stall, etc.
Possible causes Overheating of torque 
1 (See Troubleshooting of hydraulic and mechanical system (H-
and standard converter oil
mode).)
value in normal
state Defective torque converter
2 oil temperature sensor Perform troubleshooting for failure code [DGT1KX].
system
WA500-6R 25
SEN02934-01 Failure code [B@GAZK] Battery electrolyte: Low level
Failure code [B@GAZK] Battery electrolyte: Low level 1
Action code Failure code Battery electrolyte: Low level

Trouble
E01 B@GAZK (Machine monitor system)
Contents of
• The electrolyte level sensor (if equipped) voltage is below 2 V (for continuous 10 seconds).
trouble
Action of • Turns the electrolyte level caution lamp ON.
Problem that • Turns the electrolyte level caution lamp ON.
appears on • The electrolyte level is low.
machine • Engine may not start easily.
• The input state (voltage) from the electrolyte level sensor can be checked with the monitoring func-
Related
tion (Code: 40300, BATTERY A).
information

1 The electrolyte level is low The electrolyte level may be low. Check it.
2. Disconnect connector R18, and connect T-adapter to male side.
Defective electrolyte level Battery electrolyte
Voltage Min. 2 V
2 sensor (Internal disconnec- Between R18 (male) level: Normal
tion) (1) and chassis Battery electrolyte
ground level: Insufficient level Voltage Max. 2 V
(Low level)
Possible causes 1. Turn starting switch to OFF position.
and standard Disconnection in wiring  2. Disconnect connectors L55 and R18 and connect T-adapters to
value in normal 3 harness (Disconnection or each female side.
state defective contact) Between L55 (female) (5) and R18 (female) Resis-
Max. 1 z
(1) tance
Battery electrolyte
4 Defective machine monitor Voltage Min. 2 V
level: Normal
Between L55 (5) and
chassis ground Battery electrolyte
level: Insufficient level Voltage Max. 2 V
(low level)
Circuit diagram related to battery electrolyte level sensor
26 WA500-6R
Failure code [B@HANS] Hydraulic oil: Overheating SEN02934-01
Failure code [B@HANS] Hydraulic oil: Overheating 1
Action code Failure code Hydraulic oil: Overheating

Trouble
E02 B@HANS (Machine monitor system)
Contents of
• The hydraulic oil temperature is above 100°C. (Detected time 10 seconds)
trouble
Problem that
• The hydraulic oil overheat warning is turned ON (If the machine is used as it is, the pump and cylin-
appears on
der seals may be broken).
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404 HYD TEMP).

and standard 1 Overheating of hydraulic oil Hydraulic oil may be overheating. Check it.
value in normal Defective hydraulic oil
state 2 Perform troubleshooting for failure code [DGH2KX].
temperature sensor
WA500-6R 27
SEN02934-01 Failure code [CA111] Abnormality in engine controller
Failure code [CA111] Abnormality in engine controller 1
Action code Failure code Abnormality in engine controller

Failure
E03 CA111 (Engine controller system)
Detail of failure q Trouble occurred in engine controller.

Action of con-
q Turns the centralized warning lamp and alarm buzzer ON.
troller
Problem on
q Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
q Power supply voltage of engine controller can be checked with monitoring function.
Related infor-
(Code: 03200 Battery voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position

1 Loose or corroded battery terminal Battery cable terminal may be loose or corroded. Check it.
Loosened terminal or partial dis- 1. Turn starting switch to OFF position.

2
connection at terminal Check terminals of alternator, battery relay, ground (E22) etc. for looseness.
See descriptions of wiring harness and connectors in "Electrical equipment" in
Defective wiring harness connec-
3 "Checks before troubleshooting" of "General information on troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position, then carry out troubleshooting.
2. Perform troubleshooting when engine is cranked.
4 Improper battery voltage
Between battery terminal (+) and (-). Voltage 20 – 30 V

2. Insert T-adapter between male and female side of connector ER1.
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Between ER1 (4) and ground Voltage 26 – 30.5 V
2. Disconnect connector E19, and connect T-adapter to female side.
a If abnormality is found, perform troubleshooting for contents of trouble 2)
6 Defective input power supply
"Engine controller power supply circuit is defective" in failure code [DB2RKR].
Between E19 (female) (4) and (1) Voltage 20 – 30 V
Between E19 (female) (3) and (2) Voltage 20 – 30 V
If no abnormality is found by above checks, engine controller is defective.
q Reference: The followings are standard values in normal condition.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Insert T-adapter between male and female sides of E19.
3. Connect the ground cable.
7 Defective engine controller
4. Measure voltage with starting switch at OFF position and when starting
engine.
Between E19 (4) and (1) Voltage 20 – 30 V
Between E19 (3) and (2) Voltage 20 – 30 V
28 WA500-6R
Failure code [CA111] Abnormality in engine controller SEN02934-01
WA500-6R 29
SEN02934-01 Failure code [CA111] Abnormality in engine controller
Circuit diagram related to engine controller power supply
30 WA500-6R
Failure code [CA115] Engine Ne or Bkup speed sensor error SEN02934-01
Failure code [CA115] Engine Ne or Bkup speed sensor error 1
Action code Failure code Abnormality in engine Ne/Bkup speed sensor

Failure
Detail of failure • Abnormality occurred in the signal of Ne and Bkup speed sensor circuits at the same time.
Action of con- • Stops the engine.
troller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on • The engine does not start. (if engine has been stopped.)
machine • Engine stops. (if engine has been running.)
Related infor-
mation

1 Defective Ne speed sensor system Carry out troubleshooting for failure code [CA689].
2 Defective Bkup speed sensor system Carry out troubleshooting for failure code [CA778].
If cause is not found by above checks,, engine controller may be
3 Defective engine controller defective. (Since failure is in it, troubleshooting cannot be per-
formed.)
WA500-6R 31
SEN02934-01 Failure code [CA122] Charge (boost) pressure sensor high error
Failure code [CA122] Charge (boost) pressure sensor high error 1
Action code Failure code Charge pressure sensor too high

Failure
Detail of failure • High voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con- • Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Problem on
• Engine output drops.
machine
• The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36502 (V)).
• Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
Related infor-
checked with monitoring function (Code: 36500 (kPa)).
mation
• Method of reproducing failure code: Turn starting switch to ON position.
• If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal con-
dition.

tor
and check them.
Defective sensor power supply If failure code [CA187] or [CA227] is displayed at the same time, carry out trou-
2
system bleshooting for that first.
2. Disconnect connector PIM.
Defective charge pressure (boost 3. Turn starting switch to ON position.
3
pressure) sensor
If failure code changes from [CA122] to [CA123], charge pressure (boost pres-
sure) sensor is defective.
Open circuit in witing haress (wire a To check open circuit in GND line
4 breakage or defective contact of • See "Troubleshooting method for open circuit in wiring harness of pressure
connector) sensor system" of "Related information on troubleshooting".
2. Disconnect connectors ENG and PIM, and connect T-adapter to female side
5 Short circuit in wiring harness of ENG.
Between ENG (female) (37) and (44) Resistance Min. 1 Mz
2. Disconnect connector PIM.
Hot short circuit in wiring harness 3. Insert T-adapter into connector ENG.
6
(Short circuit with 24 V circuit) 4. Turn starting switch to ON position (with connector PIM disconnected).
Between ENG (44) and (47) Voltage Max. 1V
(Since failure is in it, troubleshooting cannot be performed.)
32 WA500-6R
Failure code [CA122] Charge (boost) pressure sensor high error SEN02934-01
Circuit diagram related to charge pressure sensor
WA500-6R 33
SEN02934-01 Failure code [CA123] Charge (boost) pressure sensor low error
Failure code [CA123] Charge (boost) pressure sensor low error 1
Action code Failure code Charge pressure sensor too low

Failure
Detail of failure • Low voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con- • Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Problem on
machine
• The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36502 (V)).
• Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
checked with monitoring function (Code: 36500 (kPa)).
Related infor-
mation
• Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-
adapter).
• If sensor connector is disconnected, this code is displayed.

tor
and check them.
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for
it first.
Defective power supply system of 1. Turn starting switch to OFF position.
2 charge pressure sensor (boost 2. Disconnect connector PIM, and connect T-adapter to female side.
pressure sensor) 3. Turn starting switch to ON position.
4.75 – 5.25
Between PIM (female) (1) and (2) Power input Voltage
V
Open circuit in witing haress (wire a To check open circuit in GND line
3 breakage or defective contact of • See "Troubleshooting method for open circuit in wiring harness of pressure
connector) sensor system" of "Related information on troubleshooting".
2. Disconnect connectors ENG and PIM, and connect T-adapter to female side
4 Short circuit in wiring harness of ENG.
Ground fault in wiring harness 2. Disconnect connectors ENG and PIM, and connect T-adapter to female side
5 of ENG.
(Contact with ground circuit)
Between ENG (female) (44) and ground Resistance Min. 1 Mz
a If causes 1 - 5 are not the cause for the trouble and check result of cause 6
Defective charge pressure (boost is abnormal, sensor is defective.
pressure) sensor 1. Turn starting switch to OFF position.
6
(Improper input voltage to engine 2. Insert T-adapter into connector ENG.
controller) 3. Turn starting switch to ON position.
Between ENG (female) (44) and (47) Voltage 0.3 – 4.7 V
34 WA500-6R
Failure code [CA123] Charge (boost) pressure sensor low error SEN02934-01
Circuit diagram related to charge pressure sensor
WA500-6R 35
SEN02934-01 Failure code [CA131] Throttle sensor high error
Failure code [CA131] Throttle sensor high error 1
Action code Failure code Throttle sensor too high

Failure
Detail of failure • High voltage occurred in accelerator pedal signal circuit.

Action of con- • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
Problem on
• The engine does not reach full throttle.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the mon-
itoring function (Code: 31701).
Related infor-
• The input voltage from the throttle sensor can be checked with the monitoring function (Code:
mation
31707).

tor
and check them.
If failure code [CA2185] or [CA2186] is displayed, troubleshoot it first.
Defective throttle sensor power 2. Disconnect connectors L15 and connect T-adapter to female side.
2
supply system 3. Turn starting switch to ON position.
4.75 – 5.25
Between L15 (female) (1) and (3) Power input Voltage
V
Depress accelerator Approx. 3.7
Voltage
Defective accelerator pedal (throt- pedal. V
3 Between L15 (2) and (3)
tle sensor) Release accelerator Approx. 0.4
Voltage
pedal. V
Sensor voltage is measured with wiring harness connected. Accordingly, if volt-
age is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.
a If no abnormality is found in checks on cause 4, this check is not required.
2. Disconnect connectors E18 and L15, and connect T-adapter to female side
4 Short circuit in wiring harness of either of them.
Between E18 (female) (9) and (22), or between L15
Resistance Min. 1 Mz
(female) (1) and (2)
Hot short circuit in wiring harness 2. Disconnect connector L15 and connect T-adapter to female side.
(Contact with 24 V circuit)
Between L15 (female) (2) and (3) Voltage Max. 1 V
36 WA500-6R
Failure code [CA131] Throttle sensor high error SEN02934-01

If no abnormality is found by the above checks, the engine controller is defective.
• Reference; the followings are standard values in normal condition.
4. Operate accelerator pedal, and troubleshoot.
6 Defective engine controller 4.75 – 5.25
Between E18 (22) and (23) Power supply Voltage
V
Voltage
pedal. V
Between E18 (9) and (23)
Release accelerator Approx. 0.4
Voltage
pedal. V
WA500-6R 37
SEN02934-01 Failure code [CA131] Throttle sensor high error
Circuit diagram related to throttle sensor
38 WA500-6R
Failure code [CA132] Throttle sensor low error SEN02934-01
Failure code [CA132] Throttle sensor low error 1
Action code Failure code Throttle sensor too low

Failure
Detail of failure • Accelerator pedal signal circuit of throttle sensor detected abnormally low voltage.
Action of con- • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
Problem on
• The engine does not reach full speed.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the mon-
itoring function (Code: 31701).
Related infor-
• The input voltage from the throttle sensor can be checked with the monitoring function (Code:
mation
31707).

tor
and check them.
If failure code [CA2186] is also indicated, perform troubleshooting for it first.
Defective throttle sensor power 2. Disconnect connectors L15 and connect T-adapter to female side.
2
supply system 3. Turn starting switch to ON position.
4.75 – 5.25
Between L15 (female) (1) and (3) Power input Voltage
V
2. Insert T-adapter info connector L15
Voltage
Defective accelerator pedal (throt- pedal. V
3 Between L15 (2) and (3)
tle sensor) Release accelerator Approx. 0.4
Voltage
pedal. V
Sensor voltage is measured with wiring harness connected. Accordingly, if volt-
age is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.
2. Disconnect connector E18 and L15 and connect T-adapter to each female side.
Open circuit in wiring harness
4 (Open circuit in wiring or defective Between E18 (female) (22) and L15 (female) (1) Resistance Max. 1 z
contact in connector) Between E18 (female) (9) and L15 (female) (2) Resistance Max. 1 z
Between E18 (female) (23) and L15 (female) (3) Resistance Max. 1 z
5 Short circuit in wiring harness of either of them.
Between E18 (female) (9) and (23), or between L15
Ground fault in wiring harness of either of them.
6
Between E18 (female) (9) or L15 (female) (2) and
ground
WA500-6R 39
SEN02934-01 Failure code [CA132] Throttle sensor low error

• Reference: the followings are standard values in normal condition.
4. Operate accelerator pedal, and troubleshoot.
Between E18 (22) and (23) Power supply Voltage 4.75 – 5.25 V
Depress accelerator
Voltage Approx. 3.7 V
pedal.
Between E18 (9) and (23)
Release accelerator
Voltage Approx. 0.4 V
pedal.
40 WA500-6R
Failure code [CA132] Throttle sensor low error SEN02934-01
WA500-6R 41
SEN02934-01 Failure code [CA135] Engine oil pressure sensor high error
Failure code [CA135] Engine oil pressure sensor high error 1
Action code Failure code Eng Oil Press Sensor High Error
Failure
Detail of failure • High voltage was detected in engine oil pressure sensor signal circuit.
Action of con-
• Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.
troller
Problem on
machine
• Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Related infor-
• Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).

tor
and check them.
Defective power supply system of
2 If failure code [CA187] or [CA227] indicated, carry out troubleshooting for it first.
engine oil pressure sensor
Defective engine oil pressure sen- 2. Disconnect connector POIL.
sor
If failure code changes from [CA135] to [CA141], sensor is defective.
Open circuit in wiring harness 2. Disconnect connectors ENG and POIL, and connect T-adapters to each
4 (Open circuit in wiring or defective female side.
contact in connector)
Between ENG (female) (47) and POIL (female) (2) Resistance Max. 1 z
2. Disconnect connectors ENG and POIL, and connect T-adapter to female
5 Short circuit in wiring harness side of either one of them.
Between ENG (female) (13) and (37), or between
POIL (female) (1) and (3)
2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL or connect T-adapter to
Hot short circuit in wiring harness connector ENG.
6
(Short circuit with 24 V circuit) 4. Turn starting switch to ON position (with connector POIL disconnected).
Voltage Max. 1 V
42 WA500-6R
Failure code [CA135] Engine oil pressure sensor high error SEN02934-01
Circuit diagram related to engine oil pressure sensor
WA500-6R 43
SEN02934-01 Failure code [CA141] Engine oil pressure sensor low error
Failure code [CA141] Engine oil pressure sensor low error 1
Action code Failure code Eng Oil Press Sensor Low Error
Failure
Detail of failure • Low voltage was detected in engine oil pressure sensor signal circuit.
Action of con-
• Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.
troller
Problem on
machine
• Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Related infor-
• Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).

tor
and check them.
it first.
Defective power supply system of 2. Disconnect connector POIL and connect T-adapter to each female side of
2
engine oil pressure sensor them.
Power sup- 4.75 – 5.25
Between POIL (female) (1) and (2) Voltage
ply input V
2. Disconnect connectors ENG and POIL and connect T-adapter to female side.
a If power supply input in checks on cause 2 is nor-
mal, this check is not required. Resistance Max. 1 z
Open circuit in wiring harness Between ENG (female) (37) and POIL (female) (1)
3 (Open circuit in wiring or defective
contact in connector) a If power supply input in checks on cause 2 is nor-
Between ENG (female) (47) and POIL (female) (2)
Between ENG (female) (13) and POIL (female) (3)
Resistance Max. 1 z
(Sensor output)
Ground fault in wiring harness side of either one of them.
4
Between ENG (female) (13) or POIL (female) (3) and
ground
5 Short circuit in wiring harness side of either one of them.
44 WA500-6R
Failure code [CA141] Engine oil pressure sensor low error SEN02934-01

a If cause items 1 - 5 are not the cause for the trouble and check result of cause
6 is abnormal, sensor is defective.
Defective engine oil pressure sen- 1. Turn starting switch to OFF position.
6 sor (Improper input voltage to 2. Insert T-adapter into connector ENG.
engine controller) 3. Turn starting switch to ON position.
Sensor out-
Between ENG (13) and (47) Voltage 0.3 – 4.7 V
put
Circuit diagram related to engine oil pressure sensor
WA500-6R 45
SEN02934-01 Failure code [CA144] Coolant temperature sensor high error
Failure code [CA144] Coolant temperature sensor high error 1
Action code Failure code Coolant Temp Sens High Error

Failure
Detail of failure • High voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
• Sets coolant temperature to fixed temperature (90 °C), and allows for operation.
troller
Problem on • Engine does not start easily at low temperature.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04105 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
function. (Code: 04104 (°C))
Related infor-
mation
• This failure code is displayed if temperature sensor connector is disconnected.
• Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit (not
designed as a T-adapter).

tor
and check them.
2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 °C, regard coolant temperature sensor as normal.
Defective coolant temperature 0 °C Resistance 30 – 37 kz

2 Between TWTR (male)
sensor 25 °C Resistance 9.3 – 10.7 kz
(A) and (B)
a Coolant temperature - 50 °C Resistance 3.2 – 3.8 kz
Resistance character-
80 °C Resistance 1.0 – 1.3 kz
istics
95 °C Resistance 700 – 800 z
2. Disconnect connector ENG and connect T-adapter to female side.
Open or short circuit in wiring har- Between ENG (female) (15) and (38) (Coolant tem-
3
ness perature: Min. 0 °C) 700 z –
Resistance
a Use "coolant temperature -Resistance character- 37 kz
istics" table shown above as resistance criteria.
46 WA500-6R
Failure code [CA144] Coolant temperature sensor high error SEN02934-01
Circuit diagram related to coolant temperature sensor
WA500-6R 47
SEN02934-01 Failure code [CA145] Coolant temperature sensor low error
Failure code [CA145] Coolant temperature sensor low error 1
Action code Failure code Coolant Temp Sens Low Error

Failure
Detail of failure • Low voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
• Sets coolant temperature to fixed temperature (90 °C), and allows for operation.
troller
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04104 (V)).
Related infor-
function. (Code: 04104 ( °C))
mation
• If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA144] for "High Error" is displayed.

tor
and check them.
2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 °C, regard coolant temperature sensor as normal.
0 °C Resistance 30 –37 kz
Between TWTR (male)
Defective coolant temperature (A) and (B)
2
sensor a Coolant temperature - 50 °C Resistance 3.2 – 3.8 kz
Resistance character-
istics
All coolant
Between (B) and ground tempera- Resistance Min. 1 Mz
ture range
3 Short circuit in wiring harness Between ENG (female) (15) and (38) (Coolant tem-
perature: Min. 0 °C) 700 z –
Resistance
a Use "coolant temperature -Resistance character- 37 kz
Ground fault in wiring harness 2. Disconnect connectors ENG and TWTR, and connect T-adapter to female
4 side of ENG.
If no abnormality is found by above checks, engine controller is defective. (Since
failure is in it, troubleshooting cannot be performed.)
48 WA500-6R
Failure code [CA145] Coolant temperature sensor low error SEN02934-01
Circuit diagram related to coolant temperature sensor
WA500-6R 49
SEN02934-01 Failure code [CA153] Charge (boost) temperature sensor high error
Failure code [CA153] Charge (boost) temperature sensor high error 1
Action code Failure code Charge (Boost) temperature sensor signal voltage is too high.
Failure
Detail of failure • High voltage was detected in charge (boost) temperature sensor signal circuit.
Action of con- • Set charge temperature to fixed temperature (70 °C), and allow for operation.
troller • Limits engine output and allows engine to run.
machine • Engine output drops.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked by
using monitoring function. (Code: 18500 ( °C))
Related infor-
mation
• Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit (not
designed as a T-adapter).
• This failure code is displayed if temperature sensor connector is disconnected.

tor
and check them.
2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 z – 382 kz, regard charge tem-
perature sensor as normal.
-40 °C Resistance 291 – 382 kz
Defective charge temperature -20 °C Resistance 85 – 109 kz

2 Between TIM (male) (A)
sensor 0 °C Resistance 29 – 36 kz
and (B)
a Charge temperature - 30 °C Resistance 7.3 – 8.8 kz
Resistance chariacter-
istic
Open or short circuit in wiring har-
3 Between ENG (female) (23) and (47)
ness 280 z –
a Use "charge temperature-Resistance character- Resistance
382 kz
50 WA500-6R
Failure code [CA153] Charge (boost) temperature sensor high error SEN02934-01
Circuit diagram related to charge temperature sensor
WA500-6R 51
SEN02934-01 Failure code [CA154] Charge (boost) temperature sensor low error
Failure code [CA154] Charge (boost) temperature sensor low error 1
Action code Failure code Charge (Boost) temperature sensor signal volatge too low
Failure
Detail of failure • Low voltage was detected in charge (boost) temperature sensor signal circuit.
Action of con- • Set charge temperature to fixed temperature (70 °C), and allow for operation.
troller • Limits engine output and allows engine to run.
machine • Engine output drops.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked by
Related infor-
using monitoring function. (Code: 18500 ( °C))
mation
• If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA153] for "High Error" is displayed.

tor
and check them.
2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 z - 382 kz, regard charge tem-
perature sensor as normal.
-40 °C Resistance 291 – 382 kz
Defective charge temperature -20 °C Resistance 85 –109 kz

2 Between TIM (male) (A)
sensor 0 °C Resistance 29 –36 kz
and (B)
a Charge temperature - 30 °C Resistance 7.3 – 8.8 kz
Resistance chariacter-
60 °C Resistance 2.3 –2.7 kz
istic
3 Short circuit in wiring harness Between ENG (female) (23) and (47)
280 z –
a Use "charge temperature-Resistance character- Resistance
382 kz
Ground fault in wiring harness 2. Disconnect connectors ENG and TIM and connect T-adapter to female side
4 of ENG.
52 WA500-6R
Failure code [CA154] Charge (boost) temperature sensor low error SEN02934-01
Circuit diagram related to charge temperature sensor
WA500-6R 53
SEN02934-01 Failure code [CA187] Sensor power supply 2 low error
Failure code [CA187] Sensor power supply 2 low error 1
Action code Failure code Sens Supply 2 Volt Low Error

Failure
Detail of failure • Low voltage appears in sensor power supply 2 (5 V) circuit.

• Controller does not use signals from Bkup speed sensor and controls engine by using Ne speed sen-
sor signals.
• Controller does not use signals from engine oil pressure sensor, takes it that engine oil pressure is
default value (250 kPa {2.5 kg/cm2}), and allows engine to run.
Action of con-
• Controller does not use signals from ambient pressure sensor, takes it that ambient pressure is de-
troller
fault value (52.44 kPa {0.53 kg/cm2}), and allows engine to run.
• Controller does not use signals from boost pressure sensor, takes it that boost pressure is at fixed
value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Problem on
machine
Related infor-
mation

tor
and check them.
Defective input power supply sys- If failure code [CA441] or [CA442] is displayed, perform troubleshooting for fail-
2
tem ure code [CA441] first.
2. Disconnect following connectors sequentially one by one and turn starting
switch to ON position each time.
3. After troubleshooting, return to 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [CA187].
3 Defective sensor or wiring harness
Sensor, harness Connector
Bkup speed sensor G connector
Oil pressure sensor POIL connector
Charge (boost) pressure sensor PIM connector
Ambient pressure sensor PAMB connector
Engine harness ENG
2. Disconnect connector ENG and connect T-adapter to male side.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness disconnected.
4.75 – 5.25
Between ENG (male) (37) and (47) Voltage
V
54 WA500-6R
Failure code [CA187] Sensor power supply 2 low error SEN02934-01
Circuit diagram related to sensor power supply 2
WA500-6R 55
SEN02934-01 Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA221] Atmospheric pressure sensor high error 1
Action code Failure code Ambient Press Sens High Error

Failure
Detail of failure • High voltage was detected in ambient pressure sensor signal circuit.
Action of con- • Takes it that ambient pressure value is default value (52.44 kPa {0.53 kg/cm2}), and allows engine
troller to run.
Problem on
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function (Code: 37402
(V)).
Related infor-
• Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
mation
(Code: 37400 (kPa)).

tor
and check them.
Defective power supply line of If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for
2
ambient pressure sensor it first.
Defective ambient pressure sen- 2. Disconnect connector PAMB.
sor
Open circuit in witing haress (wire • See "Troubleshooting method for open circuit in wiring harness of pressure
4 breakage or defective contact of sensor system" of "Related information on troubleshooting".
connector) a To check open circuit in GND line
2. Disconnect connector ENG and PAMB, and connect T-adapter to female
5 Short circuit in wiring harness side of ENG.
2. Disconnect connector PAMB.
6
(Contact with 24 V circuit) 4. Turn starting switch to ON position (with connector PAMB disconnected).
Between ENG (3) and (38) Voltage Max. 1 V
56 WA500-6R
Failure code [CA221] Atmospheric pressure sensor high error SEN02934-01
Circuit diagram related to ambient pressure sensor
WA500-6R 57
SEN02934-01 Failure code [CA222] Atmospheric pressure sensor low error
Failure code [CA222] Atmospheric pressure sensor low error 1
Action code Failure code Ambient Press Sens Low Error

Failure
Detail of failure • Low voltage was detected ambient pressure sensor signal circuit.
Action of con- • Takes it that ambient pressure value is default value(52.44 kPa {0.53 kg/cm2}), and allows engine to
troller run.
Problem on
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function (Code: 37402
(V)).
• Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
(Code: 37400 (kPa)).
Related infor-
mation
• Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-
adapter).
• If sensor connector is disconnected, this code is displayed.

tor
and check them.
it first.
Defective power supply line of
2 2. Disconnect connector PAMB, and connect T-adapter to female side.
ambient pressure sensor
Power sup- 4.75 – 5.25
Between PAMB (1) and (2) Voltage
ply input V
2. Disconnect connectors PAMB and ENG.
3 Short circuit in wiring harness 3. Connect T-adapter to female side of ENG.
Ground fault in wiring harness 2. Disconnect connectors PAMB and ENG and connect T-adapter to female
4 side of ENG.
Open circuit in witing haress (wire
5 breakage or defective contact of If no failure is found by above checks, wiring harness may have open circuit. (*)
connector)
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related information on
troubleshooting".
58 WA500-6R
Failure code [CA222] Atmospheric pressure sensor low error SEN02934-01

a If causes 1 - 5 are not the cause for the trouble and check result of cause 6
is abnormal, sensor is defective.
Defective ambient pressure sen- 1. Turn starting switch to OFF position.
sor 2. Insert T-adapter into connector ENG.
6
(Improper input voltage to engine 3. Turn starting switch to ON position.
controller)
Sensor out-
Between ENG (3) and (38) Voltage 0.3 - 4.7 V
put
If no abnormality is found by above checks, the engine controller is defective.
Circuit diagram related to ambient pressure sensor
WA500-6R 59
SEN02934-01 Failure code [CA227] Sensor power supply 2 high error
Failure code [CA227] Sensor power supply 2 high error 1
Action code Failure code Sensor power supply circuit voltage is too high
Failure
Detail of failure • High voltage appears in sensor power supply 2 (5 V) circuit.

• Controller does not use signals from Bkup speed sensor and controls engine by using Ne speed sen-
sor signals.
• Controller does not use signals from engine oil pressure sensor, takes it that engine oil pressure is
default value (250 kPa {2.5 kg/cm2}), and allows engine to run.
Action of con-
• Controller does not use signals from ambient pressure sensor, takes it that ambient pressure is de-
troller
fault value (52.44 kPa {0.53 kg/cm2}), and allows engine to run.
• Controller does not use signals from boost pressure sensor, takes it that boost pressure is at fixed
value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Problem on
machine
Related infor-
mation

Perform troubleshooting for failure code [CA187].
60 WA500-6R
Failure code [CA227] Sensor power supply 2 high error SEN02934-01
WA500-6R 61
SEN02934-01


© 2017 KOMATSU
All Rights Reserved
62
SEN02935-01
WA500-6R

WA500-6R 60001 and up
Failure code [CA234] Engine overspeed ........................................................................................................ 3
Failure code [CA238] Ne speed sensor power supply error ........................................................................... 4
Failure code [CA263] Fuel Temp Sensor High Error....................................................................................... 6
Failure code [CA265] Fuel Temp Sensor Low Error ....................................................................................... 8
Failure code [CA271] PCV1 Short circuit...................................................................................................... 10
Failure code [CA272] PCV1 Disconnection ...................................................................................................11
Failure code [CA273] PCV2 Short circuit...................................................................................................... 12
Failure code [CA274] PCV2 Disconnection .................................................................................................. 13
Failure code [CA322] Injector #1 open/short error........................................................................................ 14
WA500-6R 1
SEN02935-01
Failure code [CA342] Calibration code inconsistency................................................................................... 26

Failure code [CA351] Injectors drive circuit error .......................................................................................... 27
Failure code [CA352] Sens Supply 1 Volt Low Error..................................................................................... 28
Failure code [CA386] Sensor power supply 1 high error .............................................................................. 30
Failure code [CA431] Idle validation switch error.......................................................................................... 31
Failure code [CA432] Idle validation action error .......................................................................................... 34
Failure code [CA441] Battery voltage low error ............................................................................................ 36
Failure code [CA442] Battery voltage high error ........................................................................................... 37
Failure code [CA449] Common rail pressure high error 2............................................................................. 38
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 40
Failure code [CA452] Rail Press Sensor Low Error ...................................................................................... 42
Failure code [CA553] Common rail pressure high error 1............................................................................. 44
Failure code [CA554] Common rail pressure sensor in range error.............................................................. 45
Failure code [CA559] Supply pump pressure very low error 1...................................................................... 46
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 50
Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 52
Failure code [CA757] All continuous data lost error ...................................................................................... 53
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 54
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 56
2 WA500-6R
Failure code [CA234] Engine overspeed SEN02935-01
Failure code [CA234] Engine overspeed 1
Action code Failure code Engine overspeed

Failure
– CA234 (Engine controller defective)
Detail of failure • Engine speed exceeded operating range.

Action of con- • Reduce fuel injection rate until engine speed lowers in operating range.
Problem on
• Engine speed fluctuates.
machine
Related infor- • Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
mation • Method of reproducing failure code: Start engine and keep it running at high idle.

1 Use of improper fuel Improper fuel may be used. Check it.
2 Defect in related system If another failure code is displayed, perform troubleshooting for it.
The method of using machine may be improper, so instruct the operator on how
3 Usage is improper
to use machine properly.
If causes 1 and 2 are not cause of failure, engine controller may be defective.
WA500-6R 3
SEN02935-01 Failure code [CA238] Ne speed sensor power supply error
Failure code [CA238] Ne speed sensor power supply error 1
Action code Failure code Ne Speed Sens Supply Volt Error

Failure
Detail of failure • Abnormality occurred in Ne speed sensor power supply (5 V) circuit.

Action of con- • Controls engine by using signals from Bkup speed sensor.
troller • Limits engine output and continues operation.
Problem on
• Engine stops during operation (When engine Bkup speed sensor is also defective).
machine
• Engine cannot be started if it is stopped. (When engine Bkup speed sensor is also defective)
Related infor-
• Method of reproducing failure code: Turn the starting switch to ON position.
mation

tor
and check them.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [CA238].
Ne speed sensor NE
Engine harness ENG
4.75 to 5.25
Between ENG (male) (16) and (48) Voltage
V
Circuit diagram related to Ne speed sensor
4 WA500-6R
Failure code [CA238] Ne speed sensor power supply error SEN02935-01
WA500-6R 5
SEN02935-01 Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA263] Fuel Temp Sensor High Error 1

Action code Failure code Fuel temperature sensor signal voltage is too high
Failure
(Engine controller system)
E01 CA263
Detail of failure q High voltage was detected in fuel temperature sensor signal circuit.
q Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
Action of con- temperature.
troller (If coolant temperature sensor is also defective, sets fuel temperature value to fixed value (95 °C)
and allows engine to run.)
Problem on
machine
q Signal voltage from the fuel temperature sensor can be checked with the monitoring function (Code:
14201 (V)).
q Temperature sensed by fuel temperature sensor can be checked with the monitoring function (Code:
Related infor- 14204 (°C)).
mation q Method of reproducing failure code: Turn the starting switch to ON position.
q This failure code is displayed if temperature sensor connector is disconnected.
q Because that T-adapter for sensor connector is “socket” type, it cannot be connected to wiring har-
ness.

Defective wiring harness
1 "Checks before troubleshooting" of "General information on troubleshooting", and
connector
check them.
2. Disconnect connector TFUEL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 z – 37 kz with coolant temperature
is above 0 °C, regard coolant temperature sensor as normal.
0 °C Resistance 30 - 37 kz
Defective fuel temperature
2
sensor TFUEL(male) between  25 °C Resistance 9.3 - 10.7 kz
(A) and (B)
50 °C Resistance 3.2 - 3.8 kz
a Fuel temperature -Re-
sistance characteristic 80 °C Resistance 1.0 - 1.3 kz
95 °C Resistance 700 - 800 z
Open or short circuit in wir- Between ENG (female) (30) and (47) (Fuel temperature :
3
ing harness above 0 °C) 700 z -
Resistance
a Use “Fuel temperature - Resistance characteristics” 37 kz
table shown above as resistance critaeria.
If no abnormality is found by above checks, engine controller is defective. (Since this
is an internal failure, troubleshooting is impossible.)
6 WA500-6R
Failure code [CA263] Fuel Temp Sensor High Error SEN02935-01
Circuit diagram related to fuel temperature sensor
WA500-6R 7
SEN02935-01 Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA265] Fuel Temp Sensor Low Error 1

Action code Failure code Fuel temperature sensor signal voltage is to low
Failure
E01 CA265
Detail of failure q Low voltage was detected in fuel temperature sensor signal circuit.
q Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
Action of con-
temperature.
troller
(If coolant temperature sensor is also defective, sets to fixed value (95 °C) and allows engine to run)
Problem on
machine
q Signal voltage from fuel temperature sensor can be checked with monitoring function (Code: 14201
(V)).
q Temperature sensed by fuel temperature sensor can be checked with monitoring function (Code:
Related infor-
04204 (°C)).
mation
q Method of reproducing failure code: Turn the starting switch to ON position.
q This code is not displayed but failure code for “High Error” is displayed, if sensor connector is dis-
connected.

Defective wiring harness Check wire harness and connectors by referring to "Electrical equipment" described in
1
connector "Check before troubleshooting" of "General information on troubleshooting".
2. Disconnect connector TFUEL and connect socket to male side.
a If coolant temperature sensor resistance is 700 z – 37 kz with coolant temperature
is above0 °C, regard coolant temperature sensor as normal.
0 °C Resistance 30 - 37 kz
TFUEL(male) between  25 °C Resistance 9.3 - 10.7 kz
Defective fuel temperature
2 (A) and (B)
sensor 50 °C Resistance 3.2 - 3.8 kz
a Fuel temperature - Re-
sistance characteristic 80 °C Resistance 1.0 - 1.3 kz
95 °C Resistance 700 - 800 z
All fuel tem-
Between (B) and ground perature Resistance Min. 1 Mz
range
Short circuit in wiring har- Between ENG (female) (30) and (47) (Fuel temperature :
3
ness above 0 °C) 700 z -
Resistance
a Use ”Fuel temperature - Resistance characteristics” 37 kz
table shown above as resistance criteria.
Ground fault in wiring har- 1. Turn starting switch to OFF position.
4 ness 2. Disconnect connector TFUEL, and connect T-adapter to female side of ENG.
(Contact with ground circuit) Between ENG (female) (30) and ground Resistance Min. 1 Mz
If no abnormality is found by the above checks, engine controller is defective. (Since
this is an internal failure, troubleshooting is impossible.)
8 WA500-6R
Failure code [CA265] Fuel Temp Sensor Low Error SEN02935-01
Circuit diagram related to fuel temperature sensor
WA500-6R 9
SEN02935-01 Failure code [CA271] PCV1 Short circuit
Failure code [CA271] PCV1 Short circuit 1
Action code Failure code IMV/PCV1 Short Error

Failure
Detail of failure • Short circuit was detected in supply pump PCV1 circuit.
Action of con-
troller
Problem on
machine
Related infor- • Under normal conditions, pulse voltage of approx. 24 V is applied to PCV1 (1) while engine is run-
mation ning. However, it cannot be measured with multimeter since it is pulse voltage.

tor
and check them.
2. Disconnect connector PCV1.
Defective supply pump PCV1 3. Turn starting switch to ON position.
2
(internal short circuit)
If failure code changes from [CA271] to [CA272], supply pump PCV1 is defec-
tive.
3 Short circuit in wiring harness
Between ENG (female) (4) and (5) (PCV1 resis-
Resistance 2.3 – 5.3 z
tance)
2. Disconnect connector ENG and PCV1, and connect T-adapter to female side
Ground fault in wiring harness of ENG.
4
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position (with connector PCV1 disconnected).
(Since failure is in it troubleshooting cannot be performed.)
Circuit diagram related to PCV1
10 WA500-6R
Failure code [CA272] PCV1 Disconnection SEN02935-01
Failure code [CA272] PCV1 Disconnection 1
Action code Failure code IMV/PCV1 Open Error

Failure
Detail of failure • Disconnection was detected in supply pump PCV1 circuit.

Action of con-
troller
Problem on
machine
• Under normal conditions, pulse voltage of approx. 24 V is applied to PCV (1) while engine is running.
Related infor- However it cannot be measured with multimeter since it is pulse voltage.
mation • Because troubleshooting "socket" for PCV1 features female connector alone, it is not connectable
to female connector of sensor wiring harness, and thus not usable for checking open circuit (not de-
signed as a T-adapter).

tor
and check them.
Defective supply pump PCV1 2. Disconnect connectors PCV1 and connect socket to male side.
2
(Internal disconnection) Resis- 2.3 –
Between PCV1 (male) (1) and (2)
tance 5.3 z
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness Resis- 2.3 –
Between ENG (female) (4) and (5) (PCV1 resistance)
tance 5.3 z
2. Disconnect connectors ENG and PCV1.
3. Connect T-adapter to female side of connector ENG.
Ground fault in wiring harness
4 Resis-
(Contact with ground circuit) Between ENG (female) (4) and ground Min. 1 Mz
tance
Resis-
Between ENG (female) (5) and ground Min. 1 Mz
tance
WA500-6R 11
SEN02935-01 Failure code [CA273] PCV2 Short circuit
Failure code [CA273] PCV2 Short circuit 1
Action code Failure code PCV2 short circuit error

Failure
Detail of failure • Short circuit was detected in supply pump PCV2 circuit.
Action of con-
troller
Problem on
machine
Related infor-
• While engine is running normally, approximately 24 V of pulse voltage is applied to PCV2 (1). But it
mation
is pulse voltage and cannot be measured by using multimeter.

tor
and check them.
Defective supply pump PCV2 2. Disconnect connector PCV2.
(Internal short)
If failure code changes from [CA273] to [CA274], supply pump PCV2 is defective.
Between ENG (female) (9) and (10) (PCV2 resis-
tance)
2. Disconnect connector ENG and PCV2, and connect T-adapter to female side
Ground fault in wiring harness of ENG.
4
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position (with connector PCV2 disconnected).
12 WA500-6R
Failure code [CA274] PCV2 Disconnection SEN02935-01
Failure code [CA274] PCV2 Disconnection 1
Action code Failure code PCV2 disconnection

Failure
Detail of failure • Disconnection was detected in supply pump PCV2 circuit.

Action of con-
troller
Problem on
machine
Related infor-
• While engine is running normally, approximately 24 V of pulse voltage is applied to PCV2 (1). But it
mation
is pulse voltage and cannot be measured by using multimeter.

tor
and check them.
Defective supply pump PCV2 2. Disconnect connector PCV2 and connect socket to male side.
2
(internal open circuit)
Between PCV2 (male) (1) and (2) Resistance 2.3 – 5.3 z
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness Between ENG (female) (9) and (10) (PCV2 resis-
tance)
2. Disconnect connector ENG and PCV2.
Ground fault in wiring harness 3. Connect T-adapter to female side of connector ENG.
4
(Since the failure is in it, troubleshooting cannot be performed.)
WA500-6R 13
SEN02935-01 Failure code [CA322] Injector #1 open/short error
Failure code [CA322] Injector #1 open/short error 1
Action code Failure code Injector #1(L#1) open/short circuit error

Failure
Detail of failure • Disconnection or short circuit was detected in injector #1 circuit.

Action of con-
troller
Problem on • Engine output drops.
machine • Engine speed does not stabilize
Related infor-
• While engine is running normally, approximately 70 V of pulse voltage is applied to injector (positive)
mation
side. But it is pulse voltage and cannot be measured by using multimeter.

tor
and check them.
2. Disconnect connector CN1 and connect T-adapter to male side.
2 Defective injector #1
Between CN1 (male) (1) and (2) Resistance 0.4 – 1.1 z
Between CN1 (male) (1) and ground Resistance Min. 1 Mz
Open circuit or ground fault of wir-
3
ing harness Between ENG (female) (45) and (53) Resistance 0.4 – 1.1 z
Open circuit in wiring harness 2. Disconnect connectors ENG and CN1, and connect T-adapters to each
Between ENG (female) (45) and CN1 (female) (1) Resistance Max. 1 z
Ground fault in wiring harness 2. Disconnect connectors ENG and CN1, and connect T-adapter to female side
5 of either one of them.
Between ENG (female) (45) or CN1 (female) (1) and
ground
2. Disconnect connectors ENG and CN1, and connect T-adapter to female side
of ENG.
a Check with circuit tester in continuity mode.
Between ENG (female) (45) and each pin other than No continuity
(45) (No sound is heard)
1. If the failure codes for other injectors are displayed, perform troubleshooting
Defective other cylinder injectors of them, too.
7
or wiring harness 2. Confirm that injector wiring harnesses (H) of all cylinders are in good condi-
tion by referring to the following page.
14 WA500-6R
Failure code [CA322] Injector #1 open/short error SEN02935-01
Circuit diagram related to injector #1
q Improper installation of injector wiring harness (H)
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
X: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.
WA500-6R 15
Action code Failure code Injector #5(L#5) open/short circuit error

Failure

Action of con-
troller
machine • Engine speed does not stabilize.
Related infor-
mation

tor
and check them.
3
ing harness Between ENG (female) (46) and (60) Resistance 0.4 - 1.1 z
ground
of ENG.
1. If failure codes for other injectors are displayed, perform troubleshooting for
Defective other cylinder injectors them, too.
7
16 WA500-6R
WA500-6R 17
Action code Failure code Injector #3(L#3) open /short circuit error
Failure

Action of con-
troller
Related infor-
mation

tor
and check them.
3
ground
of ENG.
7
18 WA500-6R
WA500-6R 19
Action code Failure code Injector #6 (L#6) open / short circuit error
Failure
Detail of failure • Opening or short circuit was detected in drive circuit of No. 6 injector.
Action of con-
troller
Related infor-
mation

tor
and check them.
3
ground
of ENG.
Between ENG1 (female) (57) and each pin other No continuity
than (57) (No sound is heard)
Between ENG1 (female) (59) and each pin other No continuity
than (59) (No sound is heard)
1. If the failure codes for other injectors are displayed, perform troubleshooting
Defective injector or wiring har- for them, too.
7
ness of another cylinder 2. Confirm that injector wiring harnesses (H) of all cylinders are in good condi-
20 WA500-6R
WA500-6R 21
Action code Failure code Injector #2 Open/Short circuit error

Failure

Action of con-
troller
Related infor-
mation

tor
and check them.
3
ground
2. Disconnect connectors ENG and CN, and connect T-adapter to female side
of ENG.
7
22 WA500-6R
WA500-6R 23
Action code Failure code Injector #4 (L#4) open / short circuit error
Failure

Action of con-
troller
Related infor-
mation

tor
and check them.
3
ground
of ENG.
7
24 WA500-6R
WA500-6R 25
SEN02935-01 Failure code [CA342] Calibration code inconsistency
Failure code [CA342] Calibration code inconsistency 1
Action code Failure code Engine controller data inconsistency

Failure
Detail of failure • Data inconsistency occurred in engine controller.

Action of con-
troller
Problem on • Engine continues running ordinarily, but it may stop during operation or may not restart once it is
machine stopped.
Related infor-
mation

Preform troubleshooting for failure code [CA111].
26 WA500-6R
Failure code [CA351] Injectors drive circuit error SEN02935-01
Failure code [CA351] Injectors drive circuit error 1
Action code Failure code Injectors drive circuit error

Failure
Detail of failure • Abnormality has occurred in injector drive circuit.

Action of con- • Limits engine output for travel (Limits common rail pressure) and allows engine to run
Problem on
machine
Related infor-
mation

Check whether other failure code (failure code related to injector system ) are
1 Defect in related system
displayed together. If another code is displayed, perform troubleshooting for it.
Perform troubleshooting for failure code [ CA111]
WA500-6R 27
SEN02935-01 Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA352] Sens Supply 1 Volt Low Error 1

Action code Failure code Sensor power supply 1voltage is too low
Failure
E03 CA352
Detail of failure q Low voltage was detected in sensor power supply 1 (5 V) circuit.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
q Engine output drops.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Defective wiring harness Check wire harness and connectors by referring to "Electrical equipment" described
1
connector in "Check before troubleshooting" of "General information on troubleshooting".
2. Disconnect following connectors one by one and turn starting switch to ON posi-
tion each time.
3. After each troubleshooting, turn starting swith to OFF position.
If this failure code is not displayed when sensor is disconnected, the sensor or
Defective sensor or wiring engine wiring harness is defective.
2 harness a Other failure code(s) is(are) displayed at the same time. This is because the sen-
sor connector is disconnected. Therefore, ignore failure codes other than [CA352].
Common rail pressure sensor PFUEL
Engine harness ENG
Between ENG (male) (33) and (47) Voltage 4.75 – 5.25 V
28 WA500-6R
Failure code [CA352] Sens Supply 1 Volt Low Error SEN02935-01
Circuit diagram related to sensor power supply 1
WA500-6R 29
SEN02935-01 Failure code [CA386] Sensor power supply 1 high error
Failure code [CA386] Sensor power supply 1 high error 1
Action code Failure code Sensor power supply 1 voltage is too high
Failure
Detail of failure • High voltage is detected in sensor power supply 1 (5 V) circuit.

Action of con- • Limits engine output (limits common rail pressure) and allows engine to run
Problem on
machine
Related infor-
mation

Perform troubleshooting for failure code [CA352]
30 WA500-6R
Failure code [CA431] Idle validation switch error SEN02935-01
Failure code [CA431] Idle validation switch error 1
Action code Failure code Idle validation switch : error

Failure
Detail of failure • Signals 1 and 2 (IVS1 and IVS2) from idle validation switch are unusual.
Action of
• Runs engine at the throttle opening based on signal from throttle sensor.
controller
Problem on
machine
• Input (ON/OFF) from the idle validation switch 1 can be checked by using monitoring function.
(Code: ENGINE, 18300, IVS 1)
Related
information
No. Cause Procedure, measuring location, criteria, and remarks

See the descriptions of wiring harness and connectors in "Electrical equipment" of
1 "Check before troubleshooting" in "General information on troubleshooting", and
connector
check them.
Defective power supply 3. Turn starting switch to ON position.
2
system a If normal, go to cause 6.
Between L14 (1) and (2) Voltage 4.75 to 5.25 V
Open circuit in wiring harness  2. Disconnect connector L04 and L14 and connect T-adapters to each female side.
3 (Wire breakage or defective Between L04 (female) (34) and L14 (female) (1) Resistance Max. 1 z
contact of connector)
Between L02 (female) (4) and L14 (female) (2) Resistance Max. 1 z
Ground fault in wiring har- 2. Disconnect connectors L04 and L14 and connect T-adapter to female side of
4 ness 1 either of them.
(Contact with ground circuit) Between L04 (female) (34) or L14 (female) (1) and
ground
Defective transmission con- If cause is found by cause 2, and if cause is not found by the check of cause 3 or 4,
5
troller transmission controller is defective.
4. Operate accelerator pedal and troubleshoot.
Defective accelerator pedal
6 a If abnormal, check wiring harness for causes 7 and 8. When wiring harness is
(internal failure)
not abnormal, accelerator pedal is defective.
Between L15 (5) and (4) See Signal 1 in the figure 1.
Between L15 (6) and (4) See Signal 2 in the figure 1.
WA500-6R 31
SEN02935-01 Failure code [CA431] Idle validation switch error

1. Turn starting switch to OFF position and disconnect battery ground cable. (Turn
battery disconnect switch to OFF position.)
2. Disconnect connectors L15, L14 and E18, and connect T-adapters to female
side of them.
Open circuit 2 in wiring
harness Between E18 (female) (32) and L15 (female) (4) Resistance Max. 1 z
7
(Wire breakage or defective Between E18 (female) (11) and L15 (female) (5) Resistance Max. 1 z
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connectors L15, E18 and L04, and connect T-adapters to female
side of connectors E18 and L04.
Between E18 (female) (11) and each pin other than (11) Resistance Min. 1 Mz
If no failure is found by above checks, engine controller is defective. (Since this is
an internal failure, troubleshooting cannot be performed.)
• Reference
Defective engine controller
9 2. Insert T-adapter into connector E18.
(internal failure)
Between E18 (11) and (32) See Signal 1 in the figure 1 below.
Between E18 (1) and (32) See Signal 2 in the figure 1 below.
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Signal 1: Signal voltage of idle validation switch 1
...Dash line
...Bold line
Operating range: Operating range of accelerator

pedal (Pin 2 of connector L15)
32 WA500-6R
Failure code [CA431] Idle validation switch error SEN02935-01
Circuit diagram related to idle validation
WA500-6R 33
SEN02935-01 Failure code [CA432] Idle validation action error
Failure code [CA432] Idle validation action error 1
Action code Failure code Idle validation switch : action error

Failure
Detail of failure • Idle validation switch signal and throttle sensor signal are inconsistent.
Action of • Operates at position of throttle of accelerator pedal (throttle sensor).
Problem on • Engine speed does not rise from low idle.
machine • Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related
• Input voltage from the throttle sensor can be checked by using monitoring function.
information
(Code: ENGINE, 31707, THROTTLE POS)
• Accelerator pedal position sensed by the throttle sensor can be checked by using monitoring func-
tion. (Code: ENGINE, 31701, THROTTLE POS)

As for idle validation switch, perform troubleshooting for failure code [CA431].
1
(For throttle sensor, perform troubleshooting for causes 2 and after.)
Defective power supply 3. Turn starting switch to ON position.
2
system a If abnormal, go to cause 4.
Between L15 (1) and (3) Voltage 4.75 to 5.25 V
4. Operate accelerator pedal and troubleshoot.
Defective accelerator pedal a If abnormal, check wiring harness for causes 4 and 5. When wiring harness is
3 not abnormal, accelerator pedal is defective.
(internal failure)
Approx. 3.7
Between L15 (2) and (3) Depress accelerator pedal. Voltage
V
a See output voltage in
the figure 1. Approx. 0.4
Release accelerator pedal. Voltage
V
2. Disconnect connectors L15 and E18, and connect T-adapters to female side of
Open circuit in wiring harness them.
4 (Wire breakage or defective Between E18 (female) (22) and L15 (female) (1) Resistance Max. 1 z
2. Disconnect connectors L15 and E18, and connect T-adapter to female side of
5 Short circuit in wiring harness connector E18.
34 WA500-6R
Failure code [CA432] Idle validation action error SEN02935-01

If no abnormality is found in the above checks, engine controller is defective.
• Reference
2. Insert T-adapter into connector E18.
Defective engine controller 3. Turn starting switch to ON position.
6 4. Operate accelerator pedal and troubleshoot.
(internal failure)
Approx. 3.7
Between E18 (9) and (23) Depress accelerator pedal. Voltage
V
a See output voltage in
the figure 1. Approx. 0.4
Release accelerator pedal. Voltage
V
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
...Dash line
...Bold line
Operating range: Operating range of accelerator

pedal (Pin 2 of connector L15)
Circuit diagram related to idle validation
WA500-6R 35
SEN02935-01 Failure code [CA441] Battery voltage low error
Failure code [CA441] Battery voltage low error 1
Action code Failure code Battery power circuit voltage is to low

Failure
Detail of failure • Low voltage (5.7 V or below) is detected in power supply circuit.
Action of con-
troller
Problem on • Engine continues running ordinarily, but it may stop during operation or may not restart once it is
machine stopped.
Related infor-
mation

36 WA500-6R
Failure code [CA442] Battery voltage high error SEN02935-01
Failure code [CA442] Battery voltage high error 1
Action code Failure code Battery Voltage High Error

Failure
Detail of failure • High voltage (36 V or higher) appears in power supply circuit.
Action of con-
troller
Problem on
• Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
Related infor-
• Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03200
mation
(V))

Preform troubleshooting for failure code [CA111].
WA500-6R 37
SEN02935-01 Failure code [CA449] Common rail pressure high error 2
Failure code [CA449] Common rail pressure high error 2 1
Action code Failure code Rail Press Very High Error

Failure
• Common rail pressure sensor circuit detects abnormally high pressure (pressure exceeding set
Detail of failure
maximum level).
Action of con-
• Limits engine output (limits common rail pressure) and allows engine to run.
troller
machine • Turns the centralized warning lamp and alarm buzzer ON.
• Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36402 (V)).
Related infor-
• Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).

38 WA500-6R
Failure code [CA449] Common rail pressure high error 2 SEN02935-01
WA500-6R 39
SEN02935-01 Failure code [CA451] Rail Press Sensor High Error
Failure code [CA451] Rail Press Sensor High Error 1

Action code Failure code Common rail pressure sensor signal voltage is too high.
Failure
E03 CA451
Detail of failure q High voltage was detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
machine
q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36401 (V)).
Related infor- q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation function (Code: 36400 (MPa)).
q This failure code is displayed if common rail pressure sensor connector is disconnected.
q Method of reproducing failure code: Turn the starting switch to ON position.

1
a If failure code [CA352] (Ground fault in sensor power supply line) or [CA386] is dis-
played, perform troubleshooting for it first.
Defective common rail pres- 1. Turn starting switch to OFF position.
2 sure sensor power supply 2. Disconnect connector PFUEL and connect T-adapter to female side.
line 3. Turn starting switch to ON position.
Power supply
Between PFUEL (female) (1) and (3) Voltage 4.75 – 5.25V
input
2. Disconnect connectors PFUEL and ENG and connect T-adapters to each female
side.
a If power supply input in checks on cause 2 is normal,
Open circuit in wiring har-
this check is not required. Resistance Max. 1 z
ness
3 Between ENG(female) (33) and PFUEL (female) (1)
(wire breakage or defective
a If power supply input in checks on cause 2 is normal,
this check is not required. Resistance Max. 1 z
Between ENG (female) (47) and PFUEL (female) (3)
Between ENG (female) (25) and PFUEL (female) (2)
Resistance Max. 1 z
(Sensor output)
Short circuit in wiring har- 2. Disconnect connectors PFUEL and ENG
4 3. Connect T-adapter to female side of ECM.
ness
2. Disconnect connectors PFUEL and insert T-adapter into connector ECM.
Hot short in wiring harness 3. Turn starting switch to ON position (with connector PFUEL disconnected).
5
(Contact with 24 V circuit) a ENG (25) pin is connected to 5V source through resistor in engine controller.
Between ENG (25) and (47) Voltage Approx. 5V
a If causes 1 – 5 are not cause of failure and check result of cause 6 is abnormal,
Defective common rail pres- sensor is defective.
sure sensor 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector ENG.
(Improper input voltage to
engine controller) 3. Turn starting switch to ON position.
Between ENG (25) and (47) Sensor output Voltage 0.2 – 4.6V
If no abnormality is found by the above checks, the engine controller is defective.
(Since this is an internal failure, troubleshooting cannot be performed.)
40 WA500-6R
Failure code [CA451] Rail Press Sensor High Error SEN02935-01
Circuit diagram related to common rail pressure
WA500-6R 41
SEN02935-01 Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA452] Rail Press Sensor Low Error 1

Action code Failure code Common rail pressure sensor signal voltage is to low
Failure
E03 CA452
Detail of failure q Low voltage was detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output (limits common rail pressure), and allows engine to run.
troller
Problem on
machine
q Signal voltage from the common rail pressure sensor can be checked with monitoring function
(Code: 36401 (V)).
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
Related infor-
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q This failure code is not displayed but failure code, [CA451] for “High Error” is displayed when sen-
sor connector is disconnected even if it is normal.

1
a If failure code [CA352] or [CA386] is displayed, perform troubleshooting for it first.
Defective common rail pres- 1. Turn starting switch to OFF position.
2 sure sensor power supply 2. Disconnect connector PFUEL and connect T-adapter to female side.
line 3. Turn starting switch to ON position.
Power supply
Between PFUEL (female) (1) and (3) Voltage 4.75 – 5.25V
input
Defective common rail pres- 2. Disconnect connector PFUEL
sure sensor
Ground fault in wiring har- 2. Disconnect connectors ENG and PFUEL, and connect T-adapter to female side of
4 ness ENG.
Short circuit in wiring har- 2. Disconnect connectors ENG and PFUEL, and connect T-adapter to female side of
5 ENG.
ness
Between ENG (25) and (47) Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective. (Since this
is an internal failure, troubleshooting cannot be performed.)
42 WA500-6R
Failure code [CA452] Rail Press Sensor Low Error SEN02935-01
Circuit diagram related to common rail pressure
WA500-6R 43
SEN02935-01 Failure code [CA553] Common rail pressure high error 1
Failure code [CA553] Common rail pressure high error 1 1
Action code Failure code Common rail pressure is high

Failure
• Abnormal high pressure (higher than set pressure) was detected more than 10 seconds in the signal
Detail of failure
circuit of common rail pressure sensor.
Action of con-
troller
Problem on
machine
36402 (V)).
Related infor-
mation

2 Use of improper fuel Check fuel used (for high viscosity).
Defective electrical system of Electrical system of common rail pressure sensor may be defective. Perform
3
common rail pressure sensor troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system of
4 Check mechanical system of common rail pressure sensor.
common rail pressure sensor
5 Defective overflow valve Check overflow valve for broken spring, worn seat, and stuck ball.
6 Clogging of overflow piping Check overflow piping for clogging.
7 Defective pressure limiter A mechanical defect of the pressure limiter may exist, check the limiter.
44 WA500-6R
Failure code [CA554] Common rail pressure sensor in range error SEN02935-01
Failure code [CA554] Common rail pressure sensor in range error 1
Action code Failure code Common rail pressure sensor signal voltage is beyond input range
Failure
Detail of failure • Signal voltage of common rail pressure sensor is beyond input range.
Action of con- • Limits engine output (limits common rail pressure) and allows engine to run.
Problem on
machine
36402 (V)).
Related infor-
• Common rail pressure sensed by common rail pressure sensor can be checked with monitoring func-
mation
tion (Code: 36400 (MPa)).

Perform troubleshooting for failure code [CA451], [CA452]
WA500-6R 45
SEN02935-01 Failure code [CA559] Supply pump pressure very low error 1
Failure code [CA559] Supply pump pressure very low error 1 1
Action code Failure code Supply pump pressure very low error 1
Trouble
Contents of
• There is no-pressure feed error (level 1) in supply pump.
trouble
Action of • Limits common rail pressure.
Problem that
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
Related
the monitoring function (Code: 36400 RAIL PRESS).
information

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Use of improper fuel Fuel used may be improper. Check it directly.
a For more information on troubleshooting, see Note 1. For check
of pressure in fuel low pressure circuit, see Testing and adjusting,
Defect in low pressure  “Testing fuel pressure”.
3
circuit parts Pressure in fuel
Min. 0.15 MPa
low-pressure circuit
{Min. 1.5 kg/cm2}
(high idle or rated load (stall load))
4 Clogged fuel filter, strainer a For more information on troubleshooting, see Note 2.
Electrical system of supply pump PCV may be defective. Carry out
Defective electrical system of
5 troubleshooting for failure code [CA271], [CA272], [CA273], or
supply pump PCV
[CA274].
Defective common rail  Mechanical system of common rail pressure sensor may be defec-
Possible causes 6
pressure sensor tive. Check whether wiring harness is damaged.
and standard
value in normal a For check of leakage through pressure limiter, see Testing and
state adjusting, “Testing fuel return rate and leakage”.
7 Defective pressure limiter
Max. 10 cc/min
Leakage through pressure limiter
Rated load (stall load)
a For check of limited return rate (spill) from injector, see Testing
and adjusting, “Testing fuel return rate and leakage”.
Limited return (spill) rate from
Rated load (stall load)
injector
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
If causes 1 – 8 are not the cause of the trouble, supply pump may
9 Defective supply pump
be defective.
<Using check sheet>

While carrying out troubleshooting above, record troubleshooting contents on the “Check sheet for no-pres-
sure feed” attached separately.
46 WA500-6R
Failure code [CA559] Supply pump pressure very low error 1 SEN02935-01
Note 1: When low-pressure circuit is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Water separator/Prefilter filled with water
4) Clogged fuel tilter
5) Clogged screen in water separator
6) Stuck or worn feed pump, clogged filter
7) Leaked or clogged low-pressure fuel pipe
8) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
9) Clogged fuel filter
10) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
WA500-6R 47
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q Fuel filter: Replace. (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it. (See Fig. 2.)
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
Fig. 2
48 WA500-6R
Check sheet for no-pressure feed

Machine model Working No.
Model serial No. # Checked on / /
Engine Service meter h
Engine serial No. # Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle rpm 790 ± 25
01002 Engine speed High idle rpm 2,120 ± 50
Full stall (P-mode) rpm —
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
4 36200 Rating or equivalent MPa
command
36400 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
36300 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
kPa Min. 89
36500 Boost pressure Rating or equivalent — —
{mmHg} {Min. 670}
04104 Engine coolant temperature Low idle °C — — —
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Function Cut-out cylinder Check conditions Unit Good Bad
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
Cylinder
cut-out
function

C. Checking fuel circuit pressure Check conditions Unit Good Bad
MPa Min. 0.15
6 Pressure in fuel low-pressure circuit High idle or rated load (stall load)
{kg/cm2} {Min. 1.5}
D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

E. Checking leakage and fuel return rate Check conditions Unit Good Bad
11 Leakage through pressure limiter Rated load (stall load) cc/min Max. 10
Rating or equivalent Speed:
cc/min 960
<by model> 1,600 rpm
Rating or equivalent
cc/min 1,020
12 Return rate from injector cc/min 1,080 Return rate:
cc/min 1,140
cc/min 1,200
WA500-6R 49
SEN02935-01 Failure code [CA689] Engine Ne speed sensor error
Failure code [CA689] Engine Ne speed sensor error 1
Action code Failure code Eng Ne Speed Sensor Error

Failure
Detail of failure • Abnormal signal appear in engine Ne speed sensor circuit.
Action of con-
• Controls engine by using signals from engine Bkup speed sensor.
troller
• Engine stops during operation (When engine Bkup speed sensor is also defective).
Problem on
• Engine cannot be started if it is stopped. (When engine Bkup speed sensor is also defective)
machine
• Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
Related infor- sensor cannot be determined to be normal by measuring its resistance with circuit tester.
mation • Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured with
multimeter.
• Speed sensor calculates engine speed by detecting holes made in the flywheel.

tor
and check them.
Defective Ne speed sensor power
2 If failure code [CA238] is also displayed, perform troubleshooting for it first.
supply line
Breakage or improper installation
Engine Ne speed sensor may be damaged or improperly installed (loose).
3 (looseness) of engine Ne speed
Check sensor.
sensor
2. Disconnect connector NE and connect T-adapter to female side.
Defective Ne speed sensor power 3. Turn starting switch to ON position.
4
supply input
Power sup-
Between NE (female) (1) and (2) Voltage 4.75 – 5.25 V
ply input
2. Disconnect connectors ENG and NE.
If no abnormality is found in checks on cause 4, this
Open circuit in wiring harness check is not required. Resistance Max. 1 z
5 (Open circuit in wiring or defective Between ENG (female) (16) and NE (female) (1)
contact in connector) If no abnormality is found in checks on cause 4, this
check is not required. Resistance Max. 1 z
Between ENG (female) (48) and NE (female) (2)
Between ENG (female) (27) and NE (female) (3) Resistance Max. 1 z
2. Disconnect connectors ENG and NE.
6 Short circuit in wiring harness Resistance Min. 1 Mz
NE (female) (1) and (3)
NE (female) (2) and (3)
Ground fault in wiring harness 2. Disconnect connectors ENG and NE.
7
(Contact with ground circuit) Between ENG (female) (27) or NE (female) (3) and
ground
50 WA500-6R
Failure code [CA689] Engine Ne speed sensor error SEN02935-01

Hot short circuit in wiring harness 2. Disconnect connector NE.
Between NE (female) (3) and ground Voltage Max. 1 V
If failure is not found by above checks, engine Ne speed sensor may be defec-
9 Defective engine Ne speed sensor
tive. (Since failure is in it, troubleshooting cannot be performed.)
If cause is not found by above checks,, engine controller may be defective.
Circuit diagrams related to engine Ne speed sensor
q Ne speed sensor detects part (A) of flywheel (1), where hole (H) is not made to recognize one turn of fly-
wheal, and the engine controller calculates the engine speed and phase.
WA500-6R 51
SEN02935-01 Failure code [CA731] Engine Bkup speed sensor phase error
Failure code [CA731] Engine Bkup speed sensor phase error 1
Action code Failure code Engine Bkup speed sensor phase error
Failure
• Engine Bkup speed sensor circuit detects phase error.

Detail of failure
• (Bkup speed sensor signal is out of phase with Ne speed sensor signal.)
Action of con- • Controls the engine by using signals from engine Ne speed sensor.
• Engine stops during operation (when Ne speed sensor is also defective at the same time).
Problem on
• Engine cannot be started once it is stopped (when Ne speed sensor is also defective at the same
machine
time).
Related infor-
a To replace Bkup speed sensor, fuel supply pump must be replaced as a unit. (See Disassembly and
mation
assembly, "Removal and installation of fuel supply pump".)

Defective engine Ne speed sensor Engine Ne speed sensor may be defective. Perform troubleshooting for failure
1
system code [CA689]
Defective engine Bkup speed sen- Engine Bkup speed sensor may be defective. Perform troubleshooting for fail-
2
sor system ure code [CA778]
52 WA500-6R
Failure code [CA757] All continuous data lost error SEN02935-01
Failure code [CA757] All continuous data lost error 1
Action code Failure code All engine controller data lost error
Failure
Detail of failure • All data in engine controller are lost.

Action of con-
troller
Problem on
• Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
Related infor-
mation

WA500-6R 53
SEN02935-01 Failure code [CA778] Engine Bkup speed sensor error
Failure code [CA778] Engine Bkup speed sensor error 1

Action code Failure code Eng Bkup Speed Sensor Error
Failure
E03 CA778
Detail of failure q Abnormality has occurred in engine Bkup speed sensor circuit.
q Controls engine by using Ne speed sensor signal.
Action of con-
q Limits engine output and allows engine to run.
troller
q Turns the centralized warning lamp and alarm buzzer ON.
q Engine stops during operation (when Ne speed sensor is also defective at the same time).
Problem on
q Engine cannot be started once it is stopped (when Ne speed sensor is also defective at the same
machine
time).
q Method of reproducing failure code: Start engine.
a If engine Bkup speed sensor is replaced, fuel supply pump must be replaced.
Related infor- (See "Disassembly and assembly", "Removal and installation of fuel supply pump assembly".)
mation q Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor cannot be
determined to be normal by measuring its resistance with circuit tester.
q Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with circuit tester.

1
Defective sensor power sup-
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
ply line
Damage or improper instal-
Engine Bkup speed (G) sensor may be damaged or improperly installed (loose).
3 lation (loose) of engine Bkup
Check sensor.
speed (G) sensor
4 Defective resistor (RES) 2. Disconnect connector RES and connect T-adapter to male side.
Between RES (male) (1) and (2) Resistance 620 z
Defective engine Bkup 2. Disconnect connector G and connect T-adapter to female side.
5 speed sensor power supply 3. Turn starting switch to ON position.
input Power supply
Between G (female) (1) and (2) Voltage 4.75 – 5.25 V
input
Open or short circuit in wir- 1. Turn starting switch to OFF position.
6 ing harness 2. Disconnect connectors ENG and G, and connect T-adapter to female side of ENG.
(Resistor RES line) Between ENG (female) (37) and (26) Resistance 620 z
2. Disconnect connectors ENG, G and RES, and connect T-adapters to each female
side.
Open circuit in wiring har- a If power supply voltage in checks on cause 5 is nor-
ness mal, this check is not required. Resistance Max. 1 z
7
(wire breakage or defective Between ENG (female) (37) and G (female) (1)
contact of connector) a If power supply voltage in checks on cause 5 is nor-
Between ENG (female) (47) and G (female) (2)
Between ENG (female) (26) and G (female) (3) Resistance Max. 1 z
54 WA500-6R
Failure code [CA778] Engine Bkup speed sensor error SEN02935-01

2. Disconnect connectors ENG, G and RES, and connect T-adapter to female side
of ENG or G.
Short circuit in wiring har- Between ENG (female) (26) and (37), or between G
8 Resistance Min. 1 Mz
ness (female) (1) and (3)
Between ENG (female) (26) and (47), or between G
Ground fault in wiring har- 2. Disconnect connectors ENG and G and connect T-adapters to either female side.
9 ness (contact with ground
circuit) Between ENG (female) (26) or G (female) (3) and
ground
Hot short circuit in wiring 2. Disconnect connectors G and RES, and connect T-adapter to female side.
10 harness (Contact with 24 V 3. Turn starting switch to ON position.
circuit)
Between G (female) (3) and ground Voltage Max. 1 V
Defective engine Ne speed If engine failure is not found by above checks, engine Bkup speed sensor may be
11
sensor defective. (Since this is an internal failure, troubleshooting cannot be performed.)
If failure is not found by above checks, engine controller may be defective. (Since
failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to engine Bkup speed sensor
WA500-6R 55
SEN02935-01 Failure code [CA1633] KOMNET datalink timeout error
Failure code [CA1633] KOMNET datalink timeout error 1
Action code Failure code CAN (KOMNET) communication disconnection

Failure
• Engine controller detected communication error in CAN (KOMNET) communication circuit between
Detail of failure
engine controller and power train controller, work equipment controller or machine monitor.
Action of con- • Controls engine in default mode, and holds state at the time of abnormally.
troller • If cause of failure disappears, machine becomes normal by itself.
• Information may not be transmitted normally through CAN (KOMNET) communication and machine
Problem on
may not operate normally.
machine
(Trouble phenomenon depends on failed section.)
Related infor-
mation

Perform troubleshooting for cause 2 - 5 in failure code [DAQRKR].
56 WA500-6R
Failure code [CA1633] KOMNET datalink timeout error SEN02935-01
WA500-6R 57
SEN02935-01


© 2017 KOMATSU
All Rights Reserved
58
SEN02936-01
WA500-6R

WA500-6R 60001 and up
Troubleshooting by failure code 
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................... 4
Failure code [CA2186] Throttle sensor power supply low error ...................................................................... 6
Failure code [CA2249] Supply pump pressure very low error 2 ..................................................................... 8
Failure code [CA2555] Intake air heater relay open circuit error .................................................................. 10
Failure code [CA2556] Intake air heater relay short circuit error .................................................................. 12
Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit ................................................... 14
Failure code [D191KA] Joystick steering neutral safety relay: Disconnection .............................................. 16
Failure code [D191KB] Joystick steering neutral safety relay: Short circuit.................................................. 18
Failure code [D192KA] ECSS solenoid: Disconnection ................................................................................ 20
Failure code [D192KB] ECSS solenoid: Short circuit.................................................................................... 21
Failure code [D192KY] ECSS solenoid: Short circuit with power supply line ............................................... 22
Failure code [D193KA] Joystick steering solenoid cut relay: Disconnection................................................. 24
Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit .................................................... 26
Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit with power supply line ................ 28
WA500-6R 1
SEN02936-01
Failure code [D5ZHKA] Terminal C signal: Disconnection ............................................................................ 30

Failure code [D5ZHKB] Terminal C signal: Short circuit................................................................................ 34
Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit..................................................... 36
Failure code [D5ZHL6] Terminal C signal: Signal does not match engine running or stopped state ............ 38
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree.................................................... 41
Failure code [DAF3KK] Machine monitor: Low source voltage (input).......................................................... 44
Failure code [DAF5KP] Machine monitor: Low output voltage...................................................................... 46
Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in
target component system)......................................................................................................................... 48
Failure code [DAQ0KK] Transmission controller: Low source voltage.......................................................... 49
Failure code [DAQ0KT] Transmission controller: Abnormality in controller .................................................. 52
Failure code [DAQ2KK] Transmission controller load power supply line: Low source voltage (input) .......... 53
Failure code [DAQ9KQ] Transmission controller model selection: Disagreement of model selection signals
.................................................................................................................................................................. 56
2 WA500-6R
SEN02936-01
WA500-6R 3
SEN02936-01 Failure code [CA2185] Throttle sensor supply voltage high error
Failure code [CA2185] Throttle sensor supply voltage high error 1
Action code Failure code Throttle sensor power supply voltage is high
Failure
Detail of failure • High voltage (5.25 V or higher) is detected in throttle sensor power supply circuit.
Action of • Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle when
controller pedal is depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
Related
information

See descriptions of wiring harness and connectors in "Electrical equipment" of
1 "Check before troubleshooting" of "General information on troubleshooting", and
connector
check them.
2. Disconnect connector L15 and turn starting switch to ON position.
Defective throttle sensor
2 If this failure code is not displayed, throttle sensor is defective.
(accelerator pedal)
a Other failure codes are displayed, too. This is because connector is disconnect-
ed. Ignore failure codes other than [CA2185].
2. Disconnect connectors E18 and L15, and connect T-adapters to female sides of
3 Short circuit in wiring harness E18.
Between E18 (female) (22) and each pin other than
E18 (22)
2. Disconnect connector E18 and connect T-adapter to male side.
4 Defective engine controller 3. Turn starting switch to ON position.
Between E18 (male) (22) and (23) Voltage 4.75 to 5.25 V
Hot short circuit in wiring 2. Disconnect connector L15 and connect T-adapter to female side.
5 harness 3. Turn starting switch to ON position.
(Contact with 24 V)
Between L15 (female) (1) and ground Voltage 4.75 to 5.25 V
4 WA500-6R
Failure code [CA2185] Throttle sensor supply voltage high error SEN02936-01
WA500-6R 5
SEN02936-01 Failure code [CA2186] Throttle sensor power supply low error
Failure code [CA2186] Throttle sensor power supply low error 1
Action code Failure code Throttle sensor power supply voltage is low
Failure
Detail of failure • Low voltage is detected in throttle sensor power supply circuit.
Action of • Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle when
controller accelerator pedal is depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
Related
information

See descriptions of wiring harness and connectors in "Electrical equipment" of
1 "Check before troubleshooting" of "General information on troubleshooting", and
connector
check them.
2. Disconnect connector L15 and turn starting switch to ON position.
Defective throttle sensor
2 If this failure code is not displayed, throttle sensor is defective.
(accelerator pedal)
a Other failure codes are displayed too. This is because that connector is discon-
nected. Ignore failure codes other than [CA2186].
Ground fault in wiring 2. Disconnect connectors E18 and L15, and connect T-adapter to female side of
3 harness one of them.
(Contact with ground circuit) Between E18 (female) (22) or L15 (female) (1) and
ground
2. Disconnect connectors E18 and L15, and connect T-adapter to female side of
4 Short circuit in wiring harness E18.
Between E18 (female) (22) and each pin other than
E18 (22)
2. Disconnect connector E18 and connect T-adapter to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.
Between E18 (male) (22) and (23) Voltage 4.75 to 5.25 V
6 WA500-6R
Failure code [CA2186] Throttle sensor power supply low error SEN02936-01
WA500-6R 7
Failure code [CA2249] Supply pump pressure very low error 2 1
Action code Failure code Supply pump no-pressure feed error 2

Failure
Detail of failure • No-pressure feed error (level 2) in supply pump was detected.
Action of con- • Limits common rail pressure.
Problem on
machine
• The signal voltage from the common rail pressure sensor can be checked with the monitoring func-
tion (Code: 36402 (V)).
Related infor-
mation

8 WA500-6R
WA500-6R 9
SEN02936-01 Failure code [CA2555] Intake air heater relay open circuit error
Failure code [CA2555] Intake air heater relay open circuit error 1
Action code Failure code Intake air heater relay open circuit
Failure
Detail of failure • Open circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
• None in particular
troller
Problem on • Intake air heater does not work (degraded starting performance at low temperature and emission
machine of white smokes)
Related infor- • Method of reproducing failure code: Turn starting switch to ON position (Coolant temperature: Max.
mation -5 °C)
• Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheat relay L106.

See the descriptions of harness and connectors in "Electrical equipment" of
1 Defective harness connector "Checks before troubleshooting" in "General information on troubleshooting",
and check them.
2. Disconnect relay L106, and connect T-adapter to male side.
Between L106 (male) (1) and (2) Resistance 200 – 400 z
2 Defective preheat relay 1. Turn starting switch to OFF position.
2. Replace relay L106 with another one.
If this failure code disappears, original preheat relay L106 is defective.
2. Disconnect connector E18, and connect T-adapter to female side.
3 Open or short circuit in harness
Between E18 (female) (40) and (42)
Resistance 200 – 400 z
a Relay L106 coil resistance
2. Disconnect connector E18 and relay L106, and connect T-adapter to female
4 Open circuit in harness side.
(Since this is an internal failure, troubleshooting is impossible.)
10 WA500-6R
Failure code [CA2555] Intake air heater relay open circuit error SEN02936-01
Circuit diagram related to intake heater relay
WA500-6R 11
SEN02936-01 Failure code [CA2556] Intake air heater relay short circuit error
Failure code [CA2556] Intake air heater relay short circuit error 1
Action code Failure code Intake air heater relay short circuit
Failure
Detail of failure • Short circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
• None in particular
troller
Problem on • Intake air heater does not work (degraded starting performance at low temperature and emission of
machine white smokes)
Related infor- • Method of reproducing failure code: Turn starting switch to ON position (Coolant temperature: Max.
mation -5 °C)
• Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheat relay L106.

See the descriptions of harness and connectors in "Electrical equipment" of
1 Defective harness connector "Checks before troubleshooting" in "General information on troubleshooting",
and check them.
Between L106 (male) (1) and (2) Resistance 200 – 400 z
2 Defective preheat relay 1. Turn starting switch to OFF position.
2. Replace relay L106 with another one.
If this failure code disappears, original preheat relay L106 is defective.
2. Disconnect connector E18 and relay L106, and connect T-adapters to either
3 Ground fault in harness female side.
Between E18 (female) (40) or L106 (female) (1) and
ground
2. Disconnect connector E18 and relay L106, and connect T-adapter to female
side of E18.
4 Short circuit in harness a Check by using multimeter in continuity mode.
Between E18 (female) (40) and each pin other than No continuity
(Since this is an internal failure, troubleshooting is impossible.)
12 WA500-6R
Failure code [CA2556] Intake air heater relay short circuit error SEN02936-01
Circuit diagram related to intake heater relay
WA500-6R 13
SEN02936-01 Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit
Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit 1
Action code Failure code Backup lamp relay: Disconnection or short circuit
Trouble
E01 D160KZ (Transmission controller system)
Contents of • Since the backup lamp relay output system is disconnection or shorted, signals are not output to the
trouble backup relay.
Action of • Turns the output to the backup lamp relay OFF.
Problem that
• Backup lamp does not light up.
appears on
• Backup buzzer does not sound.
machine
Related • Method of reproducing failure code: Turn starting switch ON and set FNR (directional) lever, joystick
information steering FNR (directional) switch, or right FNR (directional) switch to R (reverse).

Defective backup lamp relay 2. Disconnect connector L101 andconnect T-adapter to male side.
1
(L101) (Internal short circuit) Resis- 200 – 400
tance z
2. Disconnect connectors L101 and L04, and connect T-adapters to
Disconnection in wiring har- each female side.
ness 
2 Between L04 (female) (18) and L101 Resis-
(Disconnection or defective Max. 1 z
(female) (1) tance
Possible causes Between L101 (female) (2) and chassis Resis-
Max. 1 z
and standard ground tance
value in normal 1. Turn starting switch to OFF position.
state
Grounding fault in wiring  2. Disconnect connectors L101 and L04, and connect T-adapter to
3 harness either female side.
(Contact with ground circuit) Between L04 (female) (18) or L101 (female) Resis-
Min. 1 Mz
Defective transmission  4. Operate FNR (directional) lever, joystick steering FNR (direc-
4
controller tional) switch, or right FNR (directional) switch.
Between L04 (18) R (Reverse) Voltage 20 – 30 V
and chassis ground Other than above Voltage Max. 1 V
14 WA500-6R
Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit SEN02936-01
Circuit diagram related to backup lamp relay
WA500-6R 15
SEN02936-01 Failure code [D191KA] Joystick steering neutral safety relay: Disconnec-
Failure code [D191KA] Joystick steering neutral safety relay:

Disconnection 1
Action code Failure code Joystick steering neutral safety relay: Disconnection
Trouble
E01 D191KA (Work equipment controller system)
Contents of • Signals are not output to neutral safety relay due to disconnection of joystick steering neutral safety
trouble relay output system.
Action of
controller
Problem that • While operating the joystick steering, engine can be started (Steering moves immediately after
appears on engine started.).
machine • Engine can be started while joystick or right FNR switch is not in N (neutral).
• The neutral safety relay does not operate when the joystick steering neutral position is not adjusted
(initial setting).
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
Related
(Code: 40954, D-OUT-20).
information
• Machine with joystick steering only
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering
(engine stopped state)

Defective Joystick steering 2. Disconnect relay L104, and connect T-adapter to male side.
1 neutral safety relay (L104)
(Internal open circuit) Resis- 200 to
tance 400 z
2. Disconnect connectors L07 and L104 and connect T-adapters to
Possible causes Open circuit in wiring each female side.
and standard harness
value in normal 2 Between L07 (female) (4) and L104 (female) Resis-
(Wire breakage or defective Max. 1z
state (1) tance
Resis-
Between L104 (female) (2) and ground Max. 1z
tance
Defective work equipment 3. Operate Joystick steering lever with starting switch in ON posi-
3
controller tion.
Between L07 (4) and ground Voltage 20 to 30V
16 WA500-6R
Failure code [D191KA] Joystick steering neutral safety relay: Disconnec- SEN02936-01
Circuit diagram related to joystick steering neutral safety relay
WA500-6R 17
SEN02936-01 Failure code [D191KB] Joystick steering neutral safety relay: Short circuit
Failure code [D191KB] Joystick steering neutral safety relay: Short

circuit 1
Action code Failure code Joystick steering neutral safety relay: Short circuit
Trouble
E01 D191KB (Work equipment controller system)
Contents of • Signals are not output to joystick steering neutral safety relay due to grounding fault in joystick
trouble steering neutral safety relay output system.
Action of • Turns the output to the joystick steering neutral safety relay OFF.
Problem that • While operating the joystick steering, engine can be started (Steering moves immediately after
appears on engine started.).
machine • Engine can be started while joystick or right FNR switch is not in N (neutral).
• The neutral safety relay does not operate when the joystick steering neutral position is not adjusted
(initial setting).
• Work equipment controller does not output signals to joystick steering neutral safety relay while out-
putting a failure code.
Related
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
information
(Code: 40954, D-OUT-20).
• Method of reproducing failure code: Turn the starting switch ON and joystick steering operation
Cause Standard value in normal condition, remarks for troubleshooting

Defective Joystick steering
1 neutral safety relay (L104) Resis- 200 to
tance 400 z
Resis-
Between L104 (male) (1) and ground Min. 1 MΩ
tance
Probable 1. Turn starting switch to OFF position.
causes and cri- Ground fault in wiring 2. Disconnect connectors L07 and L104, and connect T-adapter
teria 2 harness to either female side.
(Contact with ground circuit) Between ground and L07 (female) (4) or Resis-
Min. 1 MΩ
L104 (female) (1) tance
Defective work equipment 3. Operate Joystick steering lever with starting switch in ON posi-
3
controller tion.
Between L07 (4) and ground Voltage 20 to 30V
18 WA500-6R
Failure code [D191KB] Joystick steering neutral safety relay: Short circuit SEN02936-01
Circuit diagram related to joystick steering neutral safety relay
WA500-6R 19
SEN02936-01 Failure code [D192KA] ECSS solenoid: Disconnection
Failure code [D192KA] ECSS solenoid: Disconnection 1
Action code Failure code ECSS (travel damper) solenoid: Disconnection

Trouble
E01 D192KA (Transmission controller system)
Contents of • Since the ECSS solenoid system is disconnected, no current flows when ECSS solenoid output is
trouble turned ON.
Action of • None in particular.
Problem that
appears on • The ECSS does not operate.
machine
• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code:
93300 ECSS V DIR).
Related
• Applicable only to ECSS specification machines (if equipped)
information
• Method of reproducing failure code: Turn the starting switch and travel damper switch ON, and travel
at a speed other than 1st.

Defective ECSS solenoid  2. Disconnect connector F24 and connect T-adapter to male side.
1
(Internal disconnection) Resis-
Between F24 (male) (1) and (2) 5 – 15 z
tance
2. Disconnect connector L04 and connect T-adapter to female
Disconnection or short circuit side.
2
in wiring harness
Possible causes Resis-
and standard Between L04 (female) (17) and (3) 5 – 15 z
tance
value in normal
state
2. Disconnect connectors F24 and L04, and connect T-adapters to
Disconnection in wiring har- each female side.
ness 
3 Between L04 (female) (17) and F24 (female) Resis-
(1) tance
Between F24 (female) (2) and L04 (female) Resis-
Max. 1 z
(3) tance
If no failure is found by above checks, transmission controller is
Defective transmission con-
4 defective. (Since this is an internal defect, troubleshooting is impos-
troller
sible.)
Circuit diagram related to ECSS solenoid
20 WA500-6R
Failure code [D192KB] ECSS solenoid: Short circuit SEN02936-01
Failure code [D192KB] ECSS solenoid: Short circuit 1
Action code Failure code ECSS (travel damper) solenoid: Short circuit
Trouble
E01 D192KB (Transmission controller system)
Contents of • Since the ECSS solenoid system is shorted with the chassis ground, abnormal current flowed when
trouble ECCS solenoid output is ON
Action of • Turns the output to the ECSS solenoid OFF.
Problem that
• The ECSS does not operate.
appears on
• The wiring harness or controller may be burnt out.
machine
93300 ECSS V DIR).
Related
• Applicable only to ECSS specification machines (if equipped)
information
• Method of reproducing failure code: Turn starting switch ON + Travel dumper switch ON + non-1st
speed

2. Disconnect connector F24 and connect T-adapter to male side.
Defective ECSS solenoid Resis-
1 Between F24 (male) (1) and (2) 5 – 15 z
(Internal short circuit) tance
Between F24 (male) (1), (2) and  Resis-
Min. 1 Mz
Possible causes
and standard Grounding fault in wiring har- 2. Disconnect connectors F24 and L04, and connect T-adapter to
value in normal 2 ness  either female side.
state (Contact with ground circuit) Between L04 (female) (17) or F24 (female) Resis-
Min. 1 Mz
Disconnection or short circuit 2. Disconnect connector L04 and connect T-adapter to female side.
3
in wiring harness Resis-
Between L04 (female) (17) and (3) 5 – 15 z
tance
troller
sible.)
WA500-6R 21
SEN02936-01 Failure code [D192KY] ECSS solenoid: Short circuit with power supply line
Failure code [D192KY] ECSS solenoid: Short circuit with power supply
line 1
Action code Failure code ECSS (travel damper) solenoid: Short circuit with power supply line
Trouble
E01 D192KY (Transmission controller system)
Contents of • Since the ECSS solenoid system is shorted with the power source, abnormal voltage was applied
trouble when ECSS solenoid output was turned OFF.
Action of
controller
Problem that
appears on • ECCS keeps operating.
machine
Related 93300 ECSS V DIR).
information • Applicable only to ECSS specification machines (if equipped)

2. Disconnect connector F24, and connect T-adapter to female
Possible causes Hot short in wiring harness side.
1
and standard (Contact with 24 V circuit)
value in normal Between F24 (female) (1) and chassis
Voltage Max. 3 V
state ground
troller
sible.)
22 WA500-6R
Failure code [D192KY] ECSS solenoid: Short circuit with power supply SEN02936-01
WA500-6R 23
SEN02936-01 Failure code [D193KA] Joystick steering solenoid cut relay: Disconnection
Failure code [D193KA] Joystick steering solenoid cut relay:

Disconnection 1
Action code Failure code Joystick steering solenoid cut relay: Disconnection
Trouble
E03 D193KA (Work equipment controller system)
Contents of • Signals are not output to joystick steering solenoid cut relay due to disconnection of joystick steering
trouble solenoid cut relay output system.
• Stops outputting the signal to the joystick steering left-right EPC solenoid.
Action of • Turns the output to the joystick steering cut relay OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the moni-
toring function (Code: 40953, D-OUT-8).
Related
information

Defective joystick steering 2. Disconnect connector L118, and connect T-adapter to male side.
1 neutral cut relay (L118)
(Internal disconnection) Resis- 200 – 400
tance z
2. Disconnect connectors L118 and L07 and connect T-adapters to
Possible causes Disconnection in wiring  each female side.
and standard harness
value in normal (Disconnection or defective Max. 1 z
state (female) (1) tance
Max. 1 z
ground tance
Defective work equipment 3. Turn starting switch to ON position.
3
controller 4. Operate the joystick steering lever.
Between L07 (26) and chassis ground Voltage 20 – 30 V
24 WA500-6R
Failure code [D193KA] Joystick steering solenoid cut relay: Disconnec- SEN02936-01
Circuit diagram related to joystick steering cut relay
WA500-6R 25
SEN02936-01 Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit
Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit 1
Action code Failure code Joystick steering solenoid cut relay: Short circuit
Trouble
E03 D193KB (Work equipment controller system)
Contents of • Signals are not output to joystick steering solenoid cut relay due to grounding fault in joystick steer-
trouble ing solenoid cut relay output system.
• Stops the output to the joystick steering left-right EPC solenoid.
Action of • Turns the output to the joystick steering cut relay OFF.
Problem that
machine
Related
information

2. Disconnect connector L118, and connect T-adapter to male side.
Defective joystick steering
Resis- 200 – 400
1 cut relay (L118) (Internal Between L118 (male) (1) and (2)
tance z
short circuit)
Resis-
Between L118 (1) and chassis ground Min. 1 Mz
tance
Possible causes
value in normal 2. Disconnect connectors L118 and L07 and connect T-adapter to
Ground fault in wiring harness either female side.
state 2
Between L07 (female) (26) or L118 (female) Resis-
Min. 1 Mz
3
controller 4. Operate the joystick steering lever.
Between L07 (26) and chassis ground Voltage 20 – 30 V
26 WA500-6R
Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit SEN02936-01
WA500-6R 27
SEN02936-01 Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit
Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit
with power supply line 1
Action code Failure code Joystick steering solenoid cut relay: Short circuit with power supply
Trouble line
E03 D193KY (Work equipment controller system)
Contents of • Signals are not output to joystick steering solenoid cut relay due to hot short circuit in joystick steer-
trouble ing solenoid cut relay output system.
• Stops the output to the joystick steering left-right EPC solenoid.
Action of • Stops the output to the joystick steering cut relay.
Problem that
machine
Related
information

2. Disconnect connector L118, and connect T-adapter to female
Hot short in wiring harness side.
Possible causes (Contact with 24V circuit)
and standard Between L118 (female) (1) and chassis
Voltage Max. 3 V
value in normal ground
2
controller a Trounleshoot with the joystick steering switch OFF.
Between L07 (26) and chassis ground Voltage Max. 1 V
28 WA500-6R
Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit SEN02936-01
WA500-6R 29
SEN02936-01 Failure code [D5ZHKA] Terminal C signal: Disconnection
Failure code [D5ZHKA] Terminal C signal: Disconnection 1
Action code Failure code Terminal C signal: Disconnection

Trouble
E01 D5ZHKA (Transmission controller system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and no starting switch terminal C signal has been input.)
Problem that
appears on • Engine does not start easily.
machine
• The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked
Related
information
• Method of reproducing failure code: START position of starting switch

Defective fuse No.2 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
1
box A (See cause 4.)
2. Disconnect connector LS4, and connect T-adapter to male side.
3. Perform troubleshooting with starting switch in ON/OFF and
Defective starting switch START position.
2
START Max. 1 z
Between LS4 (1) and tance
(3) Resis-
OFF/ON Min. 1 Mz
tance
2. Disconnect connectors LS4, L120, L02, L103, L104, and connect
T-adapters to each female side.
Between LS4 (female) (3) and L120 (female) Resis-
Disconnection in wiring  Max. 1 z
(3) tance
Possible causes harness
and standard 3 Between L120 (female) (6) and L103 Resis-
value in normal (female) (5) tance
state Between L103 (female) (3) and L104 Resis-
Max. 1 z
(female) (6) tance
Between L104 (female) (3) and L02 (female) Resis-
Max. 1 z
(6) tance
2. Disconnect connectors LS4, L120, L02, L80, L103, L104, L06,
L10, D03, D04, and E01, and connect T-adapter to either female
side in the following.
Between LS4 (female) (3) or L120 (female) Resis-
Grounding fault in wiring  Min. 1 Mz
4 harness
(Contact with ground circuit) Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
30 WA500-6R
Failure code [D5ZHKA] Terminal C signal: Disconnection SEN02936-01

Possible causes
and standard
value in normal Defective transmission  START position.
5
state controller Starting switch:
Voltage 20 to 30 V
Between L02 (6) and START
ground Starting switch:
Voltage Max. 1 V
OFF/ON
WA500-6R 31
SEN02936-01 Failure code [D5ZHKA] Terminal C signal: Disconnection
Circuit diagram related to engine starting system
32 WA500-6R
Failure code [D5ZHKA] Terminal C signal: Disconnection SEN02936-01
WA500-6R 33
SEN02936-01 Failure code [D5ZHKB] Terminal C signal: Short circuit
Failure code [D5ZHKB] Terminal C signal: Short circuit 1
Action code Failure code Terminal C signal: Short circuit

Trouble
E01 D5ZHKB (Transmission controller system)
Contents of • Terminal C system is shorted with the power source (Engine speed is above 500 rpm and starting
trouble switch terminal C signal has been input.).
Action of • Engine start assistance is not working.
Problem that
appears on • Engine does not start easily.
machine
• The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked
Related
information

2. Disconnect connector CL12, and connect T-adapter to male
side.
1
Resis-
START Max. 1 z
Between CL12 (1) tance
and (3) Resis-
OFF/ON Min. 1 Mz
tance
2. Disconnect connectors L103 and L104, and connect T-adapters
Possible causes to each female side.
and standard 3. Turn starting switch to ON position.
value in normal Hot short in wiring harness Between L103 (female) (5) and chassis
2 Voltage Max. 1 V
state (Contact with 24 V circuit) ground
Between L103 (female) (3) or L104 (female)
Voltage Max. 1 V
(6) and chassis ground
Between L104 (female) (3) and chassis
Voltage Max. 1 V
ground
Defective transmission  START position.
3
controller Starting switch:
Voltage 20 to 30 V
Voltage Max. 1 V
OFF/ON
34 WA500-6R
Failure code [D5ZHKB] Terminal C signal: Short circuit SEN02936-01
WA500-6R 35
SEN02936-01 Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit
Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit 1
Action code Failure code Terminal C signal: Disconnection or short circuit

Trouble
E01 D5ZHKZ (Work equipment controller system)
Contents of • Terminal C system is disconnected (Engine speed is above 500 rpm and no starting switch terminal
trouble C signal has been input.)
Problem that
• Engine starts when work equipment control lever is not at Neutral (Disconnection).
appears on
• While engine is stopped, residual pressure in work equipment cannot be released (Short circuit).
machine
• The input state (ON/OFF) from starting switch terminal C to work equipment controller can be
Related
checked with the monitoring function (Code: 40912, D-IN-17).
information
• Method of reproducing failure code: Set the starting switch to START position

1
2
START Max. 1 z
(3) Resis-
OFF/ON Min. 1 Mz
tance
2. Disconnect connectors LS4, L120, L103, and L06, and connect
Disconnection in wiring  Between LS4 (female) (3) and L120 (female) Resis-
harness Max. 1 z
3 (3) tance
(Disconnection or defective
Possible causes contact in connector) Max. 1 z
(female) (5) tance
and standard
value in normal Max. 1 z
state (25) tance
2. Disconnect connectors LS4, L120, L103, and L06, and connect
T-adapter to either female side.
Grounding fault in wiring  Between LS4 (female) (3) or L120 (female) Resis-
Min. 1 Mz
4 harness (3) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
Defective work equipment START position.
5
controller Starting switch:
Voltage 20 to 30V
Between L06 (25) START
and ground Starting switch:
Voltage Max. 1 V
OFF/ON
36 WA500-6R
Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit SEN02936-01
WA500-6R 37
SEN02936-01 Failure code [D5ZHL6] Terminal C signal: Signal does not match engine
Failure code [D5ZHL6] Terminal C signal: Signal does not match engine
running or stopped state 1
Action code Failure code Terminal C signal: Signal does not match engine running or stopped
Trouble state
E01 D5ZHL6 (Machine monitor system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and alternator terminal R voltage has been checked.)
Problem that
appears on • The engine does not start.
machine
• The input state (ON/OFF) from starting switch terminal C to machine monitor can be checked with
Related
the monitoring function (Code: 40900, D-IN-2).
information
• Method of reproducing failure code: Set the starting switch to START position

1
START Max. 1 z
(3) Resis-
OFF/ON Min. 1 Mz
tance
2. Disconnect connectors LS4, L103, L104, L120, and L52, and
connect T-adapters to each female side.
Between LS4 (female) (3) and L120 (female) Resis-
Disconnection in wiring  Max. 1 z
(3) tance
harness
Possible causes (Disconnection or defective Max. 1 z
and standard (female) (5) tance
value in normal Between L103 (female) (3) and L104 Resis-
Max. 1 z
state (female) (6) tance
Max. 1 z
(2) tance
2. Disconnect connectors LS4, L103, L104, L120, L02, L06, L80,
L10, D03, D04 and E01, and connect T-adapter to either female
side in the following.
Grounding fault in wiring  Min. 1 Mz
3 harness
(Contact with ground circuit) Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
38 WA500-6R
Failure code [D5ZHL6] Terminal C signal: Signal does not match engine SEN02936-01

Possible causes
and standard
START position.
value in normal 4 Defective machine monitor
state Starting switch:
Voltage 20 to 30V
Voltage Max. 1 V
OFF/ON
WA500-6R 39
SEN02936-01 Failure code [D5ZHL6] Terminal C signal: Signal does not match engine
40 WA500-6R
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree SEN02936-01
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree 1
Action code Failure code Auto grease controller: ON/OFF signals disagree
Trouble
— DA80L4 (Machine monitor system)
Contents of
• Both circuits of auto-greasing sensor inputs A and B are open, or their voltage is 24V simultaneously.
trouble
Problem that
• Auto grease does not work.
appears on
• Auto grease lamp goes off.
machine
• The input state (ON/OFF) from the auto grease controller can be checked with the monitoring function
Related (Code: 40900, D-IN-4, D-IN-5).
information • Applicable only to machines equipped with auto grease function (if equipped)
• Method of reproducing failure code: Turn the starting switch ON (auto grease install)

Defective auto grease con-
1 troller (Internal disconnec- a Refer to and troubleshoot for auto grease system.
tion or short circuit)
2. Disconnect connectors L52 and R38, and connect T-adapters to
Open circuit in wiring each female side.
harness
2 Between L52 (female) (3) and R38 (female) Resis-
(Wire breakage or defective Max. 1 Ω
(2) tance
Between L52 (female) (12) and R38 (female) Resis-
Max. 1 Ω
(3) tance
Possible causes
value in normal 2. Disconnect connectors L52 and R38, and connect T-adapter to
state Ground fault in wiring either female side.
3 harness Between ground and L52 (female) (3) or R38 Resis-
Min. 1 MΩ
(Contact with ground circuit) (female) (2) tance
Between ground and L52 (female) (12) or Resis-
Min. 1 MΩ
R38 (female) (3) tance
2. Disconnect connector R38, and connect T-adapter to female
Hot short circuit in wiring side.
4 harness 3. Turn starting switch to ON position.
(Contact with 24V circuit)
Between R38 (female) (2) and ground Voltage Max. 1 V
Between R38 (female) (3) and ground Voltage Max. 1 V
WA500-6R 41
SEN02936-01 Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree

3. Turn starting switch to ON position and press auto-greasing start
button.
Real-time monitor
Between L52 (3) and
(Code: 40900):
Auto ground (0 V) Auto
D-IN-4 0
grease: grease
Operating Between L52 (12) Real-time monitor lamp:ON
(Code: 40900):
and ground (24 V)
D-IN-5 1
Real-time monitor
Between L52 (3) and Auto
(Code: 40900):
Auto ground (0 V) grease
Defective auto-greasing D-IN-4 0
grease: lamp:
Possible causes controller Abnormal Between L52 (12) Real-time monitor Blink
5
and standard (Internal open or short (Code: 40900): (2 Hz)
and ground (0 V)
value in normal circuit) D-IN-5 0
state Real-time monitor
Between L52 (3) and Auto
Auto (Code: 40900):
ground (24 V) grease
grease: D-IN-4 1
lamp:
Tank Real-time monitor
Between L52 (12) Blink
empty (Code: 40900):
and ground (0 V) (1 Hz)
D-IN-5 0
Real-time monitor
Between L52 (3) and
(Code: 40900):
Auto ground (24 V) Auto
D-IN-4 1
grease: grease
Abnormal Between L52 (12) Real-time monitor lamp:OFF
(Code: 40900):
and ground (24 V)
D-IN-5 1
If no failure is found by checks on causes 1 to 5, machine monitor
6 Defective machine monitor may be defective. (Since this is an internal defect, troubleshooting is
impossible.)
42 WA500-6R
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree SEN02936-01
Circuit diagram related to auto grease
WA500-6R 43
SEN02936-01 Failure code [DAF3KK] Machine monitor: Low source voltage (input)
Failure code [DAF3KK] Machine monitor: Low source voltage (input) 1
Action code Failure code Machine monitor: Low source voltage (input)
Trouble
E03 DAF3KK (Machine monitor system)
Contents of • When the voltage of the SW power supply (power supply for operation) is above 17 V, the voltage of
trouble the constant power supply (power supply for operation) is below 17 V.
Problem that
• The service meter reading is abnormal, the odometer does not advance and failure history data is
appears on
not saved.
machine
Related
information

Defective fuse No. 8 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
1
1. Turn starting switch to OFF position and disconnect battery
ground cable.
side.
2 Defective wiring harness 3. Install the battery ground cable, and turn starting switch to ON
position (connect ACC).
a Leave machine monitor disconnected.
Between L51 (female) (4) and (9) Voltage 20 to 30 V
ground cable.
2. Disconnect connector L51, and connect T-adapter to female side.
Resis-
Between L51 (female) (9) and ground Max. 1 z
Possible causes tance
and standard Resis-
value in normal Between L51 (female) (10) and ground Max. 1 z
tance
state
Resis-
tance
Resis-
Disconnection in wiring  tance
harness Resis-
3 Between L51 (female) (19) and ground Max. 1 z
(Disconnection or defective tance
contact) Resis-
tance
If no failure is found by check on cause 2, this check is not required.
ground cable.
2. Remove fuse No. 8 in fuse box A.
Between LR1 (male) (1) and fuse No.8 of Resis-
Max. 1 z
fuse box A tance
Between fuse No. 8 of fuse box A or L51 Resis-
Max. 1 z
(female) (4), (5) and chassis ground tance
44 WA500-6R
Failure code [DAF3KK] Machine monitor: Low source voltage (input) SEN02936-01

ground cable.
Possible causes Grounding fault in wiring  2. Remove fuse No. 8 in fuse box A.
and standard 4 harness 3. Disconnect connector L51, and connect T-adapter to female
value in normal (Contact with ground circuit) side.
state
Between fuse No. 8 of fuse box A or L51 Resis-
Max. 1 z
(female) (4), (5) and chassis ground tance
When machine monitor is replaced, if condition becomes normal,
machine monitor is defective.
Circuit diagram related to machine monitor power supply
WA500-6R 45
SEN02936-01 Failure code [DAF5KP] Machine monitor: Low output voltage
Failure code [DAF5KP] Machine monitor: Low output voltage 1
Action code Failure code Machine monitor: Low output voltage

Trouble
E01 DAF5KP (Machine monitor system)
Contents of • When the voltage of the switch power supply (power supply for operation) of the machine monitor is
trouble above 17 V, the voltage of the sensor is below 5 V.
controller • Even if cause of failure disappears, system does not reset itself until it is restarted.
Problem that
appears on • Machine monitor does not display load.
machine
Related • Only for load meter (if equipped)
information • Method of reproducing failure code: Turn starting switch ON.

2. Disconnect connectors of following sensors one by one, and turn
starting switch to ON position each time.
a If this failure code lights off, disconnected sensor is defec-
tive.
Defective angle sensor or a Since connector is disconnected, other failure codes appear.
1 pressure sensor (internal Ignore all the other failure codes except this one.
defect) 3. Each time troubleshooting is finished, return to step 1.
Sensor Connector
Lift arm angle sensor F13
Possible causes Lift arm bottom pressure sensor F14
and standard
value in normal Lift arm rod pressure sensor F15
Ground fault in wiring 2. Disconnect connectors L51, F13, F14, and F15.
2 harness 3. Connect T-adapter to female side of connector L51.
(Contact with ground circuit) Resis-
Between L51 (female) (16) and ground Min. 1 Mz
tance
2. Disconnect connectors F13, F14, and F15, and connect T-
adapter to either female side.
3 Defective machine monitor 3. Turn starting switch to ON position (with connectors F13, F14,
and F15 disconnected).
Between ground and F13 (female) (A), F14 4.85 to
Voltage
(female) (A) or F15 (female) (A) 5.15 V
46 WA500-6R
Failure code [DAF5KP] Machine monitor: Low output voltage SEN02936-01
Circuit diagram related to machine monitor sensor
WA500-6R 47
SEN02936-01 Failure code [DAFRKR] CAN communication with machine monitor: Com-
Failure code [DAFRKR] CAN communication with machine monitor:

Communication error (Abnormality in target component system) 1
Action code Failure code CAN communication with machine monitor: Communication error
Failure (Abnormality in target component system)
E03 DAFRKR (Transmission controller system)
• Transmission controller cannot receive information from machine monitor through CAN communi-
Detail of failure
cation.
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
• Uses CAN information obtained from machine monitor just before failure occurs.
troller
• If failure disappears, machine becomes normal by itself.
Problem on
• Machine monitor does not display normally.
machine
• Check that power supply circuit of machine monitor is normal.
• Start of CAN communication is recognized by each controller when ACC signal of starting switch is
received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication. Accord-
ingly, if CAN communication with machine monitor fails, failure code [DAFRKR] is not displayed on
Related infor- machine monitor and it can be observed only through KOMTRAX system.
mation • When failure code [D**RKR] or [DB9RMC] is also displayed, write down all of displayed codes.
• Failure code [DAFRKR] is displayed. That is, there cannot be short circuit, ground fault, or hot short
circuit in CAN communication line.
• Since each controller and machine monitor are connected directly to the battery, they are supplied
with power even when starting switch is in OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by using mul-
timeter.

Probable Defective power supply to
1 Perform troubleshooting for failure code [DAF3KK].
causes and cri- machine monitor
teria
Defective CAN Perform checks on causes 2 to 5 in troubleshooting for failure code
2
communication [DAQRKR].
48 WA500-6R
Failure code [DAQ0KK] Transmission controller: Low source voltage SEN02936-01
Failure code [DAQ0KK] Transmission controller: Low source voltage 1
Action code Failure code Transmission controller: Low source voltage

Trouble
E03 DAQ0KK (Transmission controller system)
• Voltage of constant power supply (battery direct power supply) of the transmission controller is low.
Contents of
• Voltage of constant power supply (battery direct power supply) is below 18 V and engine speed is
trouble
above 500 rpm.
• Cannot sense the input signals normally.
Action of
controller
stick FNR (directional) switch, or right FNR (directional) switch is set to “N (Neutral)”.
Problem that
appears on • The machine cannot operate normally.
machine
Related
information

Defective slow blow fuse If the slow blow fuse is shut down, the circuit probably has a ground-
1
(SBF1) ing fault, etc. (See cause 5.)
2
ground cable.
3. Install the battery ground cable, and turn starting switch to ON
3 Defective wiring harness position (connect ACC).
a Leave transmission controller disconnected.
Possible causes ground cable.
and standard 2. Disconnect connector L04, and connect T-adapter to female side.
value in normal
Resis-
state Between L04 (female) (21) and ground Max. 1 z
tance
Resis-
tance
Resis-
Disconnection in wiring  Between L04 (female) (32) and ground Max. 1 z
tance
harness
4 Resis-
(Disconnection or defective Between L04 (female) (33) and ground Max. 1 z
tance
ground cable.
side.
Between fuse No.6 of fuse box A and L04 Resis-
Min. 1 Mz
(female) (1), (11) tance
WA500-6R 49
SEN02936-01 Failure code [DAQ0KK] Transmission controller: Low source voltage

ground cable.
Grounding fault in wiring  2. Remove fuse No. 6 in fuse box A.
5 harness 3. Disconnect connector L04, and connect T-adapter to female
(Contact with ground circuit) side.
Possible causes
and standard Between fuse No.6 of fuse box A or L04 Resis-
Min. 1 Mz
value in normal (female) (1), (11) and chassis ground tance
state 1. Turn starting switch to OFF position and disconnect battery
ground cable.
Defective transmission  3. Install the battery ground cable, and turn starting switch to ON
6
controller position.
Between L04 (1) and (21) Voltage 20 to 30 V
50 WA500-6R
Failure code [DAQ0KK] Transmission controller: Low source voltage SEN02936-01
Circuit diagram related to transmission controller power supply
WA500-6R 51
SEN02936-01 Failure code [DAQ0KT] Transmission controller: Abnormality in controller
Failure code [DAQ0KT] Transmission controller: Abnormality in

controller 1
Action code Failure code Transmission controller: Abnormality in controller

Trouble
E01 DAQ0KT (Transmission controller system)
• The information in the ROM (non-volatile memory) of the transmission controller is abnormal.
Contents of
• Just after starting switch was turned OFF, battery direct power source was lost and finishing opera-
trouble
tion was not carried out normally.
• Sets the internal adjustment values to the default values.
Action of
controller
Problem that
appears on • The gear shifting feeling of the transmission may become bad.
machine
Related
information

and standard Since trouble is in system, troubleshooting cannot be carried out.
value in normal Defective transmission 
1 (If there is not any visible trouble in machine, controller may be used
state controller
as it is after initial setting and adjustment.)
52 WA500-6R
Failure code [DAQ2KK] Transmission controller load power supply line: SEN02936-01
Failure code [DAQ2KK] Transmission controller load power supply line:

Low source voltage (input) 1
Action code Failure code Transmission controller load power supply line: Low source voltage
Trouble (input)
E03 DAQ2KK (Transmission controller system)
• The voltage of the 24 V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input turned OFF, constant power supply (battery direct power sup-
trouble
ply) above 20 V and solenoid power supply below 18 V
• Strain itself not to display failure codes that may be false detected due to low 24 V solenoid source
Action of
voltage
controller
• Even if cause of failure disappears, system does not reset itself until directional lever, joystick steer-
ing FNR (directional) switch, or directional selector switch is set to N (Neutral).
Problem that
• Transmission is stuck in Neutral.
appears on
• The fan rotates forward if reversed.
machine
Related
information

2. Disconnect connector L114 and replace fan motor relay with
Defective fan motor relay another relay of same model.
1 (L114) (Internal disconnection 3. Turn starting switch to ON position.
or short circuit)
When failure code [DA2QKK] is not displayed, original fan motor
Possible causes relay is defective.
and standard 1. Turn starting switch to OFF position and disconnect battery
value in normal ground cable.
state 2. Disconnect connector L04, and connect T-adapter to female side.
2 Defective wiring harness
a Leave transmission controller disconnected.
WA500-6R 53
SEN02936-01 Failure code [DAQ2KK] Transmission controller load power supply line:

ground cable.
side.
Resis-
tance
Resis-
tance
Resis-
tance
Resis-
Disconnection in wiring  Between L04 (female) (33) and ground Max. 1 z
tance
harness
3 If no failure is found by check on cause 2, this check is not required.
ground cable.
2. Disconnect connectors L114 and L04, and connect T-adapters to
each female side.
Resis-
Possible causes tance
and standard Between L04 (female) (4) and L114 (female) Resis-
(1) tance
state
Between L114 (female) (5) and each of L04 Resis-
Max. 1 z
(female) (2), (12), and (22) tance
Max. 1 z
(1) tance
Grounding fault in wiring  ground cable.
4 harness 2. Disconnect connectors L114 and L04, and connect T-adapter to
(Contact with ground circuit) either female side.
Between ground and L04 (female) (2), (12), Resis- Min.
(22), or L114 (female) (5) tance 1 Mz
ground cable.
Defective transmission 
5 position.
controller
54 WA500-6R
Failure code [DAQ2KK] Transmission controller load power supply line: SEN02936-01
Circuit diagram related to transmission controller power supply
WA500-6R 55
SEN02936-01 Failure code [DAQ9KQ] Transmission controller model selection: Dis-
Failure code [DAQ9KQ] Transmission controller model selection:

Disagreement of model selection signals 1
Action code Failure code Transmission controller model selection: Disagreement of model
Trouble selection signals
E03 DAQ9KQ (Machine monitor system)
Contents of
• The transmission controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
• Does not display failure codes which may be false detected.
Problem that
appears on • If machine travels as it is, transmission may be broken.
machine
Related
information

Possible causes Select the model using the machine monitor and service mode
and standard Improper machine monitor adjustment function.
1
value in normal model selection (See “Special functions of machine monitor (EMMS)” in “Testing and
state adjusting”.)
2 Transmission controller Check part No. of controller. If it is wrong, replace controller.
56 WA500-6R
Failure code [DAQ9KQ] Transmission controller model selection: Dis- SEN02936-01
WA500-6R 57
SEN02936-01


© 2017 KOMATSU
All Rights Reserved
58
SEN02937-02
WA500-6R

WA500-6R 60001 and up
Troubleshooting by failure code 
Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormal-
ity in target component system) .................................................................................................................. 3
Failure code [DAQRMA] Transmission controller option setting: Malfunction................................................. 8
Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in
target component system) ........................................................................................................................ 10
Failure code [DB90KK] Work equipment controller: Low source voltage (input) .......................................... 15
Failure code [DB90KT] Work equipment controller: Abnormality in controller .............................................. 18
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...... 19
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range ............ 22
Failure code [DB99KQ] Work equipment controller model selection: Disagreement of model selection signals
.................................................................................................................................................................. 24
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnor-
mality in target component system) .......................................................................................................... 25
Failure code [DB9RMA] Work equipment controller option setting: Malfunction........................................... 26
WA500-6R 1
SEN02937-02
Failure code [DB9RMC] CAN communication with work equipment controller: Defective operation............ 27
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ............................. 28
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time............................. 30
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time .............................. 32
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time .............................. 34
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time
.................................................................................................................................................................. 36
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long
time ........................................................................................................................................................... 38
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time........................... 40
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time........ 42
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time ........ 44
Failure code [DD1HLD] Load meter display selector switch: Switch is kept pressed for long time .............. 46
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree............................................... 48
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit ................................. 50
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit ............................ 53
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree ................................ 56
2 WA500-6R
Failure code [DAQRKR] CAN communication with transmission control- SEN02937-02
Failure code [DAQRKR] CAN communication with transmission

controller: Communication error (Abnormality in target component
system) 1
Action code Failure code CAN communication with transmission controller: Communication
Failure error (Abnormality in target component system)
E03 DAQRKR (Machine monitor system)
Contents of • Machine monitor cannot receive information from transmission controller through CAN communica-
trouble tion circuit.
• Uses CAN information obtained from transmission controller just before failure occurs.
Action of con-
troller
Problem on
• Machine monitor does not display normally.
machine
received.
• When failure code [D**RKR] or [DB9RMC], is also displayed, at least CAN communication between
another controller and machine monitor is established. That is, there cannot be short circuit, ground
fault, or hot short circuit in CAN communication line.
• When [DAQRKR] is displayed, but none of failure codes [D**RKR] and [DB9RMC], is displayed,
Related infor-
CAN communication may not be established between any controllers. That is, there may be short
mation
circuit, ground fault, or hot short circuit in CAN communication line.
• Machine monitor detects only this code in CAN communication errors. Accordingly, when this code
is displayed, it does not always indicate that transmission controller has failure.
• Another controller may have failure and disable whole CAN communication.
• Since active signal is pulse voltage, it cannot be measured by using multimeter.

Defective power supply to
1 Perform troubleshooting for failure code [DAQ0KK].
transmission controller
Probable 2. Disconnect connectors CAN1 and E21, and connect T-adapters
causes and cri- to each male side.
teria Defective CAN terminating
3. Perform troubleshooting with starting switch in OFF position.
resistor
2
(Internal open or short Resis- 120 ±
Between CAN1 (male) (A) and (B)
circuit) tance 12 z
Resis- 120 ±
Between E21 (male) (A) and (B)
tance 12 z
WA500-6R 3
SEN02937-02 Failure code [DAQRKR] CAN communication with transmission controller:

• CAN communication line
a Since 2 CAN terminating resistors of 120 z are connected in
parallel, when circuit resistance is measured at any connector, if
it is 60 z of combined resistance, there is no open circuit.
ground cable.
2. Disconnect following connectors L03, E18, L56, and L06 one by
one, and connect T-adapter to female side of disconnected one.
a If open circuit is found (resistance between 2 terminals is 1 z or
below), disconnect all CAN communication connectors of every
Open or short circuit in
3 controller and check whether short circuit occurs in wiring har-
wiring harness
ness or inside controller.
Resis- Approx.
Between L03 (female) (32) and (22)
tance 60 z
Resis- Approx.
Between E18 (female) (46) and (47)
tance 60 z
Probable
Resis- Approx.
causes and cri- Between L56 (female) (3) and (8)
teria tance 60 z
Resis- Approx.
Between L06 (female) (32) and (22)
tance 60 z
ground cable.
2. Insert T-adapters into connectors L04, E18, E19, L51, and L07.
3. Connect battery ground cable and turn starting switch to ON
position.
Defective starting switch Between L04 (14) and (21) Voltage 20 to 30 V
ACC signal
4 (Start of CAN Between L04 (24) and (31) Voltage 20 to 30 V
communication is not Between E18 (39) and E19 (1) Voltage 20 to 30 V
recognized)
4 WA500-6R

a If no failure is found by check on cause 3, this check is not re-
quired.
ground cable.
2. Disconnect connectors L03, E18, L56, L06, CAN1, and E21, and
connect T-adapters to their female side.
Between L03 (female) (32) and E21 (female) Resis-
Max. 1 z
(A) tance
Max. 1 z
(B) tance
Max. 1 z
(32) tance
Max. 1 z
(22) tance
Max. 1 z
(3) tance
Max. 1 z
(8) tance
Probable Between L03 (female) (32) and E18 (female) Resis-
Open circuit in wiring Max. 1 z
causes and cri- harness (46) tance
teria 5
(Wire breakage or defective Between L03 (female) (22) and E18 (female) Resis-
Max. 1 z
contact of connector) (47) tance
Between L03 (female) (32) and CAN1 Resis-
Max. 1 z
(female) (A) tance
Between L03 (female) (22) and CAN1 Resis-
Max. 1 z
(female) (B) tance
a If no failure is found by check on cause 4, this check is not re-
quired.
ground cable.
2. Disconnect connectors L04, E18, L51, and L07, and connect T-
adapters to their female side.
Between starting switch (ACC) and L04 Resis-
Max. 1 z
Max. 1 z
Between starting switch (ACC) and E18 Resis-
Max. 1 z
(female) (39) tance
Max. 1 z
WA500-6R 5
SEN02937-02 Failure code [DAQRKR] CAN communication with transmission controller:

a If no failure (no open circuit) is found by check on cause 5, mea-
sure resistance at any 1 place in each case.
ground cable.
2. Disconnect connectors L03, E18, L56, and L06, and connect T-
Ground fault in wiring adapter to either female side.
6 harness
Between ground and any of E18 (female)
(Contact with ground circuit) Resis-
(46), L03 (female) (32), L56 (female) (3) or Min. 1 Mz
tance
L06 (female) (32)
Resis-
(47), L03 (female) (22), L56 (female) (8) or Min. 1 Mz
tance
L06 (female) (22)
a If no failure (no open circuit) is found by check on cause 5, mea-
sure resistance at any 1 place in each case.
ground cable.
2. Disconnect one of connectors L03, E18, L56 and L06, and
connect T-adapter to either female side.
Short circuit or hot short 3. Connect battery ground cable.
7 circuit in wiring harness 4. Turn starting switch to ON position.
(contact with 24 V circuit)
Probable
(46), L03 (female) (32), L56 (female) (3) or Voltage 1 to 4 V
causes and cri-
teria L06 (female) (32)
(47), L03 (female) (22), L56 (female) (8) or Voltage 1 to 4 V
L06 (female) (22)
a Identify which controller is defective by disconnecting them one
by one from CAN communication line by repeating the following
steps 1 to 3.
ground cable.
2. Disconnect CAN communication connectors of engine controller,
transmission controller, work equipment controller, and
Defective engine controller, KOMTRAX terminal one by one (See related circuit diagrams).
transmission controller, work
8 3. Connect battery ground cable, turn starting switch to ON position,
equipment controller, or
and perform troubleshooting.
KOMTRAX terminal 4. Return to step 1 and check next controller.
Did failure code change to [D**RKR] other If YES, the discon-

nected controller is
than [DAQRKR] ? defective.
If NO, the discon-
Is this failure code displayed? nected controller is
defective.
a If no failure is found by above checks, machine monitor may be
9 Defective machine monitor defective. (Since this is an internal defect, troubleshooting is im-
possible.)
6 WA500-6R
Circuit diagram related to CAN communication line
WA500-6R 7
SEN02937-02 Failure code [DAQRMA] Transmission controller option setting: Malfunc-
Failure code [DAQRMA] Transmission controller option setting:

Malfunction 1
Action code Failure code Transmission controller option setting: Malfunction

Trouble
E03 DAQRMA (Machine monitor – transmission controller)
Contents of
• Optional setting of the machine monitor disagrees with its recognition in the transmission controller.
trouble
Action of • The transmission controller complies with its optional setting recognition.
Problem that
appears on • Optional components do not operate normally.
machine
Related
information

Perform option setting again in adjustment function of the machine
Possible causes monitor.
1 Improper option setting
and standard (See “Special functions of machine monitor (EMMS)” in “Testing and
value in normal adjusting”.)
state 2 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.
Defective transmission
3 Since trouble is in system, troubleshooting cannot be carried out.
controller
8 WA500-6R
Failure code [DAQRMA] Transmission controller option setting: Malfunc- SEN02937-02
WA500-6R 9
SEN02937-02 Failure code [DB2RKR] CAN communication from engine controller: Com-
Failure code [DB2RKR] CAN communication from engine controller:

Communication error (Abnormality in target component system) 1
Action code Failure code CAN communication from engine controller: Communication error
Contents of Failure (Abnormality in target component system)
DB2RKR (Transmission controller system)
trouble
Detail of failure 1) Transmission controller cannot recognize engine controller through CAN communication.
• Does not update CAN communication information from engine controller.
• Fixes engine speed to 2,100 rpm.
Action of con- • Fixes throttle position recognition to 80%.
troller • Does not detect slip of modulation clutch.
Problem on • Information to be obtained from engine controller is not displayed and special functions that need
machine information do not work. In another case, received data are not updated.
received.
• When failure code [D**RKR], or [DB9RMC] is also displayed, write down all of displayed codes.
Related infor-
• Failure code [DB2RKR] is displayed. That is, there cannot be short circuit, ground fault, or hot short
mation

Defective No.1 and No.3 2. Remove fuses No.1 (5A) and No.3 (30A) in fuse box A.
1
fuses in fuse box A
a If fuse is blown, controller may have internal short circuit.
2. Disconnect connector E19, and connect T-adapter to male side.
Defective engine controller a If measured resistance is below 10 z, engine controller is defec-
2 tive (internal short circuit).
(internal short circuit)
Resis-
Between E19 (male) (3) and (1) Min. 10 z
tance
a Check ground terminal E14A and E14B for looseness and rust.
Probable 1. Turn starting switch to OFF position.
causes and cri- 2. Disconnect connector E19, and connect T-adapter to female
teria side.
a If fuse No.3 in fuse box A is blown, replace it.
Improper power supply to 3. Turn starting switch to ON position.
3
engine controller
Between E19 (female) (3) and (1) Voltage 20 - 30 V
Between E19 (female) (4) and (2) Voltage 20 - 30 V
a If abnormality is found, perform troubleshooting for contents of
trouble 2) "Engine controller power supply circuit is defective."
Defective CAN
4 Perform checks on causes 2 to 5 in failure code [DAQRKR].
communication system
a If no failure is found by above checks, engine controller may be
5 Defective engine controller defective.
(Since this is an internal defect, troubleshooting is impossible.)
10 WA500-6R
Failure code [DB2RKR] CAN communication from engine controller: Com- SEN02937-02
Circuit diagram related to CAN communication
WA500-6R 11
Circuit diagram related to engine controller power supply
12 WA500-6R
Failure code [DB2RKR] CAN communication from engine controller: Com- SEN02937-02
Contents of
2) Engine controller power supply circuit is defective.
trouble
a See the circuit diagram in contents of trouble 1).
Causes Standard value in normal state/Remarks on troubleshooting
Defective relays (L117 and 2. Exchange relays (L117 and L119 one by one) for engine
1 L119 for engine controller controller power supply with other relays.
power supply 3. Turn starting switch to ON position.
If this failure code is not displayed, original relay is defective.
2. Remove diode array D01 and connect T-adapter to male side.
a Measure by using multimeter in diode range.
2 Defective diode D01 Between D01 (male) (1) (+) and (2) (-) Continuity
Between D01 (male) (2) (+) and (1) (-) No continuity
Between D01 (male) (3) (+) and (2) (-) Continuity
Between D01 (male) (2) (+) and (3) (-) No continuity
2. Remove fuse No.3 in fuse box A. (30 A fuse).
3. Disconnect connectors each of LS4, D01, L117, L119, E18 and
E19, and connect T-adapters to each female side.
Between LS4 (female) (2) and D01 (female) Resis-
Max. 1 z
(1) tance
Between D01 (female) (2) and L117 (female) Resis-
Max. 1 z
(1) tance
Between D01 (female) (2) and L119 (female) Resis-
Max. 1 z
Possible causes (1) tance
and standard Between L117 (female) (2) and L119 Resis-
value in normal Disconnection in wiring har- Max. 1 z
ness (female) (2) tance
state 3
(wire breakage or defective Between L119 (female) (2) and E18 (female) Resis-
Max. 1 z
contact of connector) (33) tance
Between fuse No. 3 of fuse box A and L119 Resis-
Max. 1 z
(female) (5) tance
Max. 1 z
(female) (5) tance
Max. 1 z
(3) tance
Max. 1 z
(4) tance
Between E19 (female) (1), (2) and chassis Resis-
Max. 1 z
ground tance
1. Turn starting switch to OFF position and disconnect ground cable
from battery.
2. Remove fuse No.3 in fuse box A (30 A fuse).
3. Disconnect connectors L117, L119, and E19, and connect T-
adapter to female side.
Ground fault in wiring har-
4 ness Between fuse No.3 of fuse box A, L117 Resis-
Min. 1 Mz
(contact with ground circuit) (female) (5) or L119 (female) (5) and ground tance
Between L117 (female) (3), or E19 (female) Resis-
Min. 1 Mz
(3) and ground tance
Between L119 (female) (3) or E19 (female) Resis-
Min. 1 Mz
(4) and ground tance
WA500-6R 13

1. Turn starting switch to OFF position and disconnect ground cable
Possible causes from battery.
and standard 2. Disconnect connector E19 and connect T-adapter to female side.
value in normal Short circuit in wiring har-
5 Resis-
state ness Between E19 (female) (3) and (1) Min. 1 Mz
tance
Resis-
Between E19 (female) (4) and (2) Min. 1 Mz
tance
14 WA500-6R
Failure code [DB90KK] Work equipment controller: Low source voltage SEN02937-02
Failure code [DB90KK] Work equipment controller: Low source voltage

(input) 1
Action code Failure code Work equipment controller: Low source voltage (input)
Trouble
E03 DB90KK (Work equipment controller system)
Contents of • Voltage of work equipment controller UNSW power supply (battery direct power supply) is low.
trouble • Voltage of constant power supply (battery direct power supply) is 18 V or less.
• Does not display failure codes other than this code if voltage of constant power supply (battery direct
power supply) remains under 18 V for more than 2 seconds.
Action of • Even if cause of failure disappears, system does not reset itself until joystick steering lever and work
controller equipment lever are set to N (Neutral).
• Cannot operate normally since it cannot sense the input signals properly.
Problem that
appears on • The machine cannot operate normally.
machine
Related
information

1
2
ground cable.
side.
3 Defective wiring harness 3. Install the battery ground cable, and turn starting switch to ON
a Leave work equipment controller disconnected.
Possible causes ground cable.
and standard
value in normal Resis-
state tance
Resis-
tance
Resis-
tance
Open circuit in wiring
Resis-
harness Between L07 (female) (33) and ground Max. 1 z
4 tance
(Wire breakage or defective
contact of connector) If no failure is found by check on cause 3, this check is not required.
ground cable.
side.
Between battery (+) and fuse No. 7 terminal Resis-
Max. 1 z
in fuse box A tance
Between fuse No. 7 in fuse box A and L07 Resis-
Max. 1 z
WA500-6R 15
SEN02937-02 Failure code [DB90KK] Work equipment controller: Low source voltage

ground cable.
Ground fault in wiring 3. Disconnect connector L07, and connect T-adapter to female
5 harness side.
Possible causes Between ground and battery (+) or terminal Resis- Min.
of fuse No. 7 in fuse box A tance 1 Mz
and standard
value in normal Between ground and terminal of fuse No. 7 Resis- Min.
state in fuse box A or L07 (female) (1), (11) tance 1 Mz
ground cable.
Defective work equipment 3. Install the battery ground cable, and turn starting switch to ON
6
controller position.
16 WA500-6R
Failure code [DB90KK] Work equipment controller: Low source voltage SEN02937-02
Circuit diagram related to work equipment controller power supply
WA500-6R 17
SEN02937-02 Failure code [DB90KT] Work equipment controller: Abnormality in control-
Failure code [DB90KT] Work equipment controller: Abnormality in controller 1
Action code Failure code Work equipment controller: Abnormality in controller

Trouble
E01 DB90KT (Work equipment controller system)
Contents of • The information in the ROM (non-volatile memory) of the work equipment controller system is abnor-
trouble mal.
• Sets the internal adjustment values to the default values.
Action of
controller
Problem that
• The machine may false detect errors.
appears on
• Performance degrades since the machine is controlled with improper data.
machine
Related
information

and standard
value in normal Defective work equipment Since trouble is in system, troubleshooting cannot be carried out.
1
state controller Replace the work equipment controller.
18 WA500-6R
Failure code [DB92KK] Work equipment controller load power supply line: SEN02937-02
Failure code [DB92KK] Work equipment controller load power supply line:
Low source voltage (input) 1
Action code Failure code Work equipment controller load power supply line: Low source volt-
Trouble age (input)
E03 DB92KK (Work equipment controller system)
• The voltage of the 24V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input turned OFF, constant power supply (battery direct power sup-
trouble
ply) above 20 V and solenoid power supply below 18 V
• Cannot supply voltage to the solenoid. (If the voltage is below 18 V, all outputs are turned OFF.)
controller • Even if cause of failure disappears, system does not reset itself until joystick steering lever and work
equipment lever are set to N (Neutral).
Problem that
appears on • Work equipment does not move.
machine
Related
information

1
2
box B (See cause 4.)
Possible causes
ground cable.
and standard
value in normal
side.
state
3 Defective wiring harness position (connect ACC).
a Leave work equipment controller disconnected.
WA500-6R 19
SEN02937-02 Failure code [DB92KK] Work equipment controller load power supply line:

ground cable.
Resis-
tance
Resis-
tance
Resis-
Disconnection in wiring  tance
harness Resis-
4 Between L07 (female) (33) and ground Max. 1 z
(Disconnection or defective tance
contact in connector) If no failure is found by check on cause 3, this check is not required.
ground cable.
Between battery (+) and terminal of fuse No. Resis-
Max. 1 z
Possible causes 7 in fuse box B tance
and standard
Between terminal of fuse No. 7 in fuse box B Resis-
and L07 (female) (2), (12), (22) tance
state
ground cable.
Grounding fault in wiring  3. Disconnect connector L07, and connect T-adapter to female
5 harness side.
Between ground and battery (+) or terminal Resis- Min.
of fuse No. 7 in fuse box B tance 1 Mz
Between ground and terminal of fuse No. 7 Resis- Min.
in fuse box B or L07 (female) (2), (12), (22) tance 1 Mz
ground cable.
Defective work equipment
6 position.
controller
20 WA500-6R
Failure code [DB92KK] Work equipment controller load power supply line: SEN02937-02
Circuit diagram related to work equipment controller 24V power supply
WA500-6R 21
SEN02937-02 Failure code [DB95KX] Work equipment controller power supply output:
Failure code [DB95KX] Work equipment controller power supply output:

Out of input signal range 1
Action code Failure code Work equipment controller power supply output: Out of input signal
Trouble range
E03 DB95KX (Work equipment controller system)
Contents of
• Normal voltage output of 5 V sensor power supply system is out of range (Outside 4.7 – 5.3 V)
trouble
• Cannot sense the input signals normally due to abnormal potentiometer signal.
Action of
controller
Problem that
• The operator cannot operate the work equipment (all stop).
appears on
• The potentiometer errors below occur.
machine
Related • Method of reproducing failure code: Turn starting switch ON.
information • See failure code DH21KA for open circuit in wiring harness.

2. Disconnect one of connectors in the following potentiometers
and pressure sensor one by one, and turn starting switch to ON
position each time.
a If this failure code is not displayed, disconnected potentiom-
eter or pressure sensor is defective.
a Since connector is disconnected, other failure codes is dis-
Defective potentiometer played. Ignore all the other failure codes except this one.
1
(Internal short circuit) 3. Each time troubleshooting is finished, return to step 1.
Joystick steering potentiometer Connector JS3
3-spool valve EPC lever potentiometer Connector S25
Bucket EPC lever potentiometer Connector S02
Boom EPC lever potentiometer Connector S03
Possible causes Loader pump pressure sensor Connector F16
and standard
value in normal
Ground fault in wiring 2. Disconnect connectors L05, JS3, S25, S03, S02, and F16.
state
2 harness 3. Connect T-adapter to female side of connector L05.
(Contact with ground circuit) Resis- Min.
Between L05 (female) (22) and ground
tance 1 Mz
3
controller
4.7 to 5.3
Between L05 (male) (22) and (21) Voltage
V
2. Disconnect connectors JS3, S25, S02, S03, and F16, and
Hot short circuit in wiring connect T-adapter to female side of L12.
4 harness 3. Turn starting switch to ON position (with connectors JS3, S03,
(Contact with 24 V circuit) S02, S25, and F16 disconnected).
4.7 to 5.3
Between F16 (female) (B) and (A) Voltage
V
22 WA500-6R
Failure code [DB95KX] Work equipment controller power supply output: SEN02937-02
Circuit diagram related to work equipment controller 5 V power supply
WA500-6R 23
SEN02937-02 Failure code [DB99KQ] Work equipment controller model selection: Dis-
Failure code [DB99KQ] Work equipment controller model selection:

Disagreement of model selection signals 1
Action code Failure code Work equipment controller model selection: Disagreement of model
Trouble selection signals
E03 DB99KQ (Machine monitor system)
Contents of
• Work equipment controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
controller • Does not display failure codes which may be false detected.
Problem that
appears on • Work equipment may not operate normally.
machine
Related
information

Set the model with the service mode adjustment function of the
Possible causes
Improper machine monitor machine monitor.
and standard 1
model selection (See “Special functions of machine monitor (EMMS)” in “Testing and
value in normal
adjusting”.)
state
Check if work equipment controller is proper by its part No. If it is
2 Work equipment controller
not proper, replace it.
24 WA500-6R
Failure code [DB9RKR] CAN communication with work equipment con- SEN02937-02
Failure code [DB9RKR] CAN communication with work equipment

controller: Communication error (Abnormality in target component
system) 1
Action code Failure code CAN communication with work equipment controller:
Failure Communication error (Abnormality in target component system)
E03 DB9RKR (Transmission controller system)
• Transmission controller cannot receive CAN communication information from work equipment con-
Detail of failure
troller.
Action of con-
• Uses CAN information obtained from work equipment controller just before failure occurs.
troller
Problem on
machine -

received.
• When failure code [D**RKR] or [DB9RMC] is also displayed, write down all of displayed codes.
Related infor-
• Failure code [DB9RKR] is displayed. That is, there cannot be short circuit, ground fault, or hot short
mation

1 Perform troubleshooting for failure code [DB90KK].
work equipment controller
Probable
causes and cri- Defective CAN Perform checks on causes 2 to 5 in troubleshooting for failure code
2
teria communication system [DAQRKR].
a If no failure is found by above checks, work equipment controller
3 may be defective.
controller
(Since this is an internal defect, troubleshooting is impossible.)
WA500-6R 25
SEN02937-02 Failure code [DB9RMA] Work equipment controller option setting: Mal-
Failure code [DB9RMA] Work equipment controller option setting:

Malfunction 1
Action code Failure code Work equipment controller option setting: Malfunction
Trouble
E03 DB9RMA (Machine monitor system)
Contents of • Optional setting of the machine monitor disagrees with its recognition in the work equipment control-
trouble ler.
Action of • The work equipment controller complies with its optional setting recognition.
Problem that
appears on • Optional components do not operate normally.
machine
Related
information

Perform option setting again in adjustment function of the machine
Possible causes monitor.
1 Improper option setting
and standard (See “Special functions of machine monitor (EMMS)” in “Testing and
value in normal adjusting”.)
state Defective work equipment
2 Since trouble is in system, troubleshooting is impossible.
controller
3 Defective machine monitor Since trouble is in system, troubleshooting is impossible.
26 WA500-6R
Failure code [DB9RMC] CAN communication with work equipment con- SEN02937-02
Failure code [DB9RMC] CAN communication with work equipment controller:

Defective operation 1
Action code Failure code CAN communication with work equipment controller: Defective operation
Trouble
E03 DB9RMC (Work equipment controller system)
• Communication via CAN signal line between the work equipment controller and transmission control-
ler is defective.
Contents of
• The travel speed signal cannot be transmitted from transmission controller.
trouble
• The engine start prohibition signal cannot be transmitted from transmission controller.
Action of
• Judges that the travel speed is at 0 km/h.
controller
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
Problem that • The operator may not use Semi-automatic digging occasionally or cannot use it entirely.
appears on • The engine can start when the joystick steering lever is not in neutral
machine • Swing speed increases because joystick steering cannot sense travel speed properly.
received.
• When failure code [D**RKR] is also displayed, write down all of displayed codes.
Related
• Failure code [DB9RMC] is displayed. That is, there cannot be short circuit, ground fault, or hot short
information

1 Perform troubleshooting for failure code [DAQ0KK].
Possible causes transmission controller
and standard Defective CAN
value in normal 2 Perform checks on causes 2 to 5 in failure code [DAQRKR].
communication system
state
a If no failure is found by above checks, transmission controller
3 may be defective. (Since this is an internal defect, troubleshoot-
controller
ing is impossible.)
WA500-6R 27
SEN02937-02 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed
for long time 1
Action code Failure code t Switch (Panel switch 1): Switch is kept pressed for long time
Trouble
E01 DD15LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 1 “t” (Panel switch 1) is kept CLOSED
trouble for more than continuous 1 minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot operate the monitor (cannot enter the service mode).
appears on
• Character display may not display letters.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 1 “t” (Panel switch 1) can
Related be checked with the monitoring function (Code: 40901 D-IN-15).
information • The operator may not be able to use the monitoring function because of the t switch trouble.

Defective t switch (Panel t switch Resis-
Max. 1 z
1 switch 1)  (Panel switch 1): ON tance
(Internal short circuit) Between L66 (male)
(4) and (5) t switch
Resis-
(Panel switch 1): Min. 1 Mz
tance
Other than above
Possible causes 2. Disconnect connector L66, and connect T-adapter to female
and standard Hot short in wiring harness side.
value in normal 2 3. Turn starting switch to ON position.
state Between L66 (female) (4) and chassis
Voltage Max. 1 V
ground
t switch
3 Defective machine monitor Voltage 20 – 30 V
(Panel switch 1): ON
Between L52 (17)
and chassis ground t switch
(Panel switch 1): Voltage Max. 1 V
Other than above
28 WA500-6R
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed SEN02937-02
Circuit diagram related to t switch and U switch
WA500-6R 29
SEN02937-02 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept

pressed for long time 1
Action code Failure code U Switch (Panel switch 2): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 2 “U” (Panel switch 2) is kept
trouble CLOSED for more than continuous 1 minute.
Action of
controller
Problem that
• The operator cannot operate the monitor.
appears on
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 2 “U” (Panel switch 2)
Related can be checked with the monitoring function (Code: 40901 D-IN-14).
information • The operator may not be able to use the monitoring function because of the U switch trouble.

Defective U switch (Panel U switch Resis-
Max. 1 z
(5) and (6) U switch
Resis-
tance
Other than above
Possible causes 2. Disconnect connector L66, and connect T-adapter to female
and standard Hot short in wiring harness side.
value in normal 2 3. Turn starting switch to ON position.
state Between L66 (female) (6) and chassis
Voltage Max. 1 V
ground
U switch
3 Defective machine monitor Voltage 20 – 30 V
Between L52 (8) and
chassis ground U switch
(Panel switch 2): Voltage Max. 1 V
Other than above
30 WA500-6R
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed SEN02937-02
Circuit diagram related to t switch and U switch
WA500-6R 31
SEN02937-02 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed
for long time 1
Action code Failure code “<” Switch (Panel switch 3): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 3 “<” (Panel switch 3) is kept CLOSED
Action of
controller
Problem that
• The operator cannot operate the monitor.
appears on
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 3 “<” (Panel switch 3) can
information • The operator may not be able to use the monitoring function because of the “<” switch trouble.

Defective < switch (Panel < switch Resis-
Max. 1 z
(4) and (5) < switch
Resis-
tance
Other than above
Possible causes
and standard Grounding fault in wiring har- 2. Disconnect connectors L65 and L54, and connect T-adapter to
2 ness either female side.
value in normal
state (Contact with ground circuit) Between L54 (female) (7) or L65 (female) (4) Resis-
Min. 1 Mz
and chassis ground tance
< switch
3 Defective machine monitor Voltage Max. 1 V
Between L54 (7) and
chassis ground < switch
(Panel switch 3): Voltage 7 – 30 V
Other than above
32 WA500-6R
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed SEN02937-02
Circuit diagram related to > switch and < switch
WA500-6R 33
SEN02937-02 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed
for long time 1
Action code Failure code “>” Switch (Panel switch 4): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 4 “>” (Panel switch 4) is kept CLOSED
Problem that
appears on • The operator cannot operate the monitor.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 4 “>” (Panel switch 4) can
information • The operator may not be able to use the monitoring function because of the “>” switch trouble.

Defective > switch (Panel > switch Resis-
Max. 1 z
(5) and (6) > switch
Resis-
tance
Other than above
Possible causes
and standard Grounding fault in wiring  2. Disconnect connectors L65 and L54, and connect T-adapter to
value in normal
state (Contact with ground circuit) Between L54 (female) (15) or L65 (female) Resis-
Min. 1 Mz
> switch
3 Defective machine monitor Voltage Max. 1 V
Between L54 (15)
and chassis ground > switch
(Panel switch 4): Voltage 7 – 30 V
Other than above
34 WA500-6R
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed SEN02937-02
Circuit diagram related to > switch and < switch
WA500-6R 35
SEN02937-02 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise):
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise):

Switch is kept pressed for long time 1
Action code Failure code Remote positioner raise/lower set switch (raise): Switch is kept
Trouble pressed for long time
E01 DD1ALD (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (raise) system has a grounding fault, operator
trouble cannot set raising.
• Stops setting the lift arm raise set position.
Action of • Stops the remote raise stop operation.
controller • Turns the lift arm raise set indicator OFF.
Problem that
• The operator cannot set the lift arm raise set position.
appears on
• The remote positioner raise stop control does not operate.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (raise) can be checked
Related
with the monitoring function (Code: 40913 D-IN-28).
information

2. Disconnect connector S13, and connect T-adapter to male side.
Remote positioner
Resis-
raise/lower set Max. 1 z
tance
Defective remote positioner switch: Raise
Between S13 (male)
1 raise/lower set switch (raise) Remote positioner
(5) and (6)
(Internal short circuit) raise/lower set Resis-
Min. 1 Mz
switch: Other than tance
above
Between S13 (male) (5), (6) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes
value in normal Grounding fault in wiring  2. Disconnect connectors S13 and L06, and connect T-adapter to
state 2 harness either female side.
(Contact with ground circuit) Between L06 (female) (13) or S13 (female) Resis-
Min. 1 Mz
Remote positioner
Defective work equipment raise/lower set Voltage Max. 1 V
3
controller switch: Raise
Between L06 (13)
and chassis ground Remote positioner
raise/lower set
Voltage 7 – 10 V
switch: Other than
above
36 WA500-6R
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): SEN02937-02
Circuit diagram related to remote positioner raise/lower set switch
WA500-6R 37
SEN02937-02 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower):
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower):

Switch is kept pressed for long time 1
Action code Failure code Remote positioner raise/lower set switch (lower): Switch is kept
Trouble pressed for long time
E01 DD1BLD (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (lower) system has a grounding fault, operator
trouble cannot set lowering.
• Stops setting the lift arm lower set position.
Action of • Stops the remote lower stop operation.
controller • Turns the lift arm lower set indicator OFF.
Problem that
• The operator cannot set the lower set position.
appears on
• The remote positioner lower stop control does not operate.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (lower) can be checked
Related
information

Remote positioner
Resis-
raise/lower set Max. 1 z
tance
Defective remote positioner switch: Lower
Between S13 (male)
1 raise/lower set switch Remote positioner
(4) and (5)
(Internal short circuit) raise/lower set Resis-
Min. 1 Mz
switch: Other than tance
above
Min. 1 Mz
ground tance
Possible causes
(Contact with ground circuit) Between L06 (female) (3) or S13 (female) (4) Resis-
Min. 1 Mz
Remote positioner
Defective work equipment raise/lower set Voltage Max. 1 V
3
controller switch: Lower
Between L06 (3) and
chassis ground Remote positioner
raise/lower set
Voltage 7 – 10 V
switch: Other than
above
38 WA500-6R
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): SEN02937-02
Circuit diagram related to remote positioner raise/lower set switch
WA500-6R 39
SEN02937-02 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed
for long time 1
Action code Failure code Load meter subtotal switch: Switch is kept pressed for long time
Trouble
E01 DD1CLD (Machine monitor system)
Contents of • The load meter subtotal switch may not operate because of grounding fault in load meter subtotal
trouble switch system.
Action of
controller
Problem that
• The total amount of load cannot be set to 0 on the screen.
appears on
• Data cannot be output to printer (if equipped).
machine
• The input state (ON/OFF) from the load meter subtotal switch can be checked with the monitoring
Related function (Code: 40904 D-IN-32)
information • Only for load meter (if equipped)

Load meter subtotal Resis-
Max. 1 z
Defective load meter subtotal Between S08 (male) switch: ON tance
1
switch (Internal short circuit) (3) and (4) Load meter subtotal Resis-
Min. 1 Mz
switch: OFF tance
Min. 1 Mz
ground tance
Possible causes
(Contact with ground circuit) Wiring harness between L54 (female) (4) or Resis-
Min. 1 Mz
S08 (female) (3) and chassis ground tance
3 Defective machine monitor Load meter subtotal
Voltage Max. 1 V
Between L54 (4) and switch: ON
chassis ground Load meter subtotal
Voltage 7 – 30 V
switch: OFF
40 WA500-6R
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept SEN02937-02
Circuit diagram related to load meter cancel switch & subtotal switch
WA500-6R 41
SEN02937-02 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is
kept pressed for long time 1
Action code Failure code Load meter mode selector switch (A/B): Switch is kept pressed for
Trouble
E01 DD1FLD long time (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (A/B) is kept CLOSED for more than contin-
trouble uous 1 minute
Action of
controller
Problem that
• The working object cannot be changed.
appears on
machine
• The input state (ON/OFF) from the load meter mode selector switch (A/B) can be checked with the
Related monitoring function (Code: 40901 D-IN-10).

Load meter mode
Resis-
selector switch (A/B): Max. 1 z
Defective load meter mode tance
Between L69 (male) ON
1 selector switch (A/B) 
(5) and (6) Load meter mode
(Internal short circuit) Resis-
selector switch (A/B): Min. 1 Mz
tance
OFF
Between L69 (male) (5), (6) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes
value in normal 2. Disconnect connector L69 and connect T-adapter to female side.
Hot short in wiring harness 3. Turn starting switch to ON position.
state 2
Voltage Max. 1 V
ground
Load meter mode
3 Defective machine monitor selector switch (A/B): Voltage 20 – 30 V
Between L52 (6) and ON
chassis ground Load meter mode
selector switch (A/B): Voltage Max. 1 V
OFF
42 WA500-6R
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is SEN02937-02
Circuit diagram related to load meter mode selector switch
WA500-6R 43
SEN02937-02 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is
Action code Failure code Load meter mode selector switch (+/–): Switch is kept pressed for
Trouble long time
E01 DD1GLD (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (+/–) is kept CLOSED for more than continu-
trouble ous 1 minute
Action of
controller
Problem that
• The operator cannot make settings of load meter addition mode.
appears on
machine
• The input state (ON/OFF) from the load meter mode selector switch (+/–) can be checked with the
Related monitoring function (Code: 40901 D-IN-11).

Load meter mode
Resis-
selector switch Max. 1 z
Defective load meter mode tance
Between L69 (male) (+/–): ON
1 selector switch (+/–) 
(4) and (5) Load meter mode
(Internal short circuit) Resis-
selector switch Min. 1 Mz
tance
(+/–): OFF
Min. 1 Mz
ground tance
Possible causes
value in normal 2. Disconnect connector L69 and connect T-adapter to female side.
Hot short in wiring harness 3. Turn starting switch to ON position.
state 2
Voltage Max. 1 V
ground
Load meter mode
3 Defective machine monitor selector switch Voltage 20 – 30 V
Between L52 (15) (+/–): ON
and chassis ground Load meter mode
selector switch Voltage Max. 1 V
(+/–): OFF
44 WA500-6R
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is SEN02937-02
Circuit diagram related to load meter mode selector switch
WA500-6R 45
SEN02937-02 Failure code [DD1HLD] Load meter display selector switch: Switch is kept
Failure code [DD1HLD] Load meter display selector switch: Switch is

Action code Failure code Load meter display selector switch: Switch is kept pressed for long
Trouble time
E01 DD1HLD (Machine monitor system)
Contents of • The load meter display selector switch does not operate because of grounding fault in the load meter
trouble display selector switch system.
Action of
controller
Problem that
• Unable to display cumulative data
appears on
machine
• The input state (weight) from the load meter display selector switch can be checked with the monitor-
Related ing function (Code: 40902 D-IN-23).

Load meter display Resis-
Defective load meter display Max. 1 z
Between L70 (male) selector switch: ON tance
1 selector switch 
(5) and (6) Load meter display Resis-
(Internal short circuit) Min. 1 Mz
selector switch: OFF tance
Min. 1 Mz
ground tance
Possible causes
value in normal Grounding fault in wiring  2. Disconnect connectors L70 and L53, and connect T-adapter to
Min. 1 Mz
3 Defective machine monitor Load meter display
Voltage Max. 1 V
Between L53 (10) selector switch: ON
and chassis ground Load meter display
Voltage 7 – 30 V
selector switch: OFF
46 WA500-6R
Failure code [DD1HLD] Load meter display selector switch: Switch is kept SEN02937-02
Circuit diagram related to load meter display selector switch
WA500-6R 47
SEN02937-02 Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree 1
Action code Failure code RPM set ON/OFF switch: ON/OFF signals disagree
Trouble
E01 DDA7L4 (Transmission controller system)
Contents of
• RPM set does not function because of a hot short circuit in RPM set ON/OFF switch system.
trouble
Action of • Turns RPM set function OFF
Problem that
appears on • RPM setting is disabled
machine
• The input state (ON/OFF) from the RPM set ON/OFF switch (pressed upward) can be checked with
the monitoring function (Code: 95500 THROT LOCK A).
Related
• The input state (ON/OFF) from the RPM set ON/OFF switch (pressed downward) can be checked
information
with the monitoring function (Code: 95501 THROT LOCK B).
• Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON

RPM set ON/OFF Resis-
Min. 1 Mz
Between S11 (male) switch: ON , OFF tance
(4) and (5) RPM set ON/OFF Resis-
Max. 1 z
Defective RPM set ON/OFF switch: ON  tance
1
switch (Internal short circuit) RPM set ON/OFF Resis-
Max. 1 z
Between S11 (male) switch: ON  tance
(5) and (6) RPM set ON/OFF Resis-
Min. 1 Mz
switch: ON , OFF tance
Between S11 (male) (4), (5), (6) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes 2. Disconnect connector S11, and connect T-adapter to female
and standard side.
value in normal Hot short in wiring harness 3. Turn starting switch to ON position.
state 2
(Contact with 24 V circuit) Between S11 (female) (4) and chassis
Voltage Max. 1 V
ground
Between S11 (female) (6) and chassis
Voltage Max. 1 V
ground
RPM set ON/OFF
Voltage Max. 1 V
Between L02 (13) switch: ON , OFF
3 Defective machine monitor and chassis ground RPM set ON/OFF
Voltage 20 – 30 V
switch: ON 
RPM set ON/OFF
Voltage 20 – 30 V
Between L02 (19) switch: ON 
and chassis ground RPM set ON/OFF
Voltage Max. 1 V
switch: ON , OFF
48 WA500-6R
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree SEN02937-02
Circuit diagram related to RPM set ON/OFF switch
WA500-6R 49
SEN02937-02 Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up):
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up):

Short circuit 1
Action code Failure code RPM set idle-up/down selector switch (idle-up): Short circuit
Trouble
E01 DDA8KB (Transmission controller system)
Contents of • Idle-up switch is misjudged to be ON due to ground fault in RPM set idle-up/down selector switch
trouble (idle-up) system.
Problem that
machine
• The input state (ON/OFF) from the RPM set idle-up/down selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON and
operate the RPM set idle-up/down selector switch (idle-up)

RPM set idle-up/
down selector switch: Resis-
Min. 1 Mz
Idle-up position or tance
Between S12 (male) neutral
(4) and (5)
RPM set idle-up/
Resis-
down selector switch: Max. 1 z
Defective RPM set idle-up/ tance
Idle-down position
1 down selector switch 
Possible causes (Internal short circuit) RPM set idle-up/
Resis-
and standard down selector switch: Max. 1 z
tance
value in normal Idle-up position
state Between S12 (male)
(5) and (6) RPM set idle-up/
Min. 1 Mz
Idle-down position or tance
neutral
Min. 1 Mz
ground tance
Grounding fault in wiring  2. Disconnect connectors S12 and L04, and connect T-adapter to
Min. 1 Mz
50 WA500-6R
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): SEN02937-02

RPM set idle-up/
down selector switch:
Voltage 7 – 10 V
Idle-up position or
Between L04 (29) neutral
Possible causes
and chassis ground
and standard RPM set idle-up/
3 down selector switch: Voltage Max. 1 V
state controller
Idle-down position
RPM set idle-up/
down selector switch: Voltage Max. 1 V
Idle-up position
Between L04 (19)
and chassis ground RPM set idle-up/
Voltage 7 – 10 V
Idle-down position or
neutral
WA500-6R 51
SEN02937-02 Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up):
Circuit diagram related to RPM set idle-up/down selector switch
52 WA500-6R
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): SEN02937-02
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down):

Short circuit 1
Action code Failure code RPM set idle-up/down selector switch (idle-down): Short circuit
Trouble
E01 DDA9KB (Transmission controller system)
Contents of • Idle-down switch is misjudged to be ON due to ground fault in RPM set idle-up/down switch (idle-
trouble down) system.
Problem that
machine
• The input state (ON/OFF) from the RPM set idle-up/down selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON and
operate the RPM set idle-up/down selector switch (idle-down)

RPM set idle-up/
Min. 1 Mz
Idle-up position or tance
Between S12 (male) neutral
(4) and (5)
RPM set idle-up/
Resis-
down selector switch: Max. 1 z
Defective RPM set idle-up/ tance
Idle-down position
1 down selector switch 
Possible causes (Internal short circuit) RPM set idle-up/
Resis-
and standard down selector switch: Max. 1 z
tance
value in normal Idle-up position
state Between S12 (male)
(5) and (6) RPM set idle-up/
Min. 1 Mz
Idle-down position or tance
neutral
Min. 1 Mz
ground tance
Grounding fault in wiring  2. Disconnect connectors S12 and L04, and connect T-adapter to
Min. 1 Mz
WA500-6R 53
SEN02937-02 Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down):

RPM set idle-up/
Voltage 7 – 10 V
Idle-up position or
Between L04 (29) neutral
Possible causes
and chassis ground
and standard RPM set idle-up/
3 down selector switch: Voltage Max. 1 V
state controller
Idle-down position
RPM set idle-up/
down selector switch: Voltage Max. 1 V
Idle-up position
Between L04 (19)
and chassis ground RPM set idle-up/
Voltage 7 – 10 V
Idle-down position or
neutral
54 WA500-6R
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): SEN02937-02
Circuit diagram related to RPM set idle-up/down selector switch
WA500-6R 55
SEN02937-02 Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF

signals disagree 1
Action code Failure code Parking brake switch (Neutralizer): ON/OFF signals disagree
Trouble
E03 DDB6L4 (Transmission controller system)
• Controller outputs a failure signal when all the following conditions are satisfied.
Contents of 1) Parking brake switch signal ON (neutralizer signal OPEN)
trouble 2) Parking brake released (by CAN communication from the machine monitor)
3) Hydraulic oil temperature under 25°C
Problem that
appears on • Forward-reverse cannot be operated, or parking brake indicator lamp remains turned off.
machine
• The input state (ON/OFF) from the parking indicator switch to the machine monitor can be checked
• The input state (ON/OFF) from the parking brake switch can be checked with the monitoring function
(Code: 40907 D-IN-23).
• If failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) is displayed,
Related
carry out troubleshooting for it first.
information
• If failure code [DAFRKR] (Machine monitor CAN communication: Defective communication (Abnor-
mality in target component system) is displayed, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch and parking brake switch ON
• If emergency parking brake reset switch is turned ON (set to release position) while parking brake
switch is ON (set to parking position), this error may be detected.

2. Disconnect connector PB.SW, and connect T-adapter to male
side.
3. Start engine.
Parking brake oil
pressure:
Defective parking brake  Resis-
When parking brake is Max. 1 z
1 indicator switch tance
released, Min. 0.61
Between PB.SW MPa {Min. 6.2 kg/cm2}
(male) (1) and (2) Parking brake oil
pressure: When park-
Resis- Min. 1
ing brake applied, Max.
Possible causes tance Mz
0.34 MPa {Max. 3.5 kg/
and standard
cm2}
value in normal
state 1. Turn starting switch to L03 position.
side.
Parking brake switch: Resis- Min. 1
Between L58 (male) ON tance Mz
Defective parking brake (3) and (4) Parking brake switch: Resis-
Max. 1 z
2 switch  OFF tance
(Internal disconnection) Parking brake switch: Resis-
Max. 1 z
Between L58 (male) ON tance
(5) and (6) Parking brake switch: Resis- Min. 1
OFF tance Mz
Resis- Min. 1
Between L58 (3) and (6)
tance Mz
56 WA500-6R
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF sig- SEN02937-02

2. Disconnect connectors PB.SW, L03, L58 and L54, and connect
Disconnection in wiring  Between L54 (female) (1) and PB.SW Resis-
harness Max. 1 z
3 (female) (1) tance
Between PB.SW (female) (2) and chassis Resis-
contact) Max. 1 z
ground tance
Possible causes Between L58 (female) (3) and L03 (female) Resis-
and standard Max. 1 z
(6) tance
value in normal
state
Parking brake switch:
Voltage Max. 1 V
Defective transmission  ON
4
controller
Between L03 (6) and Parking brake switch:
chassis ground After starting switch
ON, turn parking Voltage 20 – 30 V
brake switch ON and
then OFF.
WA500-6R 57
SEN02937-02 Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals
Circuit diagram related to parking brake switch
58 WA500-6R
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF sig- SEN02937-02
WA500-6R 59
SEN02937-02


© 2017 KOMATSU
All Rights Reserved
60
SEN02938-00
WA500-6R

WA500-6R 60001 and up
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time) .......................................................................................................... 4
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)....................................................... 6
Failure code [DDK3KA] (Right FNR switch: Disconnection) ........................................................................... 8
Failure code [DDK3KB] (Right FNR switch: Short circuit)............................................................................. 10
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) ....................................................... 12
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit) .......................................................... 14
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)........................ 16
Failure code [DDK6KA] (FNR lever switch: Disconnection).......................................................................... 18
Failure code [DDK6KB] (FNR lever switch: Short circuit) ............................................................................. 22
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) .......................................... 24
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) .................. 26
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) ...................................... 28
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)................................................ 30
WA500-6R 1
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)........................... 32
Failure code [DF10KA] (Transmission shift lever switch: Disconnection) ..................................................... 34
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)......................................................... 38
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection) ........................................... 40
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)............................................... 42
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) ................................ 44
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection) .............................................. 46
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ............................. 48
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) ..................... 50
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) .................................. 52
2 WA500-6R
WA500-6R 3
Failure code [DDD1LD] (Remote positioner bucket angle set switch:

Switch is kept pressed for long time) 1
Action code Failure code Remote positioner bucket angle set switch: Switch is kept pressed
Trouble for long time
E01 DDD1LD (Work equipment controller system)
• Unable to set the bucket to a specified angle due to ground fault in the remote positioner bucket
Contents of
angle set switch system.
trouble
• Detected continuous operation for 30 seconds and longer.
Action of • Judged that remote positioner bucket angle set switch is turned ON
• Remote positioner raise set signal: Setting is changed to upward by 1° (degree) and the monitor dis-
Problem that plays the changed angle
appears on • Remote positioner lower set signal: Setting is changed to downward by 1° (degree) and the monitor
machine displays the changed angle
• Cannot be changed to upward or downward.
• The input state (ON/OFF) from the remote positioner bucket angle set switch can be checked with
the monitoring function (Code: 40911 D-IN-10, D-IN-11).
Related
• Only for load meter (if equipped)
information
• Method of reproducing failure code: Turn the starting switch and remote positioner bucket angle set
switch ON

Remote positioner
S14 (male) bucket angle set Resistance
switch
Defective remote positioner
1 bucket angle set switch Downward ON Max. 1 z
Between (4) and (5)
(Internal short circuit) OFF Min. 1 Mz
Upward ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (4), (5), (6)
Constant Min. 1 Mz
and chassis ground
Possible causes
and standard
value in normal Grounding fault in wiring
2 harness Min. 1 Mz
Min. 1 Mz
Remote positioner
L07 (female) bucket angle set Voltage
Defective work equipment switch
3
controller Downward ON Max. 1 V
Between (40) and
chassis ground OFF 7 – 10 V
Between (30) and Upward ON Max. 1 V
4 WA500-6R
Circuit diagram related to remote positioner bucket angle set switch
WA500-6R 5
Failure code [DDE5MA] (Emergency steering drive switch:

Malfunction) 1
Action code Failure code Emergency steering drive switch: Malfunction

Trouble
E01 DDE5MA (Machine monitor system)
Contents of • When engine stopped, steering pump pressure detected because of ground fault in the emergency
trouble steering drive switch system.
Action of
controller
Problem that
appears on —
machine
• The input state (ON/OFF) from the emergency steering motor can be checked with the monitoring
Related
function (Code: 40903 D-IN-30).
information

troubleshooting.
• Relieve the steering circuit
Defective emergency steering Steering relief oil

T04 (male) Resistance
1 drive switch pressure
(Internal defect) Low Min. 1 Mz
Between (1) and (2)
Normal Max. 1 z
Between (1), (2) and
Possible causes Constant Min. 1 Mz
chassis ground
and standard
state 2 harness
(Contact with ground circuit) Wiring harness between L54 (female) (3) – Resis-
Min. 1 Mz
T04 (female) (1) and chassis ground tance
troubleshooting.
• Relieve the steering circuit
3 Defective machine monitor Steering relief oil
L54 (female) Voltage
pressure
Between (3) and Low 20 – 30 V
chassis ground Normal Max. 1 V
6 WA500-6R
Circuit diagram related to emergency steering drive switch
WA500-6R 7
Failure code [DDK3KA] (Right FNR switch: Disconnection) 1
Action code Failure code Right FNR switch: Disconnection

Trouble
E03 DDK3KA (Transmission controller system)
Contents of • Right FNR (directional) switch signal cannot be recognized due to disconnection or hot short circuit
trouble in right FNR (directional) switch input signal system.
• Sets to neutral
controller • Even if cause of failure disappears, system does not reset itself until right FNR (directional) switch is
set to N (Neutral).
Problem that • Machine cannot be moved with right FNR switch.
appears on • Machine can be moved with directional lever.
machine • Shift lever position pilot lamp turns out.
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional)
switch can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or Code: 40942
Related D-IN-32).
information • Only for right FNR (directional) switch (If equipped)
• Method of reproducing failure code: Turn the starting switch and directional selector ON/OFF switch
ON + Operate right FNR (directional) switch.

Right FNR (direc-
S09 (male) Resistance
tional) switch
F (Forward) Max. 1 z
Defective right FNR (direc- Between (1) and (2)
tional) switch Other than above Min. 1 Mz
1
(Internal disconnection or N (Neutral). Max. 1 z
short circuit) Between (1) and (3)
Other than above Min. 1 Mz
R (Reverse) Max. 1 z
Between (1) and (4)
Between (1), (2), (3),
Constant Min. 1 Mz
and standard without turning starting switch ON.
state Max. 1 z
Disconnection in wiring S09 (female) (3) tance
harness Wiring harness between L03 (female) (37) – Resis-
2 Max. 1 z
(Disconnection or defective S09 (female) (2) tance
contact in connector) Wiring harness between L03 (female) (38) – Resis-
Max. 1 z
S09 (female) (4) tance
Wiring harness between S09 (female) (1) – Resis-
Max. 1 z
Wiring harness between L03(female) (28) –
Voltage Max. 1 V
Hot short in wiring harness S09 (female) (3) and chassis ground
3
Voltage Max. 1 V
S09 (female) (2) and chassis ground
Wiring harness between L03 (female) (38) –
Voltage Max. 1 V
8 WA500-6R

• Directional selector ON/OFF switch ON
Right FNR (direc-
Possible causes L03 Voltage
tional) switch
and standard
value in normal Defective transmission Between (37) and F (Forward) Max. 1 V
4
state controller chassis ground Other than above 7 – 10 V
Between (28) and N (Neutral). Max. 1 V
Between (38) and R (Reverse) Max. 1 V
Circuit diagram related to right FNR (directional) switch
WA500-6R 9
Failure code [DDK3KB] (Right FNR switch: Short circuit) 1
Action code Failure code Right FNR switch: Short circuit

Trouble
E03 DDK3KB (Transmission controller system)
Contents of • Multiple right FNR (directional) switch signals are input due to grounding fault in right FNR (direc-
trouble tional) switch input signal system.
• Sets to neutral
controller • Even if cause of failure disappears, system does not reset itself until right FNR (directional) switch is
set to N (Neutral).
Problem that • Machine cannot be moved with right FNR switch.
machine • Multiple shift lever position pilot lamps light up.
switch can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or D-IN-32).
Related
• Only for right FNR (directional) switch (If equipped)
information
• Method of reproducing failure code: Turn the starting switch and directional selector ON/OFF switch
ON + Operate right FNR (directional) switch.

Right FNR (direc-
tional) switch
Between (1) and (2)
Defective right FNR (direc- Other than above Min. 1 Mz
1 tional) switch
N (Neutral). Max. 1 z
(Internal short circuit) Between (1) and (3)
Possible causes
and standard R (Reverse) Max. 1 z
Between (1) and (4)
value in normal Other than above Min. 1 Mz
state
Between (1), (2), (3),
Constant Min. 1 Mz
Grounding fault in wiring Min. 1 Mz
2 harness
Min. 1 Mz
Min. 1 Mz
10 WA500-6R

• Directional selector ON/OFF switch ON
Right FNR (direc-
tional) switch
and standard
3
Circuit diagram related to right FNR (directional) switch
WA500-6R 11
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 1
Action code Failure code Joystick steering FNR switch: Disconnection

Trouble
Contents of • Joystick steering FNR (directional) switch signal is not input due to disconnection or hot short circuit
trouble in joystick steering FNR (directional) switch input signal system.
• Sets to neutral
controller • Even if cause of failure disappears, system does not reset itself until joystick steering FNR (direc-
tional) switch is set to N (Neutral).
Problem that • Machine cannot be moved with FNR switch.
switch can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or D-IN-32).
Related
• Only for joystick steering (If equipped)
information
• Method of reproducing failure code: Turn the starting switch and joystick ON/OFF switch ON + Oper-
ate joystick steering FNR (directional) switch.

Joystick steering FNR
JL2 (male) Resistance
Defective joystick steering Between (1) and (2)
FNR (directional) switch (Inter- Other than above Min. 1 Mz
1
nal disconnection or short cir- N (Neutral). Max. 1 z
cuit) Between (1) and (3)
R (Reverse) Max. 1 z
Between (1) and (4)
Between (1), (2), (3),
Constant Min. 1 Mz
state Max. 1 z
Disconnection in wiring JL2 (female) (3) tance
2 Max. 1 z
(Disconnection or defective JL2 (female) (2) tance
Max. 1 z
JL2 (female) (4) tance
Wiring harness between JL2 (female) (1) – Resis-
Max. 1 z
Voltage Max. 1 V
Hot short in wiring harness JL2 (female) (3) and chassis ground
3
Voltage Max. 1 V
JL2 (female) (2) and chassis ground
Voltage Max. 1 V
JL2 (female) (4) and chassis ground
12 WA500-6R

• Joystick selector ON/OFF switch ON
and standard
4
Circuit diagram related to joystick steering FNR (directional) switch
WA500-6R 13
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit) 1
Action code Failure code Joystick steering FNR switch: Short circuit
Trouble
Contents of • Multiple signals are input due to grounding fault in joystick steering FNR (directional) switch input sig-
trouble nal system.
• Sets to neutral
controller • Even if cause of failure disappears, system does not reset itself until joystick steering FNR (direc-
tional) switch is set to N (Neutral).
switch can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or Code: 40942
Related D-IN-32).
information • Only for joystick steering (If equipped)
• Method of reproducing failure code: Turn the starting switch and joystick ON/OFF switch ON + Oper-
ate joystick steering FNR (directional) switch.

Between (1) and (2)
Defective joystick steering Other than above Min. 1 Mz
1 FNR (directional) switch
N (Neutral). Max. 1 z
Possible causes
and standard R (Reverse) Max. 1 z
Between (1) and (4)
value in normal Other than above Min. 1 Mz
state
Between (1), (2), (3),
Constant Min. 1 Mz
JL2 (female) (3) and chassis ground tance
2 harness
Min. 1 Mz
Min. 1 Mz
14 WA500-6R

• Joystick ON/OFF switch ON
and standard
3
Circuit diagram related to joystick steering FNR (directional) switch
WA500-6R 15
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF

signals disagree) 1
Action code Failure code Joystick steering shift-up/down switch: ON/OFF signals disagree
Trouble
E01 DDK5L4 (Transmission controller system)
Contents of
• Multiple signals are input due to grounding fault in joystick steering shift-up/down switch system.
trouble
Action of • Turns the joystick steering shift-up/down function OFF.
Problem that
appears on • Shift-up/down cannot be performed by joystick steering.
machine
• The input signal (ON/OFF) from the joystick steering shift-up/down switch can be checked with the
Related monitoring function (Code: 40905 D-IN-1 or D-IN-2).
information • Method of reproducing failure code: Turn the starting switch ON + Joystick ON/OFF switch ON +
Joystick steering shift-up/down switch ON

Joystick steering
shift-up/down switch
Shift-down ON Min. 1 Mz
Between (1) and (5)
Shift-down OFF Max. 1 z
Defective joystick steering Shift-down ON Max. 1 z
1 shift-up/down switch Between (1) and (6)
Shift-down OFF Min. 1 Mz
Shift-up ON Min. 1 Mz
Between (1) and (7)
Shift-up OFF Max. 1 z
Shift-up ON Max. 1 z
Between (1) and (8)
Shift-up OFF Min. 1 Mz
Possible causes Between (5), (6), (7),
and standard Constant Min. 1 Mz
value in normal
Grounding fault in wiring
2 harness Min. 1 Mz
Min. 1 Mz
• Joystick ON/OFF switch ON
Joystick steering
L02 Resistance
Defective transmission shift-up/down switch
3
controller Shift-down ON Max. 1 z
Between (11) and
chassis ground Shift-down OFF Min. 1 Mz
Between (17) and Shift-up ON Max. 1 z
chassis ground Shift-up OFF Min. 1 Mz
16 WA500-6R
Circuit diagram related to joystick steering shift-up/down switch
WA500-6R 17
Failure code [DDK6KA] (FNR lever switch: Disconnection) 1
Action code Failure code FNR lever switch: Disconnection

Trouble
Contents of • Since the FNR (directional) lever switch signal system is disconnected or in ground fault, all the lever
trouble signals are not input
• Sets to Neutral when joystick steering ON/OFF switch is OFF.
• When joystick steering ON/OFF switch is ON:
1) Follows right FNR switch or joystick steering FNR switch.
Action of
2) Assumes FNR lever switch to be set to Neutral for control operation.
controller
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
appears on • Machine can be moved with right FNR switch or joystick steering FNR switch.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

1
FNR (directional)
L63 Voltage
lever
Defective FNR (directional) Between (1) and (10) Constant 20 – 30 V
lever switch N (Neutral). 20 – 30 V
2 Between (3) and (10)
(Internal disconnection or
Other than above Max. 1 V
short circuit)
F (Forward) 20 – 30 V
Between (2) and (10)
Possible causes Other than above Max. 1 V
and standard R (Reverse) 20 – 30 V
value in normal Between (4) and (10)
state Other than above Max. 1 V
Wiring harness between fuse No. 5 of fuse Resis-
Max. 1 z
box B – L63 (female) (1) tance
Disconnection in wiring Wiring harness between L03 (female) (16) – Resis-
Max. 1 z
harness L63 (female) (4) tance
3
(Disconnection or defective Wiring harness between L03 (female) (26) – Resis-
contact in connector) Max. 1 z
Max. 1 z
Max. 1 z
18 WA500-6R

Wiring harness between fuse No. 5 of fuse
Resis-
box B – L63 (female) (1) Min. 1 Mz
tance
Grounding fault in wiring and chassis ground
4 harness Wiring harness between L03 (female) (16) – Resis-
Min. 1 Mz
(Contact with ground circuit) L63 (female) (4) and chassis ground tance
Min. 1 Mz
L63 (female) (3) and chassis ground tance
Possible causes
and standard Min. 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
FNR (directional)
L03 Voltage
lever
Between (26) and N (Neutral). 20 – 30 V
5 chassis ground Other than above Max. 1 V
controller
Between (36) and F (Forward) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (16) and R (Reverse) 20 – 30 V
WA500-6R 19
Circuit diagram related to FNR (directional) lever switch
20 WA500-6R
WA500-6R 21
Failure code [DDK6KB] (FNR lever switch: Short circuit) 1
Action code Failure code FNR lever switch: Short circuit

Trouble
Contents of • FNR (directional) lever switch signals are input due to hot short circuit in FNR (directional) lever
trouble switch signal system.
• Sets to neutral
Action of • Follows right FNR (directional) switch or joystick steering FNR (directional) switch when joystick
controller steering ON/OFF switch is turned ON o OFF o ON.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
appears on • Machine can be moved with right FNR switch or joystick FNR switch.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information • Only for steering wheel specification (Standard)
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

FNR (directional)
L63 Voltage
lever
Between (1) and (10) Constant 20 – 30 V
Defective FNR (directional)
1 lever switch F (Forward) 20 – 30 V
(Internal short circuit) Other than above Max. 1 V
N (Neutral). 20 – 30 V
R (Reverse) 20 – 30 V
and standard Wiring harness between L03 (female) (16) –
value in normal Voltage Max. 1 V
Hot short in wiring harness L63 (female) (4) and chassis ground
state 2
Voltage Max. 1 V
L63 (female) (3) and chassis ground
Voltage Max. 1 V
FNR (directional)
L03 Voltage
lever
Between (26) and N (Neutral). 20 – 30 V
3 chassis ground Other than above Max. 1 V
controller
Between (36) and F (Forward) 20 – 30 V
Between (16) and R (Reverse) 20 – 30 V
22 WA500-6R
Circuit diagram related to FNR (directional) lever switch
WA500-6R 23
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals

disagree) 1
Action code Failure code Shift mode selector switch: ON/OFF signals disagree
Trouble
E01 DDT0L4 (Transmission controller system)
Contents of
• The signals input from the transmission manual/auto shift selector switch are combined impossibly.
trouble
Action of • Selects the manual shift mode.
Problem that
• The position of the transmission manual/auto shift selector switch does not match the shift mode dur-
appears on
ing auto shift.
machine
• The input state (H/L) from the transmission manual/auto shift selector switch can be checked with
Related the monitoring function (Code: 40905 D-IN-4, D-IN-5).
information • The operator can check the current shift mode with the automatic shift pilot lamp.

S16 (male) Shift mode Resistance
Manual shift Min. 1 Mz
Between (2) and (4) Auto shift (L) Min. 1 Mz
manual/auto-shift selector Auto shift (H) Max. 1 z
1
switch Manual shift Min. 1 Mz
(Internal defect). Between (1) and (2) Auto shift (L) Max. 1 z
Auto shift (H) Max. 1 z
Manual shift Min. 1 Mz
Between (1) and (4) Auto shift (L) Min. 1 Mz
Auto shift (H) Max. 1 z
value in normal Disconnection in wiring
state 2 Max. 1 z
Max. 1 z
3 harness Min. 1 Mz
Min. 1 Mz
Hot short in wiring harness Wiring harness between L02 (female) (18) –
4 Voltage Max. 1 V
(Contact with 24 V circuit) S16 (female) (4) and chassis ground
Voltage Max. 1 V
24 WA500-6R

L02 Shift mode Voltage
Possible causes
and standard Manual shift Max. 1 V
Defective transmission Between (18) and
value in normal 5 Auto shift (L) Max. 1 V
controller chassis ground
state Auto shift (H) 20 – 30 V
Manual shift Max. 1 V
Between (24) and
Auto shift (L) 20 – 30 V
chassis ground
Auto shift (H) 20 – 30 V
Circuit diagram related to transmission manual/auto shift selector switch.
WA500-6R 25
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept

pressed for long time) 1
Action code Failure code Transmission cut-off set switch: Switch is kept pressed for long time
Trouble
E01 DDT4LD (Transmission controller system)
Contents of • Transmission cut-off is not performed normally due to grounding fault in transmission cut-off set
trouble switch system.
Action of
controller
Problem that
appears on • Transmission cut-off is performed at unintended position.
machine
• The input state (ON/OFF) from the transmission cut-off set switch can be checked with the monitor-
Related
ing function (Code: 40906 D-IN-9).
information

Transmission cut-off
Defective transmission cut-off S19 (male) Resistance
set switch
1 set switch
ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 harness
Min. 1 Mz
Defective transmission Transmission cut-off
3 L04 (female) Resistance
controller set switch
Between (20) and ON Max. 1 z
chassis ground OFF Min. 1 Mz
26 WA500-6R
Circuit diagram related to transmission cut-off set switch
WA500-6R 27
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for

long time) 1
Action code Failure code Kick-down switch: Switch is kept pressed for long time
Trouble
E01 DDW9LD (Transmission controller system)
Contents of
• The kick-down does not function due to grounding fault in kick-down switch system.
trouble
Action of • Turns the kick-down ON when a grounding fault is detected, then do not control the kick-down.
Problem that
appears on • When ground fault occurs, kick-down is turned ON once but is not turned ON any more.
machine
• The input state (ON/OFF) from the kick-down switch can be checked with the monitoring function
Related
(Code: 40906 D-IN-10).
information

S07 (male) Kick-down switch Resistance
Defective kick-down switch
1 ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 harness
Min. 1 Mz
Defective transmission L04 Kick-down switch Voltage
3
controller
Between (30) and ON Max. 1 V
28 WA500-6R
Circuit diagram related to kick-down switch and hold switch
WA500-6R 29
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long
time) 1
Action code Failure code Hold switch: Switch is kept pressed for long time
Trouble
E01 DDWLLD (Transmission controller system)
Contents of
• Since the hold switch system is in ground fault, the hold switch does not function.
trouble
Action of • Holds once when a grounding fault occurs, then do not control holding.
Problem that
appears on • When ground fault occurs, turn the hold switch once.
machine
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function (Code:
Related
40906 D-IN-11).
information

S07 (male) Hold switch Resistance
Defective hold switch
1 ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 harness
Min. 1 Mz
Defective transmission L04 Hold switch Voltage
3
controller
30 WA500-6R
Circuit diagram related to kick-down switch and hold switch
WA500-6R 31
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed
for long time) 1
Action code Failure code Load meter cancel switch: Switch is kept pressed for long time
Trouble
E01 DDY0LD (Machine monitor system)
Contents of
• The load meter cancel switch is in ground fault and load meter cancel switch does not function.
trouble
Action of
controller
Problem that
appears on • Unable to cancel calculated load weight.
machine
• The input state (ON/OFF) from the load meter cancel switch can be checked with the monitoring
Related function (Code: 40904 D-IN-33).

Load meter cancel
Defective load meter cancel switch
1
switch (Internal short circuit) ON Max. 1 z
Between (1) and (2)
OFF Min. 1 Mz
chassis ground
and standard
state 2 harness
Min. 1 Mz
Load meter cancel
3 Defective machine monitor L54 (male) Voltage
switch
32 WA500-6R
Circuit diagram related to load meter cancel switch & subtotal switch
WA500-6R 33
Failure code [DF10KA] (Transmission shift lever switch: Disconnection) 1
Action code Failure code Transmission shift lever switch: Disconnection

Trouble
E01 DF10KA (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is disconnected or in ground fault, the
trouble signal is not input.
Action of • Fixed to the shift range before the abnormality occurred
Problem that
• The transmission is not set to the selected gear speed.
appears on
• Shift indicator displays the shift range before the abnormality occurred
machine
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
Related
40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19).
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever

L63 Shift range Voltage
1st (1st speed) 20 – 30 V
Defective transmission shift Other than above Max. 1 V
1 lever switch
2nd (2nd speed) 20 – 30 V
(Internal disconnection) Between (6) and (10)
3rd (3rd speed) 20 – 30 V
Possible causes 4th (4th speed) 20 – 30 V
and standard Other than above Max. 1 V
value in normal
Max. 1 z
Max. 1 z
Disconnection in wiring L63 (female) (8) tance
2 Max. 1 z
(Disconnection or defective L63 (female) (7) tance
Max. 1 z
Max. 1 z
Max. 1 z
34 WA500-6R

Min. 1 Mz
box B – L63 (female) (1) and chassis ground tance
3 harness
Min. 1 Mz
Min. 1 Mz
Possible causes Wiring harness between L03 (female) (35) – Resis-
and standard Min. 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Between (35) and 1st (1st speed) 20 – 30 V
Defective transmission 2nd (2nd speed) 20 – 30 V
4 Between (25) and
controller
Between (15) and 3rd (3rd speed) 20 – 30 V
Between (5) and 4th (4th speed) 20 – 30 V
WA500-6R 35
Circuit diagram related to transmission shift lever switch
36 WA500-6R
WA500-6R 37
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 1
Action code Failure code Transmission shift lever switch: Short circuit
Trouble
E01 DF10KB (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is in hot short circuit, multiple transmis-
trouble sion shift lever switch signals are input.
Action of • Uses the shift range input to the higher gear speed
Problem that • The relevant gear speed is not set. (The transmission does not shift into 1st or 2nd even if the trans-
appears on mission shift lever is used.)
machine • Shift indicator indicates the shift range input to the higher gear speed.
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
Related
40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19).
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever

1st (1st speed) 20 – 30 V
Defective transmission shift
1 lever switch 2nd (2nd speed) 20 – 30 V
(Internal short circuit) Other than above Max. 1 V
3rd (3rd speed) 20 – 30 V
4th (4th speed) 20 – 30 V
Possible causes Voltage Max. 1 V
and standard
value in normal Hot short in wiring harness Wiring harness between L03 (female) (15) –
2 Voltage Max. 1 V
state (Contact with 24 V circuit) L63 (female) (7) and chassis ground
Voltage Max. 1 V
Voltage Max. 1 V
Between (35) and 1st (1st speed) 20 – 30 V
Defective transmission 2nd (2nd speed) 20 – 30 V
3 Between (25) and
controller
Between (15) and 3rd (3rd speed) 20 – 30 V
Between (5) and 4th (4th speed) 20 – 30 V
38 WA500-6R
Circuit diagram related to transmission shift lever switch
WA500-6R 39
Failure code [DGF1KA] (Transmission oil temperature sensor:

Disconnection) 1
Action code Failure code Transmission oil temperature sensor: Disconnection

Trouble
E01 DGF1KA (Transmission controller system)
• Due to disconnection in transmission oil temperature sensor signal system, the signal level is higher
Contents of
than normal range (Transmission oil temperature sensor signal voltage: Min. 4.56 V (Max. 15°C)),
trouble
and torque converter oil temperature sensor signal voltage: Min. 3.7 V (Max. 5.5°C).
Action of • Cannot judge transmission oil temperature normally.
Problem that
appears on • Gear shift shock may occur.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600 T/M OIL TEMP).
• The input state (voltage) from the transmission oil temperature sensor can be checked with the mon-
itoring function (Code: 93601 T/M OIL TEMP).
Related
information

Defective transmission oil Transmission oil
temperature sensor TM.T (male) Resistance
1 temperature
short circuit) 25°C
35 – 50 kz
Between (1) and (2) (Normal temperature)
100°C 3.1 – 4.5 kz
Possible causes
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Disconnection or defective Wiring harness between L02 (female) (9) – Resis-
TM.T (female) (1) tance
Transmission oil
Defective transmission L02 (female) Resistance
3 temperature
controller
25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
40 WA500-6R
Circuit diagram related to transmission oil temperature sensor
WA500-6R 41
Failure code [DGF1KB] (Transmission oil temperature sensor: Short

circuit) 1
Action code Failure code Transmission oil temperature sensor: Short circuit
Trouble
E01 DGF1KB (Transmission controller system)
• Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Cannot judge transmission oil temperature normally.
Problem that
appears on • Gear shift shock may occur.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600 T/M OIL TEMP).
Related
• The input state (voltage) from the transmission oil temperature sensor can be checked with the mon-
information
itoring function (Code: 93601 T/M OIL TEMP).

Defective transmission oil Transmission oil
TM.T (male) Resistance
1 temperature sensor temperature
(Internal short circuit) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Wiring harness between L02 (female) (9) – Resis-
Min. 1 Mz
TM.T (female) (1) and chassis ground tance
Transmission oil
3 temperature
controller
25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
42 WA500-6R
Circuit diagram related to transmission oil temperature sensor
WA500-6R 43
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input

signal range) 1
Action code Failure code Hydraulic oil temperature sensor: Out of input signal range
Trouble
E01 DGH2KX (Machine monitor system)
• Due to grounding fault in hydraulic oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Hydraulic oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of
controller
Problem that
appears on • The hydraulic oil temperature gauge reads MAX position
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404 HYD TEMP).

Defective hydraulic oil tem- Hydraulic oil
1 perature sensor temperature
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
Min. 1 Mz
Hydraulic oil
3 Defective machine monitor temperature
25°C
Between (7) and 35 – 50 kz
(Normal temperature)
chassis ground
100°C 3.1 – 4.5 kz
44 WA500-6R
Circuit diagram related to hydraulic oil temperature sensor
WA500-6R 45
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)1
Action code Failure code Rear brake oil temperature sensor: Disconnection
Trouble
E01 DGR2KA (Machine monitor system)
Contents of
• Rear brake oil temperature sensor signal system disconnection.
trouble
Action of
controller
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205 R BRAKE OIL).

Defective rear brake oil Rear brake oil
R17 (male) Resistance
(Internal disconnection) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
value in normal 2 Max. 1 z
state (Disconnection or defective R17 (female) (1) tance
contact in connector) Wiring harness between R17 (female) (2) – Resis-
Max. 1 z
Rear brake oil
25°C
chassis ground
100°C 3.1 – 4.5 kz
46 WA500-6R
Circuit diagram related to rear brake oil temperature sensor
WA500-6R 47
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input
signal range) 1
Action code Failure code Rear brake oil temperature sensor: Out of input signal range
Trouble
E01 DGR2KX (Machine monitor system)
• Due to grounding fault in rear brake oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of
controller
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205 R BRAKE OIL).

Defective rear brake oil Rear brake oil
R17 (male) Resistance
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
Min. 1 Mz
R17 (female) (1) and chassis ground tance
Rear brake oil
25°C
chassis ground
100°C 3.1 – 4.5 kz
48 WA500-6R
Circuit diagram related to rear brake oil temperature sensor
WA500-6R 49
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of

input signal range) 1
Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Machine monitor system)
Contents of • Due to grounding fault in torque converter oil temperature sensor signal system, the signal level is
trouble lower than normal range (Transmission oil temperature voltage: Max. 0.97 V (Min. 150°C))
Action of
controller
Problem that
appears on • The torque converter oil temperature gauge reads MAX position
machine
Related
information

Defective torque converter Torque converter oil
1 oil temperature sensor temperature
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
Max. 1 z
Torque converter oil
25°C
chassis ground
100°C 3.1 – 4.5 kz
50 WA500-6R
Circuit diagram related to torque converter oil temperature sensor
WA500-6R 51
Failure code [DH21KA] (Work equipment pump oil pressure sensor:

Disconnection) 1
Action code Failure code Work equipment pump oil pressure sensor: Disconnection
Trouble
E01 DH21KA (Work equipment controller system)
• Due to disconnection or grounding fault in the work equipment oil pressure sensor system, the signal
Contents of
voltage is lower than normal range
trouble
(Work equipment pump oil pressure sensor signal voltage: Max. 0.3 V)
Action of • Judges that work equipment pump oil pressure reads 0
Problem that
• Remote positioner inaccuracy of stopping
appears on
• When work equipment is relieved, cut-off does not function
machine
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked
with the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the
information
monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve bucket tilt

F16 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
Defective work equipment a Prepare with starting switch OFF, then start engine, tilt the bucket
pump oil pressure sensor and carry out troubleshooting.
1
F16 Work equipment Voltage
short circuit)
Between (B) and (A) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (C) and (A)
Possible causes When bucket tilt
and standard 3.02 – 3.42 V
relieved
value in normal
Max. 1 z
harness F16 (female) (C) tance
2
F16 (female) (A) tance
Max. 1 z
F16 (female) (B) tance
3 harness Min. 1 Mz
F16 (female) (C) and chassis ground tance
Wiring harness between L05 (female) (22) - Resis-
Min. 1 Mz
F16 (female) (B) and chassis ground tance
52 WA500-6R

a Prepare with starting switch OFF, then start engine, tilt the bucket
Possible causes L05 Work equipment Voltage

and standard Between
value in normal 4 Work equipment controller (22) and (21)
state Constant 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
When bucket tilt
3.02 – 3.42 V
relieved
Circuit diagram related to work equipment pump oil pressure sensor
WA500-6R 53
SEN02938-00

© 2007 KOMATSU
All Rights Reserved
54
SEN02939-00
WA500-6R

WA500-6R 60001 and up
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit) ....................................... 4
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...................... 6
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)......................... 8
Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range).......................................... 10
Failure code [DHT2L6] (Transmission filter clogging sensor:
Signal disagrees with operating and stopped states of engine)................................................................ 12
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) ...................................... 14
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main):
Short circuit with power supply line).......................................................................................................... 18
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) ....................... 21
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) ....................................... 24
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub):
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)....................................... 30
WA500-6R 1
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main):

Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) ........................ 36
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) ........................................ 39
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub):
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main):
Disconnection) .......................................................................................................................................... 45
Failure code [DK5DKY] (3rd valve (attachment) EPC lever potentiometer (Main):
Failure code [DK5DL8] (3rd valve (attachment) EPC lever potentiometer (Main):
Analog signals disagree)........................................................................................................................... 49
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub):
Disconnection) .......................................................................................................................................... 52
2 WA500-6R
WA500-6R 3
Failure code [DH21KB] (Work equipment pump oil pressure sensor:

Short circuit) 1
Action code Failure code Work equipment pump oil pressure sensor: Short circuit
Trouble
E01 DH21KB (Work equipment controller system)
• Due to hot short circuit in the work equipment pump oil pressure sensor signal system, the signal
Contents of
voltage is higher than normal range
trouble
(Work equipment pump oil pressure sensor signal voltage: Min. 4.7 V)
Action of • Judges that work equipment pump oil pressure is higher
Problem that
• Remote positioner inaccuracy of stopping
appears on
• When work equipment is relieved, cut-off does not function
machine
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked
with the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the
information
monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve bucket tilt

Min. 1 Mz
chassis ground
Defective work equipment a Prepare with starting switch OFF, then start engine, tilt the bucket
1 pump oil pressure sensor and carry out troubleshooting.
(Internal short circuit) F16 Bucket Voltage
Between (B) and (A) Constant 4.85 – 5.15 V
Neutral 0.50 – 0.90 V
Between (C) and (A)
When bucket tilt
Possible causes 3.02 – 3.42 V
relieved
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
2 Voltage Max. 1 V
(Contact with 24 V circuit) F16 (female) (C) and chassis ground
Voltage Max. 1 V
F16 (female) (B) and chassis ground
a Prepare with starting switch OFF, then start engine, tilt the bucket
L05 Bucket Voltage
Between
Defective work equipment Constant 4.85 – 5.15 V
3 (22) and (21)
controller
Neutral 0.50 – 0.90 V
When bucket tilt
3.02 – 3.42 V
relieved
4 WA500-6R
Circuit diagram related to work equipment pump oil pressure sensor
WA500-6R 5
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of
Action code Failure code Lift arm cylinder bottom pressure sensor: Out of input signal range
Trouble
E01 DHPCKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder bottom pressure sensor signal, the lift
arm cylinder bottom pressure sensor voltage is lower than normal range
Contents of (Lift arm cylinder bottom pressure sensor signal voltage: Less than 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder bottom pressure sensor signal, the lift arm cylinder bot-
tom pressure sensor voltage is higher than normal range
(Lift arm cylinder bottom pressure sensor signal voltage: Min. 4.7 V)
Action of
controller
Problem that
machine
• The input state (oil pressure) from the lift arm cylinder bottom pressure sensor can be checked with
the monitoring function (Code: 40400 BOOM BTM PRESS).
Related • The input state (voltage) from the lift arm cylinder bottom pressure sensor can be checked with the
information monitoring function (Code: 40402 BOOM BTM PRESS).
• Method of reproducing failure code: Start engine and perform lift arm lever operation

a Replace sensor and check if error is reset.
a Prepare with starting switch OFF, then start engine, raise the lift
arm and carry out troubleshooting.
Defective lift arm cylinder F14 Lift arm Voltage

1
bottom pressure sensor Between (B) and (A) Constant 4.85 – 5.15 V
Between (C) and (A) Neutral 0.50 – 0.90 V
Lift arm bottom relief 3.02 – 3.42 V
and standard Wiring harness between L51 (female) (16) – Resis-
Disconnection in wiring Max. 1 z
value in normal F14 (female) (B) tance
harness
state 2
(Disconnection in wiring Wiring harness between L55 (female) (9) – Resis-
harness or defective contact) Max. 1 z
F14 (female) (C) tance
Wiring harness between F14 (female) (A) – Resis-
Max. 1 z
Grounding fault in wiring Resis-
F14 (female) (B), – circuit branch end and Min. 1 Mz
3 harness tance
chassis ground
Resis-
F14 (female) (C), – circuit branch end and Min. 1 Mz
tance
chassis ground
6 WA500-6R

Hot short in wiring harness F14 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24 V circuit) chassis ground
Possible causes F14 (female) (C), – circuit branch end and Voltage Max. 1 V
and standard chassis ground
value in normal a Prepare with starting switch OFF, then start engine, raise the lift
state arm and carry out troubleshooting.
L51, L55 Lift arm Voltage
Between L51 (16)
5 Defective machine monitor Constant 4.85 – 5.15 V
and chassis ground
Between L55 (9) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm bottom relief 3.02 – 3.42 V
Circuit diagram related to lift arm cylinder bottom pressure sensor
WA500-6R 7
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of
Action code Failure code Lift arm cylinder bottom head pressure sensor: Out of input signal
Trouble range
E01 DHPDKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder head pressure sensor signal, the lift
arm cylinder head pressure sensor voltage is lower than normal range
Contents of (Lift arm cylinder head pressure sensor signal voltage: Less than 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder head pressure sensor signal, the lift arm cylinder head
pressure sensor voltage is higher than normal range (Lift arm cylinder head pressure sensor signal
voltage: Min. 4.7 V)
Action of
controller
Problem that
machine
• The input state (oil pressure) from the lift arm cylinder head pressure sensor can be checked with the
monitoring function (Code: 40500 BOOM HEAD PRESS).
Related • The input state (voltage) from the lift arm cylinder head pressure sensor can be checked with the
information monitoring function (Code: 40501 BOOM HEAD PRESS).
• Method of reproducing failure code: Start engine and perform lift arm lever operation

a Replace sensor and check if error is reset.
a Prepare with starting switch OFF, then start engine, lower the lift
arm and carry out troubleshooting.
Defective lift arm cylinder F15 (male) Lift arm Voltage

1
head pressure sensor Between (B) and (A) Constant 4.85 – 5.15 V
Between (C) and (A) Neutral 0.50 – 0.90 V
Lift arm head relief 3.02 – 3.42 V
and standard Wiring harness between L51 (female) (16) – Resis-
value in normal F15 (female) (B) tance
harness
state 2
F15 (female) (C) tance
Wiring harness between F15 (female) (A) – Resis-
Max. 1 z
F15 (female) (B), – circuit branch end and Min. 1 Mz
3 harness tance
chassis ground
Resis-
F15 (female) (C), – circuit branch end and Min. 1 Mz
tance
chassis ground
8 WA500-6R

Hot short in wiring harness F15 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24 V circuit) chassis ground
Possible causes F15 (female) (C), – circuit branch end and Voltage Max. 1 V
value in normal a Prepare with starting switch OFF, then start engine, raise the lift
state arm and carry out troubleshooting.
L51, L55 Lift arm Voltage
Between L51 (16)
5 Defective machine monitor Constant 4.85 – 5.15 V
and chassis ground
Between L55 (4) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm head relief 3.02 – 3.42 V
Circuit diagram related to lift arm cylinder head pressure sensor
WA500-6R 9
Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal
range) 1
Action code Failure code Left brake pressure sensor: Out of input signal range
Trouble
E01 DHT1KX (Transmission controller system)
Contents of • Due to grounding fault in left brake pressure sensor signal system, the signal level is lower than nor-
trouble mal range
• Turns the transmission cut-off function OFF.
• Disables the change of transmission cut-off setting.
Action of
controller
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral); or the
transmission cut-off switch is turned OFF.
Problem that
appears on • The transmission cut-off indicator goes off.
machine
• Left brake pressure sensor input voltage: Max. 0.3 V
• The input state (oil pressure) from the left brake pressure sensor can be checked with the monitoring
Related function (Code: 41201 T/M CUT OFF P).
information • The input state (voltage) from the left brake pressure sensor can be checked with the monitoring
function (Code: 41202 T/M CUT OFF P).
• Method of reproducing failure code: Turn the starting switch and transmission cut-off switch ON.

• Turn transmission cut-off switch ON.
B01 Brake Voltage
Defective left brake pressure When brake released 0.9 – 1.1 V
1 sensor
(Internal short circuit) When left brake
1.1 – 5.1 V
pressed
Between (C) and (A)
When right brake
1.1 – 5.1 V
pressed
Possible causes Other than above 0.9 – 5.1 V

and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
Min. 1 Mz
B01 (female) (C) tance
L02 Brake Voltage
When brake released 0.9 – 1.1 V
3 When left brake
controller 1.1 – 5.1 V
pressed
When right brake
1.1 – 5.1 V
pressed
Other than above 0.9 – 5.1 V
10 WA500-6R
Circuit diagram related to left brake pressure sensor
WA500-6R 11
Failure code [DHT2L6] (Transmission filter clogging sensor: Signal

disagrees with operating and stopped states of engine) 1
Action code Failure code Transmission filter clogging sensor: Signal disagrees with operating
Trouble
E01 DHT2L6 and stopped states of engine (Machine monitor system)
• Due to disconnection or hot short circuit in transmission filter clogging sensor signal, transmission fil-
Contents of
ter clogging sensor signal voltage does not agree with the engine operation or stopping in normal
trouble
condition.
Action of
controller
Problem that
appears on • The transmission filter clogging caution lamp does not light up.
machine
• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the mon-
Related
itoring function (Code: 40903 D-IN-24).
information
• Method of reproducing failure code: Start engine and drive the machine in high idle

troubleshooting.
Defective transmission filter
1 clogging sensor R12 (male) Transmission filter Resistance
(Internal disconnection) Normal Max. 1 z
Between (1) and (2)
Clogging Min. 1 Mz
Possible causes 2 Max. 1 z
(Disconnection or defective R12 (female) (1) tance
and standard contact in connector) Wiring harness between R12 (male) (2) – Resis-
state chassis ground tance
3
Voltage Max. 1 V
R12 (female) (1) and chassis ground
troubleshooting.
4 Defective machine monitor L53 (female) Transmission filter Resistance
Between (5) and Normal Max. 1 z
chassis ground Clogging Min. 1 Mz
12 WA500-6R
Circuit diagram related to transmission filter clogging sensor
WA500-6R 13
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main):

Disconnection) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK59KA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer system, the signal
Contents of
voltage is lower than normal range
trouble
(Lift arm EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever • Work equipment lock lever: Lock
potentiometer S03 Lift arm EPC lever Voltage
1
short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes Lever in neutral 2.40 – 2.60 V
and standard Raise operation
value in normal 3.64 – 4.14 V
(Before detent)
state
Raise operation
Between (3) and (1) 3.86 – 4.36 V
(Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
Float operation 0.64 – 1.14 V
Max. 1 z
harness S03 (female) (3) tance
2
Max. 1 z
14 WA500-6R

3 harness Min. 1 Mz
Between L05 (female) (22) – S03 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance
Possible causes • Work equipment lock lever: Lock
and standard L05 Lift arm EPC lever Voltage
value in normal
state Between
(22) and (21)
Defective work equipment Lever in neutral 2.40 – 2.60 V
4
controller Raise operation
3.64 – 4.14 V
(Before detent)
Between Raise operation
3.86 – 4.36 V
(19) and (21) (Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
WA500-6R 15
Circuit diagram related to lift arm EPC lever potentiometer
16 WA500-6R
WA500-6R 17
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short
circuit with power supply line) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Short circuit with power
Trouble supply line
E03 DK59KY (Work equipment controller system)
• Due to hot short circuit in the lift arm EPC lever potentiometer (Main) system, the signal voltage is
Contents of
higher than normal range
trouble
(Lift arm EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
(Neutral).
Problem that
appears on —
machine
Related
information

S03 Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
• Work equipment lock lever: Lock
Defective lift arm EPC lever
1 potentiometer S03 Lift arm EPC lever Voltage
Possible causes (Internal short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
and standard Lever in neutral 2.40 – 2.60 V
value in normal
Raise operation
state 3.64 – 4.14 V
(Before detent)
Raise operation
Between (3) and (1) 3.86 – 4.36 V
(Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
2 Voltage Max. 1 V
Between L05 (female) (22) – S03 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground
18 WA500-6R

L05 Lift arm EPC lever Voltage
Between
Possible causes Constant 4.85 – 5.15 V
(22) and (21)
and standard
value in normal 3
state controller Raise operation
3.64 – 4.14 V
(Before detent)
3.86 – 4.36 V
Lower operation
0.86 – 1.36 V
(Before detent)
WA500-6R 19
20 WA500-6R
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog
signals disagree) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK59L8 (Work equipment controller system)
• Lift arm EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Lift arm EPC lever potentiometer signal voltage (Total of Main and Sub): Max. 4.7 V) or
trouble
(Lift arm EPC lever potentiometer signal voltage (Total of Main and Sub): Min. 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±
5%, as the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
Action of
trality ± 5%.
controller
• Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, lift arm does not move.
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
S03 Lift arm EPC lever Voltage
Between (4) and (1) Constant 4.85 – 5.15 V
and standard Defective lift arm EPC lever
Raise operation
value in normal potentiometer 3.64 – 4.14 V
1 (Before detent)
state (Internal disconnection or
short circuit) Raise operation
Between (3) and (1) 3.86 – 4.36 V
(Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
Lever in neutral 2.40 – 2.60 V
Raise operation
0.86 – 1.36 V
(Before detent)
Raise operation
Between (2) and (1) 0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
WA500-6R 21

Max. 1 z
2 Max. 1 z
(Disconnection in wiring S03 (female) (3) tance
harness or defective contact) Wiring harness between L05 (female) (21) – Resis-
Max. 1 z
Max. 1 z
3 harness
Min. 1 Mz
Min. 1 Mz
Voltage Max. 1 V
4
Possible causes (Contact with 24 V circuit) Wiring harness between L05 (female) (19) –
and standard Voltage Max. 1 V
value in normal
state Voltage Max. 1 V
Between
(22) and (21)
Raise operation
3.64 – 4.14 V
(Before detent)
3.86 – 4.36 V
Defective work equipment (19) and (21) (Detent position)
5
controller Float operation 0.64 – 1.14 V
Lower operation
0.86 – 1.36 V
(Before detent)
Raise operation
0.86 – 1.36 V
(Before detent)
0.64 – 1.14 V
Lower operation
3.64 – 4.14 V
(Before detent)
22 WA500-6R
WA500-6R 23
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub):

Disconnection) 1
Action code Failure code Lift arm EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5AKA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer (Sub) system, the sig-
Contents of
nal voltage is lower than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Max.
trouble
0.3 V).
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
controller
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever • Work equipment lock lever: Lock
potentiometer S03 (male) Lift arm EPC lever Voltage
1
short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
and standard Raise operation
(Before detent)
state
Raise operation
Between (2) and (1) 0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Max. 1 z
2
Max. 1 z
24 WA500-6R

3 harness Min. 1 Mz
Min. 1 Mz
Possible causes • Work equipment lock lever: Lock
and standard L05 Lift arm EPC lever Voltage
value in normal
state Between
(22) and (21)
4
controller Raise operation
0.86 – 1.36 V
(Before detent)
0.64 – 1.14 V
Lower operation
3.64 – 4.14 V
(Before detent)
WA500-6R 25
26 WA500-6R
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short
Action code Failure code Lift arm EPC lever potentiometer (Sub): Short circuit with power
Trouble supply line
E03 DK5AKY (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm EPC lever potentiometer (Sub) system, the signal voltage is
trouble higher than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
(Neutral).
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever
1 potentiometer S03 (male) Lift arm EPC lever Voltage
Possible causes (Internal short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
value in normal
Raise operation
state 0.86 – 1.36 V
(Before detent)
Raise operation
Between (2) and (1) 0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
2 Voltage Max. 1 V
Voltage Max. 1 V
WA500-6R 27

Between
Possible causes Constant 4.85 – 5.15 V
(22) and (21)
and standard
value in normal 3
state controller Raise operation
0.86 – 1.36 V
(Before detent)
0.64 – 1.14 V
Lower operation
3.64 – 4.14 V
(Before detent)
28 WA500-6R
WA500-6R 29
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main):

Disconnection) 1
Action code Failure code Bucket EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5BKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Main) system, the
Contents of
signal voltage is lower than normal range
trouble
(Bucket EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective bucket EPC lever and carry out troubleshooting.
potentiometer • Work equipment lock lever: Lock
1
S02 Bucket EPC lever Voltage
short circuit)
Possible causes Between (4) and (1) Constant 4.85 – 5.15 V
value in normal
Tilt operation
state 3.64 – 4.14 V
(Before detent)
Between (3) and (1)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V
Max. 1 z
2
Max. 1 z
30 WA500-6R

3 harness Min. 1 Mz
Min. 1 Mz
Possible causes and carry out troubleshooting.
and standard • Work equipment lock lever: Lock
value in normal
L05 Bucket EPC lever Voltage
state
Between
Defective work equipment (22) and (21)
4
controller Lever in neutral 2.40 – 2.60 V
Tilt operation
3.64 – 4.14 V
(Before detent)
Tilt operation
3.86 – 4.36 V
(Detent position)
WA500-6R 31
Circuit diagram related to bucket EPC lever potentiometer
32 WA500-6R
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short

Action code Failure code Bucket EPC lever potentiometer (Main): Short circuit with power
Trouble supply line
E03 DK5BKY (Work equipment controller system)
• Due to hot short circuit in the bucket EPC lever potentiometer (Main) system, the signal voltage is
Contents of
higher than normal range
trouble
(Bucket EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
(Neutral).
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
1 potentiometer • Work equipment lock lever: Lock
Possible causes (Internal short circuit) S02 Bucket EPC lever Voltage
and standard Between (4) and (1) Constant 4.85 – 5.15 V
value in normal Lever in neutral 2.40 – 2.60 V
state
Tilt operation
3.64 – 4.14 V
(Before detent)
Between (3) and (1)
Tilt operation
3.86 – 4.36 V
(Detent position)
2 Voltage Max. 1 V
Voltage Max. 1 V
WA500-6R 33

Possible causes Between
and standard Constant 4.85 – 5.15 V
value in normal 3
state controller Lever in neutral 2.40 – 2.60 V
Tilt operation
3.64 – 4.14 V
(Before detent)
Tilt operation
3.86 – 4.36 V
(Detent position)
34 WA500-6R
WA500-6R 35
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog

signals disagree) 1
Action code Failure code Bucket EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK5BL8 (Work equipment controller system)
• Bucket EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Bucket EPC lever potentiometer signal voltage (Total of Main and Sub): Max. 4.7 V) or (Bucket EPC
trouble
lever potentiometer signal voltage (Total of Main and Sub): Min 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality
±5%, as the regular potentiometer.
Action of
trality ±5%.
controller
• Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, bucket does not move.
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Possible causes
and standard Defective bucket EPC lever Between (4) and (1) Constant 4.85 – 5.15 V
value in normal potentiometer
1 Lever in neutral 2.40 – 2.60 V
state (Internal disconnection or
short circuit) Tilt operation
3.64 – 4.14 V
(Before detent)
Between (3) and (1)
Tilt operation
3.86 – 4.36 V
(Detent position)
Tilt operation
0.86 – 1.36 V
(Before detent)
Between (2) and (1)
Tilt operation
0.64 – 1.14 V
(Detent position)
36 WA500-6R

Max. 1 z
2 Max. 1 z
Max. 1 z
Max. 1 z
3 harness
Min. 1 Mz
Min. 1 Mz
Possible causes Wiring harness between L05 (female) (1) –
and standard Voltage Max. 1 V
value in normal 4
Voltage Max. 1 V
Between
(22) and (21)
Tilt operation
3.64 – 4.14 V
Defective work equipment (Before detent)
5 Between (7) and (21)
controller Tilt operation
3.86 – 4.36 V
(Detent position)
Tilt operation
0.86 – 1.36 V
(Before detent)
Tilt operation
0.61 – 1.14 V
(Detent position)
WA500-6R 37
38 WA500-6R
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub):

Disconnection) 1
Action code Failure code Bucket EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5CKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Sub) system,
Contents of
(Sub) signal voltage is lower than normal range (Bucket EPC lever potentiometer (Sub) signal volt-
trouble
age: Max. 0.3 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
controller
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
potentiometer • Work equipment lock lever: Lock
1
short circuit)
Tilt operation
0.86 – 1.36 V
Possible causes (Before detent)
and standard Between (2) and (1)
Tilt operation
(Detent position)
state
Max. 1 z
2
Max. 1 z
3 harness Min. 1 Mz
Min. 1 Mz
WA500-6R 39

Possible causes Between (22) and
Defective work equipment (21)
value in normal 4
Tilt operation
0.86 – 1.36 V
(Before detent)
Tilt operation
0.64 – 1.14 V
(Detent position)
40 WA500-6R
WA500-6R 41
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short

Action code Failure code Bucket EPC lever potentiometer (Sub): Short circuit with power supply
Trouble line
E03 DK5CKY (Work equipment controller system)
• Due to hot short circuit in the bucket EPC lever potentiometer (Sub) system,
Contents of
(Sub) signal voltage is lower than normal range (Bucket EPC lever potentiometer (Sub) signal volt-
trouble
age: Min. 4.7 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
(Neutral).
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
1 potentiometer (Internal short • Work equipment lock lever: Lock
Possible causes circuit) S02 Bucket EPC lever Voltage
and standard Between (4) and (1) Constant 4.85 -5.15 V
value in normal Lever in neutral 2.40 – 2.60 V
state
Tilt operation
0.86 – 1.36 V
(Before detent)
Between (2) and (1)
Tilt operation
0.64 – 1.14 V
(Detent position)
2 Voltage Max. 1 V
Voltage Max. 1 V
42 WA500-6R

Possible causes Between
value in normal 3
Tilt operation
0.86 – 1.36 V
(Before detent)
Tilt operation
0.64 – 1.14 V
(Detent position)
WA500-6R 43
44 WA500-6R
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever

potentiometer (Main): Disconnection) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Discon-
Trouble nection
E03 DK5DKA (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer
Contents of
(Main), the signal voltage is lower than normal range
trouble
(3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is
in control.
Action of
controller
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional
setting of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective 3-spool valve and carry out troubleshooting.
(attachment) EPC lever • Work equipment lock lever: Lock
1 potentiometer
(Internal disconnection or 3-spool valve
short circuit) S25 (male) (attachment) EPC Voltage
Possible causes lever
and standard
value in normal
state Lever in neutral 2.40 – 2.60 V
Full extension
3.86 – 4.36 V
Between (3) and (1) operation
Full retraction
0.64 – 1.14 V
operation
Max. 1 z
2
Max. 1 z
WA500-6R 45

Grounding fault in wiring Wiring harness between L05 (female) (20) – Resis-
Min. 1 Mz
3 harness S25 (female) (3) and chassis ground tance
(Contact with ground circuit) Wiring harness between L05 (female) (22) –
Resis-
S25 (female) (4), – circuit branch end and Min. 1 Mz
tance
chassis ground
value in normal
state 3-spool valve
L05 (attachment) Voltage
EPC lever
Defective work equipment Between
4 Constant 4.85 – 5.15 V
controller (22) and (21)
Full extension
Between 3.86 – 4.36 V
operation
(20) and (21)
Full retraction
0.64 – 1.14 V
operation
Circuit diagram related to 3-spool valve (attachment) EPC lever potentiometer
46 WA500-6R
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever

potentiometer (Main): Short circuit with power supply line) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Short
Trouble circuit with power supply line
E03 DK5DKY (Work equipment controller system)
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Main) system the
Contents of
signal voltage is higher than normal range
trouble
(3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 4.7 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is
in control.
Action of
controller
Problem that
appears on —
machine
Related
information
ment) lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
1
potentiometer 3-spool valve
Possible causes (Internal short circuit) S25 (male) (attachment) Voltage
and standard EPC lever
value in normal Between (4) and (1) Constant 4.85 – 5.15 V
state
Full extension
3.86 – 4.36 V
Full retraction
0.64 – 1.14 V
operation
Hot short in wiring harness Voltage Max. 1 V
2 S25 (female) (3) and chassis ground
S25 (female) (4), – circuit branch end and Voltage Max. 1 V
chassis ground
WA500-6R 47

3-spool valve
Possible causes L05 (attachment) Voltage
and standard EPC lever
value in normal Defective work equipment Between
3 Constant 4.85 – 5.15 V
state controller (22) and (21)
Full extension
Between 3.64 – 4.36 V
operation
(20) and (21)
Full retraction
0.64 – 1.14 V
operation
48 WA500-6R
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever

potentiometer (Main): Analog signals disagree) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Analog
Trouble signals disagree
E03 DK5DL8 (Work equipment controller system)
• The 3-spool valve (attachment) EPC lever potentiometer (Main and Sub) input signals disagree with
Contents of each other. (3-spool valve (attachment) EPC lever potentiometer signal voltage (Total of Main and
trouble Sub): Max. 4.7 V) or (3-spool valve (attachment) EPC lever potentiometer signal voltage (Total of
Main and Sub): Min. 5.3 V)
Action of
trality ± 5%.
controller
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
Problem that
neutral.
appears on
• If both Main and Sub potentiometers are abnormal, 3-spool valve (attachment) cylinder does not
machine
move.
Related
information
ment) lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Possible causes Defective 3-spool valve and carry out troubleshooting.
and standard (attachment) EPC lever • Work equipment lock lever: Lock
value in normal 1 potentiometer
state (Internal disconnection or 3-spool valve
short circuit) S25 (male) (attachment) Voltage
EPC lever
Full extension
3.86 – 4.36 V
Full retraction
0.64 – 1.14 V
operation
WA500-6R 49
Defective 3-spool valve Lever in neutral 2.40 – 2.60 V

(attachment) EPC lever Full extension
0.64 – 1.14 V
1 potentiometer Between (2) and (1) operation
(Internal disconnection or Full retraction
short circuit) 3.86 – 4.36 V
operation
Max. 1 z
2 Max. 1 z
Max. 1 z
Max. 1 z
Min. 1 Mz
Grounding fault in wiring S25 (female) (2) and chassis ground tance
3 harness Wiring harness between L05 (female) (20) – Resis-
(Contact with ground circuit) S25 (female) (3) and chassis ground Min. 1 Mz
tance
Resis-
tance
Possible causes chassis ground
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal and carry out troubleshooting.
state
Voltage Max. 1 V
Hot short in wiring harness
4 Wiring harness between L05 (female) (20) –
(Contact with 24 V circuit) Voltage Max. 1 V
chassis ground
3-spool valve
EPC lever
Between
(22) and (21)

5
controller Full extension
Between 3.86 – 4.36 V
operation
(20) and (21)
Full retraction
0.64 – 1.14 V
operation
Full extension
Between 0.64 – 1.14 V
operation
(14) and (21)
Full retraction
3.86 – 4.36 V
operation
50 WA500-6R
WA500-6R 51
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever

potentiometer (Sub): Disconnection) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Sub): Discon-
Trouble nection
E03 DK5EKA (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer
Contents of
(Sub), the signal voltage is lower than normal range (3-spool valve (attachment) EPC lever potenti-
trouble
ometer (Sub) signal voltage: Max. 0.3 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer
Action of is in control.
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed.
(If this failure code is displayed, select “None” in the 3-spool valve (attachment) optional setting on
the optional setting of the machine monitor.)
Related
information
ment) lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
1 potentiometer
(Internal disconnection or 3-spool valve
short circuit) S25 (attachment) Voltage
Possible causes EPC lever
and standard
value in normal
state Lever in neutral 2.40 – 2.60 V
Full extension
0.64 – 1.14 V
Full retraction
3.86 – 4.36 V
operation
Max. 1 z
2
Max. 1 z
52 WA500-6R

Grounding fault in wiring Wiring harness between L05 (female) (14) – Resis-
Min. 1 Mz
3 harness S25 (female) (2) and chassis ground tance
(Contact with ground circuit) Wiring harness between L05 (female) (22) –
Resis-
tance
chassis ground
value in normal
state 3-spool valve
EPC lever
4 Constant 4.85 – 5.15 V
Full extension
Between 0.64 – 1.14 V
operation
(14) and (21)
Full retraction
3.86 – 4.36 V
operation
WA500-6R 53
SEN02939-00

© 2007 KOMATSU
All Rights Reserved
54
SEN02940-00
WA500-6R

WA500-6R 60001 and up
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):
Short circuit with power supply line)............................................................................................................ 4
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) ......................... 6
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):
Short circuit with power supply line)............................................................................................................ 8
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) ........................ 10
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):
Analog signals disagree)........................................................................................................................... 14
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) ................................................................... 18
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) ................................................... 20
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) ................................... 22
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) ................................................................. 24
WA500-6R 1
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) ........................................ 26
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree) .......................... 28
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit) .......................................... 30
Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range) ...................... 32
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit).................................................. 34
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)..................................... 36
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) .................................... 38
Failure code [DV00KB] (Alarm buzzer: Short circuit) .................................................................................... 40
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)......................................................... 42
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) ............................................................ 43
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) ........................ 44
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) ....................................................... 46
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ........................................................... 47
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) ....................... 48
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection).............................................................. 50
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) ................................................................. 52
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) ............................. 54
2 WA500-6R
WA500-6R 3
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):

Short circuit with power supply line) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Sub): Short
Trouble circuit with power supply line
E03 DK5EKY (Work equipment controller system)
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Sub) system, the
Contents of
signal voltage is higher than normal range
trouble
(3-spool valve (attachment) EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer
is in control.
Action of
controller
Problem that
appears on —
machine
Related
information
ment) lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 1
state potentiometer 3-spool valve
(Internal short circuit) S25 (attachment) Voltage
EPC lever
Full extension
0.64 – 1.14 V
Full retraction
3.86 – 4.36 V
operation
4 WA500-6R

Hot short in wiring harness Voltage Max. 1 V
2 S25 (female) (2) and chassis ground
chassis ground
value in normal
state 3-spool valve
EPC lever
3 Constant 4.85 – 5.15 V
Full extension
Between 0.64 – 1.14 V
operation
(14) and (21)
Full retraction
3.86 – 4.36 V
operation
WA500-6R 5
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main):

Disconnection) 1
Action code Failure code Joystick steering EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5FKA (Work equipment controller system)
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer system
Contents of
(main), the signal voltage is lower than normal range.
trouble
(Joystick steering EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is
set to N (Neutral).
Problem that
appears on —
machine
• This failure code is not displayed when joystick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked
Related with the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked
with the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever

JS3 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
EPC lever potentiometer a Prepare with starting switch OFF, then turn starting switch ON
1 and carry out troubleshooting.
short circuit) Joystick steering EPC
JS3 (male) Voltage
lever
Possible causes
and standard Between (3) and (1) Full steering to left 1.09 – 1.59 V
value in normal Full steering to right 3.41 – 3.91 V
state
Max. 1 z
harness JS3 (female) (3) tance
2
JS3 (female) (4) tance
Wiring harness between JS3 (female) (1) – Resis-
Max. 1 z
3 harness Min. 1 Mz
JS3 (female) (3) and chassis ground tance
Min. 1 Mz
6 WA500-6R

Possible causes Joystick steering EPC

L05 Voltage
and standard lever
value in normal Defective work equipment Between (22) and
4 Constant 4.85 – 5.15 V
state controller chassis ground
Between (9) and
Full steering to left 1.09 – 1.59 V
chassis ground
Full steering to right 3.41 – 3.91 V
Circuit diagram related to joystick steering EPC lever potentiometer
WA500-6R 7
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):

Action code Failure code Joystick steering EPC lever potentiometer (Main): Short circuit with
Trouble the power supply line
E03 DK5FKY (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Main) system, the signal
Contents of
voltage is higher than normal range
trouble
(Joystick steering EPC lever potentiometer (Main) signal voltage: Max. 4.7 V).
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
set to N (Neutral).
Problem that
appears on —
machine
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective joystick steering a Prepare with starting switch OFF, then turn starting switch ON
1 EPC lever potentiometer and carry out troubleshooting.
Joystick steering EPC
JS3 (male) Voltage
lever
Possible causes Between (3) and (1) Full steering to left 1.09 – 1.59 V
and standard Full steering to right 3.41 – 3.91 V
value in normal
state
2 Voltage Max. 1 V
(Contact with 24 V circuit) JS3 (female) (3) and chassis ground
Voltage Max. 1 V
JS3 (female) (4) and chassis ground
L05 Voltage
lever
Defective work equipment Between (22) and
3 Constant 4.85 – 5.15 V
Between (9) and
chassis ground
8 WA500-6R
WA500-6R 9
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub):

Disconnection) 1
Action code Failure code Joystick steering EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5GKA (Work equipment controller system)
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer system
Contents of
(Sub), the signal voltage is lower than normal range
trouble
(Joystick steering EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V).
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
controller
Problem that
appears on —
machine

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
JS3 (male) Voltage
lever
Possible causes
state
Max. 1 z
2
Max. 1 z
3 harness Min. 1 Mz
Min. 1 Mz
10 WA500-6R

Possible causes Joystick steering EPC

L05 Voltage
and standard lever
value in normal Defective work equipment Between (22) and
4 Constant 4.85 – 5.15 V
state controller chassis ground
Between (3) and
chassis ground
WA500-6R 11
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):

Action code Failure code Joystick steering EPC lever potentiometer (Sub): Short circuit with
Trouble the power supply line
E03 DK5GKY (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Sub) system, the signal volt-
Contents of
age is higher than normal range
trouble
(Joystick steering EPC lever potentiometer (Sub) signal voltage: Max. 4.7 V).
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
set to N (Neutral).
Problem that
appears on —
machine

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
JS3 (male) Voltage
lever
Possible causes Between (2) and (1) Full steering to left 3.41 – 3.91 V
and standard Full steering to right 1.09 – 1.59 V
value in normal
state
2 Voltage Max. 1 V
(Contact with 24 V circuit) JS3 (female) (2) and chassis ground
Voltage Max. 1 V
L05 Voltage
lever
Defective work equipment Between (22) and
3 Constant 4.85 – 5.15 V
Between (3) and
chassis ground
12 WA500-6R
WA500-6R 13
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):

Analog signals disagree) 1
Action code Failure code Joystick steering EPC lever potentiometer (Main): Analog signals
Trouble
E03 DK5FL8 disagree (Work equipment controller system)
• Joystick steering EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Joystick steering EPC lever potentiometer signal voltage (both Main and Sub): Max. 4.7 V) or (Joy-
trouble
stick steering EPC lever potentiometer signal voltage (both Main and Sub): Min 5.3 V)
Action of
trality ± 5%.
controller
• Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is
set to N (Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the joystick steer-
appears on ing EPC lever is set to neutral.
machine • If both Main and Sub potentiometers are abnormal, steering cylinder does not move.
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective joystick steering and carry out troubleshooting.
EPC lever potentiometer Joystick steering EPC
1 JS3 (male) Voltage
(Internal disconnection or lever
short circuit)

state
Between (2) and (1) Full steering to left 3.41 – 3.91 V
Max. 1 z
Disconnection in wiring JS3 (female) (2) tance
2 Max. 1 z
(Disconnection in wiring JS3 (female) (3) tance
Max. 1 z
Max. 1 z
14 WA500-6R

3 harness
Min. 1 Mz
Min. 1 Mz
Voltage Max. 1 V
Hot short in wiring harness JS3 (female) (2) and chassis ground
4
Possible causes (Contact with 24 V circuit) Wiring harness between L05 (female) (9) –
Voltage Max. 1 V
and standard JS3 (female) (3) and chassis ground
value in normal Wiring harness between L05 (female) (22) –
L05 Voltage
lever
Between (22) and
chassis ground
5 Lever in neutral 2.40 – 2.60 V
controller
Between (9) and
chassis ground
Between (3) and
chassis ground
WA500-6R 15
16 WA500-6R
WA500-6R 17
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 1
Action code Failure code Lift arm angle sensor: Disconnection

Trouble
E01 DKA0KA (Work equipment controller system)
Contents of • Due to disconnection or grounding fault in lift arm angle sensor system, the signal voltage is lower
trouble than normal range (Lift arm angle sensor signal: Max. 0.3 V).
• Judges that lift arm is at the lowest position.
• Resets the remote positioner function.
• Resets semi auto digging function.
Action of • No PC control while the lift arm is rising.
controller • When the remote positioner lower setting is ON, turns OFF the lift arm float detent, and when the
remote positioner lower setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm raise detent OFF
Problem that • Remote positioner malfunction (Not stop)
appears on • Faulty semi-auto digging operation (Not operate)
machine • No PC control while the lift arm is rising
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06002 BOOM ANG).
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
Related
information
• If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshoot-
ing for it first.

Between (A) and (C) 5 kz ± 20%
Min. 1 Mz
chassis ground
Defective lift arm angle sen-
1 sor (Internal disconnection or a Prepare with starting switch OFF, then start engine and carry out
short circuit) troubleshooting.
Possible causes F13 Lift arm position Voltage

and standard Between (C) and (A) Constant 4.85 – 5.15 V
value in normal Constant 1.00 – 4.00 V
state
Between (B) and (A) Raise stroke end 3.50 – 4.00 V
Lower stroke end 1.00 – 1.88 V
Disconnection in wiring Wiring harness between F13 (female) (A) – Resis-
Max. 1 z
harness chassis ground tance
2
(Disconnection in wiring Wiring harness between F13 (female) (B) – Resis-
Wiring harness between F13 (female) (C) – Resis-
Max. 1 z
18 WA500-6R

Wiring harness between F13 (female) (B) – L05
(female) (8), L55 (female) (10) and chassis Min. 1 Mz
3 harness tance
ground
Possible causes Wiring harness between F13 (female) (C) –
and standard Resis-
L51 (female) (16), – circuit branch end and Min. 1 Mz
value in normal tance
chassis ground
state
troubleshooting.
Defective work equipment L05 Lift arm position Voltage

4
controller Constant 1.00 – 4.00 V
Between (8) and
Raise stroke end 3.50 – 4.00 V
chassis ground
Circuit diagram related to lift arm angle sensor
WA500-6R 19
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) 1
Action code Failure code Lift arm angle sensor: Out of input signal range
Trouble
E01 DKA0KX (Machine monitor system)
• Due to grounding fault in lift arm angle sensor system, the signal voltage is not input (Lift arm angle
Contents of sensor signal voltage: Max. 1 V).
trouble • Due to disconnection or hot short circuit in lift arm angle sensor system, the signal voltage is higher
than normal level (Lift arm angle sensor signal voltage: Min. 4 V).
Action of
controller
Problem that
machine
Related
information
• If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshoot-
ing for it first.

Min. 1 Mz
chassis ground
Defective lift arm angle sensor
1 (Internal disconnection or a Prepare with starting switch OFF, then start engine and carry out
short circuit) troubleshooting.
F13 Lift arm position Voltage
Between (C) and (A) Constant 4.85 – 5.15 V
Possible causes
and standard
state without turning starting switch ON.
Disconnection in wiring Wiring harness between F13 (female) (A) – Resis-
Max. 1 z
harness chassis ground tance
2
(Disconnection in wiring Wiring harness between F13 (female) (B) – Resis-
Wiring harness between F13 (female) (C) – Resis-
Max. 1 z
Grounding fault in wiring har- Resis-
(female) (8), L55 (female) (10) and chassis Min. 1 Mz
3 ness tance
ground
Wiring harness between F13 (female) (C) –
Resis-
tance
chassis ground
20 WA500-6R

and carry out troubleshooting. (Lift arm lower position)
Hot short in wiring harness (female) (8), L55 (female) (10) and chassis Voltage Max. 1 V
4
(Contact with 24 V circuit) ground
Possible causes Wiring harness between F13 (female) (C) –
and standard L51 (female) (16), – circuit branch end and Voltage Max. 1 V
value in normal chassis ground
state
troubleshooting.
L55 Lift arm position Voltage
Between (10) and
chassis ground
WA500-6R 21
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power
supply line) 1
Action code Failure code Lift arm angle sensor: Short circuit with power supply line
Trouble
E01 DKA0KY (Work equipment controller system)
Contents of • Due to hot short in lift arm angle sensor system, the signal voltage is higher than normal range
trouble (Lift arm angle sensor signal: Min. 4.7 V).
• Judges that lift arm is at the highest position.
Action of • No PC control while the lift arm is rising.
controller • When the remote positioner lower setting is ON, turns OFF the lift arm float detent, and when the
• Even if cause of failure disappears, system does not reset itself until lift arm lever is set to N (Neutral).
Problem that • Remote positioner malfunction
appears on • Faulty semi-auto digging operation
Related
information

Min. 1 Mz
chassis ground
Defective lift arm angle sensor a Prepare with starting switch OFF, then start engine and carry out
1
(Internal short circuit) troubleshooting.
Possible causes F13 Lift arm position Voltage
and standard Between (C) and (A) Constant 4.85 – 5.15 V
value in normal
state
Hot short in wiring harness (female) (8), L55 (female) (10) and chassis Voltage Max. 1 V
2
Wiring harness between F13 (female) (C) –
L51 (female) (16), – circuit branch end and Voltage Max. 1 V
chassis ground
22 WA500-6R

Possible causes troubleshooting.
and standard L05 Lift arm position Voltage
value in normal Defective work equipment
3
state controller Constant 1.00 – 4.00 V
Between (8) and
chassis ground
WA500-6R 23
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) 1
Action code Failure code Lift arm angle sensor: Double meshing
Trouble
E01 DKA0L0 (Work equipment controller system)
Contents of • Due to lift arm angle sensor dislocation, lift arm angle is not detectable correctly.
trouble (Lift arm angle upper limit + 5° and above or lift arm angle lower limit + 5° or above)
• No PC control while the lift arm is rising.
Action of
• When the remote positioner lower setting is ON, turns OFF the lift arm float detent, and when the
controller
Problem that • Remote positioner malfunction (Not stop)
appears on • Faulty semi-auto digging operation (Not operate)
• This failure code may be displayed when the initial setting of the lift arm angle sensor failed.
Related (Code: 06002 BOOM ANG).
information • The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
• Method of reproducing failure code: Start engine and set the lift arm to raise or lower stroke end

Defective lift arm angle sensor a Adjustment of lift arm angle sensor may be defective. Check it
1
adjustment directly (see “Testing and adjusting“).
Min. 1 Mz
chassis ground
Defective lift arm angle sensor a Prepare with starting switch OFF, then start engine and carry out
2
Possible causes (Internal short circuit) troubleshooting.
and standard
value in normal F13 Lift arm position Voltage
state Between (C) and (A) Constant 4.85 – 5.15 V
troubleshooting.
Defective work equipment L05 Lift arm position Voltage

3
controller Constant 1.00 – 4.00 V
Between (8) and
chassis ground
24 WA500-6R
WA500-6R 25
Failure code [DLF1KA] (Transmission input shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission input shaft speed sensor: Disconnection
Trouble
E01 DLF1KA (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission input shaft speed sensor system, the sig-
Contents of nal voltage is higher than normal range
trouble (Transmission input shaft speed sensor signal: Min. 1.5 V)
• Signal from the transmission input shaft speed sensor: 0 rpm
Action of
controller
Problem that
appears on —
machine
• The input state (speed) from the transmission input shaft speed sensor can be checked with the
Related
monitoring function (Code: 31200 T/M SPEED IN).
information
• Method of reproducing failure code: Start engine and drive the machine

Defective transmission input a The transmission input shaft speed sensor adjustment may be
1 shaft speed sensor adjust- defective. Check it directly (see “Adjustment of transmission
ment speed sensor” in “Testing and adjusting“).
Defective transmission input
shaft speed sensor REV OUT1 (male) Resistance
2
(Internal disconnection or Between (1) and (2) 500 – 1,000 z
short circuit)
Min. 1 Mz
chassis ground
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L03 (female) (39) – Resis-
3 Max. 1 z
value in normal (Disconnection in wiring REV OUT1 (female) (2) tance
state harness or defective contact) Wiring harness between L03 (female) (40) – Resis-
Max. 1 z
REV OUT1 (female) (1) tance
4
Voltage Max. 1 V
REV OUT1 (female) (1) and chassis ground
5
controller Between (39) and (40) 500 – 1,000 z
Min. 1 Mz
chassis ground
26 WA500-6R
Circuit diagram related to transmission input shaft speed sensor
WA500-6R 27
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed

signals disagree) 1
Action code Failure code Transmission input shaft speed sensor: Speed signals disagree
Trouble
E01 DLF1LC (Transmission controller system)
• Due to grounding fault in the transmission input shaft speed sensor, the transmission input shaft
speed sensor signal voltage is lower than normal range.
• This failure code appears under the following conditions. ([A] or [B])
[A]
1) Transmission output shaft speed sensor and transmission input shaft speed obtained from
reduction ratio: Min. 200 rpm
Contents of
2) Signal from transmission input shaft speed sensor: 0 rpm
trouble
3) Transmission input shaft speed sensor signal line: Disconnection is not detected.
[B]
1) Difference between actual transmission output shaft speed and output shaft speed obtained
from input shaft speed sensor and reduction ratio is larger than 200 rpm.
2) Output shaft speed is sensed.
3) Input shaft speed is sensed.
Action of
controller
Problem that
appears on —
machine
• The input state (speed) from the transmission input shaft speed sensor can be checked with the
Related monitoring function (Code: 31200, T/M SPEED IN).
information • Method of reproducing failure code: Start engine and drive the machine
• This error may be detected when engine stalls.

Defective transmission input a The transmission input shaft speed sensor adjustment may be
1 shaft speed sensor adjust- defective. Check it directly (see “Adjustment of transmission
ment speed sensor” in “Testing and adjusting“).
Defective transmission input REV OUT1 (male) Resistance
2 shaft speed sensor
(Internal short circuit) Between (1) and (2) 500 – 1,000 z
Possible causes Between (1), (2) and
Min. 1 Mz
3 harness
Min. 1 Mz
REV OUT1 (female) (1) and chassis ground tance
4
Min. 1 Mz
chassis ground
28 WA500-6R
Circuit diagram related to transmission input shaft speed sensor
WA500-6R 29
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short

circuit) 1
Action code Failure code Transmission output shaft speed sensor: Short circuit
Trouble
E03 DLT4KB (Transmission controller system)
• Due to grounding fault in the transmission output shaft speed sensor system, transmission output
shaft speed sensor signal voltage is lower than normal range.
• This failure code appears under the following conditions. ([A] or [B])
[A]
1) Transmission input shaft speed sensor and transmission output shaft speed obtained from
reduction ratio: Min. 200 rpm
Contents of
2) Transmission output shaft speed sensor: 0 rpm
trouble
3) Transmission output shaft speed sensor signal line: Disconnection is not detected.
[B]
1) Difference between actual transmission output shaft speed and output shaft speed obtained
from input shaft speed sensor and reduction ratio is larger than 200 rpm.
2) Output shaft speed is sensed.
3) Input shaft speed is sensed.
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the man-
ual mode.
Action of • In the manual-shift mode, performs the normal control.
controller • Obtains the output shaft speed from the input shaft speed and gear speed reduction ratio for control
operation.
• Does not change to auto shift mode (changes to manual shift mode).
Problem that
• No travel speed limit function
appears on
• No transmission protection function
machine
• Gear shifting shocks are made.
• The input state (speed) from the transmission output shaft speed sensor can be checked with the
Related monitoring function (Code: 31400, T/M SPEED OUT).
information • Method of reproducing failure code: Start engine and drive the machine
• This error may be detected when engine stalls.

Defective transmission a The transmission output shaft speed sensor adjustment may be
1 output shaft speed sensor defective. Check it directly (see “Adjustment of transmission
adjustment speed sensor” in “Testing and adjusting“).
Defective transmission REV OUT2 (male) Resistance
2 output shaft speed sensor
Possible causes Between (1), (2) and
Min. 1 Mz
3 harness
Min. 1 Mz
REV OUT2 (female) (1) and chassis ground tance
4
Min. 1 Mz
chassis ground
30 WA500-6R
Circuit diagram related to transmission output shaft speed sensor
WA500-6R 31
Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of

Action code Failure code Transmission output shaft speed sensor: Out of input signal range
Trouble
E03 DLT4KX (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission output shaft speed sensor system, the
Contents of signal voltage is higher than normal range
trouble (Transmission output shaft speed sensor signal: Min. 1.5 V).
• Signal from the transmission output shaft speed sensor: 0 rpm
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the man-
ual mode.
Action of • In the manual-shift mode, performs the normal control.
controller • Obtains the output shaft speed from the input shaft speed and gear speed reduction ratio for control
operation.
• Does not change to auto shift mode (changes to manual shift mode).
Problem that
• No travel speed limit function
appears on
• No transmission protection function
machine
• Gear shifting shocks are made.
• The input state (speed) from the transmission output shaft speed sensor can be checked with the
Related
monitoring function (Code: 31400, T/M SPEED OUT).
information
• Method of reproducing failure code: Start engine and drive the machine

Defective transmission a The transmission input shaft speed sensor adjustment may be
1 output shaft speed sensor defective. Check it directly (see “Adjustment of transmission
adjustment speed sensor” in “Testing and adjusting“).
Defective transmission REV OUT2 (male) Resistance
2 output shaft speed sensor
Min. 1 Mz
chassis ground
3 Max. 1 z
value in normal (Disconnection in wiring REV OUT2 (female) (1) tance
state harness or defective contact) Wiring harness between L03 (female) (29) – Resis-
Max. 1 z
REV OUT2 (female) (2) tance
4
Voltage Max. 1 V
REV OUT2 (female) (1) and chassis ground
5
Min. 1 Mz
chassis ground
32 WA500-6R
Circuit diagram related to transmission output shaft speed sensor
WA500-6R 33
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short

circuit) 1
Action code Failure code Transmission cut-off indicator lamp: Short circuit
Trouble
E01 DT20KB (Transmission controller system)
Contents of • Due to grounding fault in transmission cut-off indicator lamp system, the signal is not output to the
trouble indicator lamp.
Action of • Turns the transmission cut-off indicator lamp output OFF.
Problem that
appears on • The transmission cut-off indicator lamp does not light up.
machine
Related
• Method of reproducing failure code: Start engine and turn the transmission cut-off switch ON.
information

Defective transmission cut-off
indicator lamp (light-emitting S10 (male) Resistance
1
diode) Between (2) and (1) Min. 1 Mz (No continuity)
Min. 1 Mz
chassis ground
Possible causes
state (Contact with ground circuit) Wiring harness between L04 (female) (8) – Resis- Min.
S10 (female) (1) and chassis ground tance 1 Mz
Defective transmission Transmission cut-off
3 L04 Voltage
controller switch
34 WA500-6R
Circuit diagram related to transmission cut-off indicator lamp
WA500-6R 35
Failure code [DUM1KB] (Remote positioner raise set indicator lamp:

Short circuit) 1
Action code Failure code Remote positioner raise set indicator lamp: Short circuit
Trouble
— DUM1KB (Work equipment controller system)
Contents of • Since the remote positioner raise set indicator lamp system is shorted with the chassis ground, the
trouble signal is not output to the indicator lamp.
Action of • Turns off the remote positioner raise set indicator output.
Problem that
appears on • The remote positioner raise set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner raise set indicator lamp can be checked with the
Related
monitoring function (Code: 40954 D-OUT-18).
information

Defective remote positioner a See “Procedure for testing diodes” in “Testing and adjusting”.)
raise set indicator lamp S13 (male) Resistance
1
(light-emitting diode)
(Internal short circuit) Between (2) and (1) Min. 1 Mz (No continuity)
Min. 1 Mz
state 2 harness
Min. 1 Mz
Defective work equipment Remote positioner
3 L07 Voltage
controller raise
Between (8) and In use 20 – 30 V
chassis ground Not in use Max. 1 V
36 WA500-6R
Circuit diagram related to remote positioner raise/lower set indicator lamp
WA500-6R 37
Failure code [DUM2KB] (Remote positioner lower set indicator lamp:

Short circuit) 1
Action code Failure code Remote positioner lower set indicator lamp: Short circuit
Trouble
— DUM2KB (Work equipment controller system)
Contents of • Since the remote positioner lower set indicator lamp system is shorted with the chassis ground, the
trouble signal is not output to the indicator lamp.
Action of • Turns off the remote positioner lower set indicator output.
Problem that
appears on • The remote positioner lower set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner lower set indicator lamp can be checked with the
Related
monitoring function (Code: 40954 D-OUT-19).
information

Defective remote positioner a See “Procedure for testing diodes” in “Testing and adjusting”.)
lower set indicator lamp S13 (male) Resistance
1
(light-emitting diode)
(Internal short circuit) Between (2) and (3) Min. 1 Mz (No continuity)
Min. 1 Mz
state 2 harness
Min. 1 Mz
Defective work equipment Remote positioner
3 L07 Voltage
controller lower
Between (18) and In use 20 – 30 V
chassis ground Not in use Max. 1 V
38 WA500-6R
Circuit diagram related to remote positioner raise/lower set indicator lamp
WA500-6R 39
Failure code [DV00KB] (Alarm buzzer: Short circuit) 1
Action code Failure code Alarm buzzer: Short circuit

Trouble
E01 DV00KB (Machine monitor system)
Contents of
• The alarm buzzer output circuit is shorted with the power supply line.
trouble
Action of • Stops alarm buzzer output.
Problem that
appears on • Alarm buzzer does not sound.
machine
• The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function
Related
(Code: 40295, D-OUT-0).
information

a Prepare with starting switch OFF, then disconnect L51 and L20,
turn starting switch ON, and carry out troubleshooting.
1 Hot short in wiring harness
Voltage Min. 5 V
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal (Remove buzzer and connect +24 V to L20 (male) (1) and con-
state nect GND to L20 (male) (2))
2 Defective alarm buzzer
Alarm buzzer sounds. Alarm buzzer is normal.
Alarm buzzer does not sound. Alarm buzzer is abnormal.
a Check alarm buzzer unit.
3 Defective machine monitor • If results of 1 and 2 are normal, machine monitor is defective.
40 WA500-6R
Circuit diagram related to alarm buzzer
WA500-6R 41
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 1
Action code Failure code Lift arm raise EPC solenoid: Disconnection
Trouble
E03 DW4PKA (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm raise EPC solenoid output is ON.
Problem that
appears on • Lift arm does not rise
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
Related
(Code: 41900 RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm raise

Defective lift arm raise EPC without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 15 z
state (Disconnection in wiring F07 (female) (1) tance
Max. 1 z
F07 (female) (2) tance
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (6) and (3) 5 – 15 z
Circuit diagram related to lift arm raise EPC solenoid
42 WA500-6R
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1
Action code Failure code Lift arm raise EPC solenoid: Short circuit
Trouble
E03 DW4PKB (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the lift arm raise EPC solenoid output was ON.
• Stops outputting the signal to the lift arm raise EPC solenoid.
Action of • Stops outputting the signal to the lift arm raise detent.
Problem that
appears on • Lift arm does not rise
machine
Related
information
• Method of reproducing failure code: Engine started + lift arm raise

Defective lift arm raise EPC F07 (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 z
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
F07 (female) (1) and chassis ground tance
Defective work equipment L07 (female) Resistance
3
controller Between (6) and (3) 5 – 15 z
Min. 1 Mz
chassis ground
WA500-6R 43
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Lift arm raise EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4PKY (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the lift arm raise EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The lift arm raise EPC solenoid may be burnt out.
machine
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
information
function (Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked

Defective lift arm raise EPC F07 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (6) –
Voltage Max. 1 V
F07 (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
44 WA500-6R
WA500-6R 45
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 1
Action code Failure code Lift arm lower EPC solenoid: Disconnection
Trouble
E03 DW4QKA (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm lower EPC solenoid output is ON.
Problem that
appears on • Lift arm does not lower.
machine
Related
information
• Method of reproducing failure code: Start engine and lower the lift arm.

Defective lift arm lower EPC without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (16) and (3) 5 – 15 z
Circuit diagram related to lift arm lower EPC solenoid
46 WA500-6R
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1
Action code Failure code Lift arm lower EPC solenoid: Short circuit
Trouble
E03 DW4QKB (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the lift arm lower EPC solenoid output was ON.
• Stops outputting the signal to the lift arm lower EPC solenoid.
Action of • Stops outputting the signal to the lift arm float detent.
Problem that
appears on • Lift arm does not lower.
machine
Related
information
• Method of reproducing failure code: Start engine and lower the lift arm.

Defective lift arm lower EPC F08 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
WA500-6R 47
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with
Action code Failure code Lift arm lower EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4QKY (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the lift arm lower EPC solenoid output was OFF.
Problem that
appears on
• The lift arm lower EPC solenoid may be burnt out.
machine
Related
information
with the monitoring function (Code: 41906, 3RD EPC1 DIR).

Defective lift arm lower EPC F08 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
48 WA500-6R
WA500-6R 49
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1
Action code Failure code Bucket tilt EPC solenoid: Disconnection

Trouble
E03 DW4RKA (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid output signal system is disconnected, no current flows when the
trouble bucket tilt EPC solenoid output is ON.
Problem that
appears on • Bucket does not tilt.
machine
Related
information
• Method of reproducing failure code: Start engine and tilt the bucket.

Defective bucket tilt EPC without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (5) and (13) 5 – 15 z
Circuit diagram related to bucket tilt EPC solenoid
50 WA500-6R
WA500-6R 51
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1
Action code Failure code Bucket tilt EPC solenoid: Short circuit
Trouble
E03 DW4RKB (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system was shorted with the chassis ground, abnormal cur-
trouble rent flowed when the bucket tilt EPC solenoid output was ON.
• Stops outputting the signal to the bucket tilt EPC solenoid.
Action of • Stops outputting the signal to the bucket tilt detent.
Problem that
appears on • Bucket does not tilt.
machine
Related
information
• Method of reproducing failure code: Start engine and tilt the bucket.

Defective bucket tilt EPC F09 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
52 WA500-6R
WA500-6R 53
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with
Action code Failure code Bucket tilt EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4RKY (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system was shorted with the power source, abnormal volt-
trouble age was applied when the bucket tilt EPC solenoid output was OFF.
Problem that
appears on
• The bucket tilt EPC solenoid may be burnt out.
machine
Related
information

Defective bucket tilt EPC F09 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
54 WA500-6R
WA500-6R 55
SEN02940-00

© 2007 KOMATSU
All Rights Reserved
56
SEN02941-00
WA500-6R

WA500-6R 60001 and up
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) .......................................................... 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) .............................................................. 4
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line).......................... 6
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) .................................................................... 8
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) ...................................................................... 10
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) .................................. 12
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)............................................ 14
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) ............................................... 14
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line) ........... 15
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)........................................ 16
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) ........................................... 18
Failure code [DWM1KY] (Work equipment neutral lock solenoid:
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)......................................... 22
WA500-6R 1
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) ............................................ 24
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid:
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) .......................................... 28
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) ............................................. 30
Failure code [DWN7KY] (Lift arm float magnet detent solenoid:
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) .............................................. 34
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit).................................................. 36
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Short circuit with power supply line) ............. 38
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)............................................................... 40
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) .................................................................. 41
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) .............................. 42
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)............................................................... 43
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit) .................................................................. 44
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)................................................................ 45
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) ................................................................... 46
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) ............................... 48
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ............................................................ 50
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)................................................................ 52
2 WA500-6R
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1
Action code Failure code Bucket dump EPC solenoid: Disconnection

Trouble
E03 DW4SKA (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid output signal system is disconnected, no current flows when
trouble the bucket dump EPC solenoid output is ON.
Problem that
appears on • Bucket does not dump.
machine
Related
information
• Method of reproducing failure code: Start engine and dump the bucket.

Defective bucket dump EPC without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (15) and (13) 5 – 15 z
Circuit diagram related to bucket dump EPC solenoid
WA500-6R 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1
Action code Failure code Bucket dump EPC solenoid: Short circuit
Trouble
E03 DW4SKB (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the bucket dump EPC solenoid output was ON.
• Stops outputting the signal to the bucket dump EPC solenoid.
Action of
controller
Problem that
• Bucket does not dump.
appears on
machine
Related
information
• Method of reproducing failure code: Start engine and dump the bucket.

Defective bucket dump EPC F10 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
4 WA500-6R
WA500-6R 5
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with
Action code Failure code Bucket dump EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4SKY (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the bucket dump EPC solenoid output was OFF.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Problem that
appears on
• The bucket dump EPC solenoid may be burnt out.
machine
Related
information

Defective bucket dump EPC F10 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
6 WA500-6R
WA500-6R 7
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1
Action code Failure code Fan reverse solenoid: Disconnection

Trouble
E01 DW7BKA (Transmission controller system)
Contents of • Since the fan reverse solenoid system is disconnected, no current flows when the fan reverse sole-
trouble noid output is ON.
Action of • Disables the automatic fan reverse function (if equipped).
Problem that • The automatic fan reverse function is disabled in the case of automatic fan reverse function (if
appears on equipped) specification.
machine • Fan cannot be reversed.
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-3).
information

Defective fan reverse solenoid without turning starting switch ON.
1
(Internal disconnection) G09 (male) Resistance
Between (1) and (2) 35 – 45 z
(Disconnection or defective G09 (female) (1) tance
state contact in connector) Wiring harness between G09 (female) (2) – Resis-
Max. 1 z
controller
Between (37) and
35 – 45 z
chassis ground
8 WA500-6R
Circuit diagram related to fan reverse solenoid
WA500-6R 9
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1
Action code Failure code Fan reverse solenoid: Short circuit

Trouble
E01 DW7BKB (Transmission controller system)
Contents of • Since the fan reverse solenoid system was shorted with the chassis ground, abnormal current flowed
trouble when the fan reverse solenoid output was ON.
• Turns the output to the fan reverse solenoid OFF.
Action of
• Disables the automatic fan reverse function (if equipped).
controller
Problem that • The fan cannot turn in reverse by operating the fan reverse switch.
appears on • The automatic fan reverse function is disabled in the case of automatic fan reverse function (if
machine equipped) specification.
Related
(Code: 40949, D-OUT-3).
information

Defective fan reverse solenoid G09 (male) Resistance
1
Min. 1 Mz
state 2 harness
Min. 1 Mz
G09 (female) (1) and chassis ground tance
controller
Between (37) and
35 – 45 z
chassis ground
10 WA500-6R
WA500-6R 11
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power
supply line) 1
Action code Failure code Fan reverse solenoid: Short circuit with power supply line
Trouble
E01 DW7BKY (Transmission controller system)
Contents of • Since the fan reverse solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan reverse switch output was OFF.
Action of • Disables the automatic fan reverse function (if equipped).
• The automatic fan reverse function is disabled in the case of automatic fan reverse function (if
Problem that
equipped) specification.
appears on
• The fan does not rotate normally.
machine
• The machine may overheat.
Related
(Code: 40949, D-OUT-3).
information

Defective fan reverse solenoid G09 (male) Resistance
1
Min. 1 Mz
value in normal Hot short in wiring harness and carry out troubleshooting.
state 2
Voltage Max. 1 V
G09 (female) (1) and chassis ground
controller
Between (37) and
35 – 45 z
chassis ground
12 WA500-6R
WA500-6R 13
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid:

Disconnection) 1
Action code Failure code Hydraulic drive fan neutral solenoid: Disconnection
Trouble
E01 DW7DKA (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in WA500-6R.
information

and standard Optional setting may be improper.
value in normal 1 Referring to “10. Optional device selecting function” in “Special functions of machine monitor
state (EMMS)” in “Testing and adjusting”, check that AUTO RE FAN is set to “None”.
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short

circuit) 1
Action code Failure code Hydraulic drive fan neutral solenoid: Short circuit
Trouble
E01 DW7DKB (Transmission controller system)
Contents of
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

14 WA500-6R
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short

Action code Failure code Hydraulic drive fan neutral solenoid: Short circuit with power supply
Trouble line
E01 DW7DKY (Transmission controller system)
Contents of
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

WA500-6R 15
Failure code [DWM1KA] (Work equipment neutral lock solenoid:

Disconnection) 1
Action code Failure code Work equipment neutral lock solenoid: Disconnection
Trouble
E01 DWM1KA (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is disconnected, no current flows when the
trouble work equipment neutral lock solenoid output is ON.
• Stops outputting the signal to each work equipment solenoid according to an input signal from the
Action of
work equipment lock lever.
controller
Problem that
• Each work equipment solenoid lock normally works according to an input signal from the work equip-
appears on
ment lock lever.
machine
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position

1 neutral lock solenoid
B02 (male) Resistance
Between (1) and (2) 35 – 45 z
state (Disconnection in wiring B02 (female) (1) tance
harness or defective contact) Wiring harness between B02 (female) (2) – Resis-
Max. 1 z
3
Between (7) and chassis ground 35 – 45 z
16 WA500-6R
Circuit diagram related to work equipment neutral lock solenoid
WA500-6R 17
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short

circuit) 1
Action code Failure code Work equipment neutral lock solenoid: Short circuit
Trouble
E01 DWM1KB (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is shorted with the chassis ground, no cur-
trouble rent flows when the work equipment neutral lock solenoid output is ON.
Action of • Stops outputting the signal to each work equipment solenoid according to an input signal from the
controller work equipment lock lever.
Problem that • Each work equipment solenoid lock normally works according to an input signal from the work equip-
appears on ment lock lever.
machine • The wiring harness or controller may be burnt out.
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position

Defective work equipment B02 (male) Resistance
Min. 1 Mz
chassis ground
Possible causes B03 (male) Diode range Continuity
Defective diode (B03)
and standard 2 Measured from
(Internal short circuit) Between (2) and (1) Continue
value in normal side (2)
state
Measured from
Between (1) and (2) No continuity
side (1)
3 harness
Min. 1 Mz
B02 (female) (1) and chassis ground tance
4
18 WA500-6R
WA500-6R 19
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short

Action code Failure code Work equipment neutral lock solenoid: Short circuit with power sup-
Trouble ply line
E01 DWM1KY (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system was shorted with the power source, abnor-
trouble mal voltage was applied when the work equipment neutral lock solenoid output was OFF.
Action of • Stops outputting the signal to each work equipment solenoid according to an input signal from the
controller work equipment lock lever.
Problem that
appears on • All work equipment do not move.
machine
• The work equipment can be operated by disconnecting the connector of the work equipment neutral
lock solenoid.
Related
information
monitoring function (Code: 40952, D-OUT-0).

Defective work equipment B02 (male) Resistance
Min. 1 Mz
chassis ground
Possible causes B03 (male) Diode range Continuity
Defective diode (B03)
and standard 2 Measured from
(Internal short circuit) Between (2) and (1) Continue
value in normal side (2).
state
Measured from
Between (1) and (2) No continuity
side (1).
3
Voltage Max. 1 V
B02 (female) (1) and chassis ground
4
20 WA500-6R
WA500-6R 21
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid:

Disconnection) 1
Action code Failure code Lift arm raise magnet detent solenoid: Disconnection
Trouble
E01 DWN6KA (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm raise magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp.
controller
Problem that
• The lift arm remote positioner raise does not function.
appears on
• The lift arm is not held at the lift arm raise detent position.
machine
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Engine started + lift arm raise detent

Defective lift arm raise magnet without turning starting switch ON.
1 detent solenoid
Between (1) and (2) 35 – 45 z
Possible causes
value in normal
contact) Wiring harness between S05 (female) (2) – Resis-
state Max. 1 z
Defective work equipment L07 Lift arm lever Voltage
3
controller Neutral Max. 1 V
Between (17) and
chassis ground Raise detent
20 – 30 V
operation
22 WA500-6R
Circuit diagram related to lift arm magnet detent solenoid
WA500-6R 23
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short
circuit) 1
Action code Failure code Lift arm raise magnet detent solenoid: Short circuit
Trouble
E01 DWN6KB (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the lift arm raise magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
Problem that
• The lift arm remote positioner raise does not function.
appears on
• The lift arm is not held at the lift arm raise detent position.
machine
Related
information
• Method of reproducing failure code: Engine started + lift arm raise detent

Defective lift arm raise magnet S05 (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Between (17) and
20 – 30 V
operation
24 WA500-6R
WA500-6R 25
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short
Action code Failure code Lift arm raise magnet detent solenoid: Short circuit with power sup-
Trouble ply line
E01 DWN6KY (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system was shorted with the power source,
trouble abnormal voltage was applied when the lift arm raise magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
• If you perform lift arm raise detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
Related
information

Defective lift arm raise magnet S05 (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Between (17) and
20 – 30 V
operation
26 WA500-6R
WA500-6R 27
Failure code [DWN7KA] (Lift arm float magnet detent solenoid:

Disconnection) 1
Action code Failure code Lift arm float magnet detent solenoid: Disconnection
Trouble
Contents of • Since the lift arm float magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm float magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
Problem that
• The lift arm remote positioner lower does not function.
appears on
• The lift arm is not held at the lift arm float detent position.
machine
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.

Defective lift arm float magnet without turning starting switch ON.
1 detent solenoid
Between (1) and (2) 35 – 45 z
2 Max. 1 z
value in normal (Disconnection or defective S06 (female) (1) tance
state contact) Wiring harness between S06 (female) (2) – Resis-
Max. 1 z
3
controller
Between (27) and Neutral Max. 1 V
chassis ground Float detent operation 20 – 30 V
28 WA500-6R
WA500-6R 29
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short
circuit) 1
Action code Failure code Lift arm float magnet detent solenoid: Short circuit
Trouble
Contents of • Since the lift arm float magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the lift arm float magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
Problem that
• The lift arm remote positioner lower does not function.
appears on
• The lift arm is not held at the lift arm float detent position.
machine
Related
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.

Defective lift arm float magnet S06 (male) Resistance
1 detent solenoid
Min. 1 Mz
state 2 harness
Min. 1 Mz
3
controller
30 WA500-6R
WA500-6R 31
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short
Action code Failure code Lift arm float magnet detent solenoid: Short circuit with power sup-
Trouble ply line
Contents of • Since the lift arm float magnet detent solenoid power supply system was shorted with the power source,
trouble abnormal voltage was applied when the lift arm float magnet detent solenoid output was OFF.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp to stop lower stop control.
controller
• If you perform lift arm float detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
Related
information

Defective lift arm float magnet S06 (male) Resistance
1 detent solenoid
Min. 1 Mz
value in normal Hot short in wiring harness and carry out troubleshooting.
state 2
Voltage Max. 1 V
3
controller
32 WA500-6R
WA500-6R 33
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid:

Disconnection) 1
Action code Failure code Bucket tilt magnet detent solenoid: Disconnection
Trouble
Contents of • Since the bucket tilt magnet detent solenoid power supply system is disconnected, no current flows
trouble when the bucket tilt magnet detent solenoid output is ON.
Action of • Keeps normal output condition to the bucket tilt magnet detent solenoid.
Problem that
• Bucket leveler does not work.
appears on
• The bucket is not held at the bucket tilt detent position.
machine
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the moni-
Related
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Defective bucket tilt magnet without turning starting switch ON.
1 detent solenoid
Between (1) and (2) 35 – 45 z
Possible causes
value in normal
contact) Wiring harness between S04 (female) (2) – Resis-
state Max. 1 z
Defective work equipment L07 Bucket lever Voltage
3
Between (37) and
chassis ground Bucket detent
20 – 30 V
operation
34 WA500-6R
Circuit diagram related to bucket magnet detent solenoid
WA500-6R 35
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)1
Action code Failure code Bucket tilt magnet detent solenoid: Short circuit
Trouble
Contents of • Since the bucket tilt magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the bucket tilt magnet detent solenoid output was ON.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
Problem that
• Bucket leveler does not work.
appears on
• The bucket is not held at the bucket tilt detent position.
machine
Related
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Defective bucket tilt magnet S04 (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Between (37) and
20 – 30 V
operation
36 WA500-6R
WA500-6R 37
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Short

Action code Failure code Bucket tilt magnet detent solenoid: Short circuit with power supply
Trouble line
Contents of • Since the bucket tilt magnet detent solenoid power supply system was shorted with the power
trouble source, abnormal voltage was applied when the bucket tilt magnet detent solenoid output was OFF.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
• If you perform bucket tilt detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform bucket detent operation, return of the bucket lever to neutral is affected by the
machine
Related
information

Defective bucket tilt magnet S04 (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Between (37) and
20 – 30 V
operation
38 WA500-6R
WA500-6R 39
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 1
Action code Failure code Fan pump EPC solenoid: Disconnection

Trouble
E01 DX16KA (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is disconnected, no current flows when the fan pump EPC
trouble solenoid output is ON.
Action of
controller
Problem that
appears on • The fan speed is set to the maximum.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400 FAN EPC DIR).
information

Defective fan pump EPC without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 10 z
state (Disconnection or defective T02 (female) (2) tance
Max. 1 z
T02 (female) (1) tance
Defective transmission without turning starting switch ON.
3
Between (27) and (23) 5 – 10 z
Circuit diagram related to fan pump EPC solenoid
40 WA500-6R
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 1
Action code Failure code Fan pump EPC solenoid: Short circuit
Trouble
E01 DX16KB (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when the fan pump EPC solenoid output was ON.
Action of • Turns the output to the fan pump EPC solenoid OFF.
Problem that
appears on • The fan speed is set to the maximum.
machine
Related
information

Defective fan pump EPC T02 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
WA500-6R 41
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with
Action code Failure code Fan pump EPC solenoid: Short circuit with power supply line
Trouble
E01 DX16KY (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan pump EPC solenoid output was OFF.
Action of • Turns the output to the fan pump EPC solenoid OFF.
Problem that
appears on • The fan speed is set to the minimum.
machine
Related
information

Defective fan pump EPC T02 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
T02 (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
42 WA500-6R
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection) 1
Action code Failure code Pump PC-EPC solenoid: Disconnection

Trouble
E01 DXA1KA (Work equipment controller system)
Contents of • Since the loader pump PC-EPC solenoid system is disconnected, no current flows when the loader
trouble pump PC-EPC solenoid output is ON.
Action of • Keeps normal output condition to the loader pump PC-EPC solenoid.
• Fuel consumption may become poor when engine speed is low.
Problem that
• The engine may stop.
appears on
• Engine acceleration performance is deteriorated.
machine
• The lift arm may increase speed suddenly.
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 94500 PUMP EPC DIR).
information

Defective loader pump PC- without turning starting switch ON.
1 EPC solenoid
Between (1) and (2) 5 – 15 z
state (Disconnection or defective T01 (female) (2) tance
Max. 1 z
T01 (female) (1) tance
3
Between (23) and (36) 5 – 15 z
Circuit diagram related to loader pump PC-EPC solenoid
WA500-6R 43
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit) 1
Action code Failure code Pump PC-EPC solenoid: Short circuit

Trouble
E01 DXA1KB (Work equipment controller system)
Contents of • Since the loader pump PC-EPC solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when the loader pump PC-EPC solenoid output was ON.
Action of • Stops outputting the signal to the loader pump PC-EPC solenoid.
• Fuel consumption may become poor when engine speed is low.
Problem that
• Engine acceleration performance is deteriorated.
appears on
• The lift arm may increase speed suddenly.
machine
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 94500 PUMP EPC DIR).
information

Defective loader pump T01 (male) Resistance
1 PC-EPC solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
Circuit diagram related to loader pump PC-EPC solenoid
44 WA500-6R
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1
Action code Failure code Lockup ECMV solenoid: Disconnection

Trouble
E01 DXH1KA (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is disconnected, no current flows when the lockup solenoid
trouble output is ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
Problem that
appears on • Torque converter lockup is not turned on
machine
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related (Code: 31609 ECMV LU DIR).
information • Method of reproducing failure code: Start engine, turn the torque convertor lockup switch ON, and
drive the machine.

Defective lockup ECMV without turning starting switch ON.
1 solenoid
LC.PS (male) Resistance
Between (1) and (2) 5 – 15 z
state (Disconnection or defective LC.PS (female) (2) tance
contact of connector) Wiring harness between L04 (female) (35) – Resis-
Max. 1 z
LC.PS (female) (1) tance
3
Between (23) and (35) 5 – 15 z
Circuit diagram related to lockup ECMV solenoid
WA500-6R 45
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1
Action code Failure code Lockup ECMV solenoid: Short circuit

Trouble
E01 DXH1KB (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is short with the chassis ground, abnormal current flowed
trouble when the lockup solenoid output was ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
Problem that
appears on • Torque converter lockup is not turned on.
machine
Related
(Code: 31609 ECMV LU DIR).
information
• Method of reproducing failure code: Engine started + torque convertor lockup switch ON + Travel

Defective lockup ECMV LC.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
LC.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
46 WA500-6R
WA500-6R 47
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with

Action code Failure code Lockup ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH1KY (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the lockup ECMV solenoid output was OFF.
• Keeps the transmission in neutral.
• Releases the transmission from neutral if you move the FNR (directional) lever, joystick steering
Action of FNR (directional) switch, or right FNR (directional) switch to N (neutral).
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
• Neutral is held until the FNR (directional) lever, joystick steering FNR (directional) switch, or right
Problem that
FNR (directional) switch is set to N (neutral).
appears on
• The lockup clutch is always in the meshed state.
machine
• When fault occurs, shock and sound may be made by sudden engagement and engine may stall.
Related
(Code: 31609 ECMV LU DIR).
information

Defective lockup ECMV LC.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
LC.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
48 WA500-6R
WA500-6R 49
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1
Action code Failure code 1st clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the 1st clutch ECMV solenoid system is disconnected, no current flows when 1st clutch ECMV
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st),
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
(Code: 31602, ECMV 1 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 1st using the shift down switch or move the
gear shift lever to 1st.

Defective 1st clutch ECMV without turning starting switch ON.
1 solenoid
1.PS (male) Resistance
Between (1) and (2) 5 – 15 z
state (Disconnection or defective 1.PS (female) (2) tance
Max. 1 z
1.PS (female) (1) tance
3
Between (25) and (13) 5 – 15 z
50 WA500-6R
Circuit diagram related to 1st clutch ECMV solenoid
WA500-6R 51
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1
Action code Failure code 1st clutch ECMV solenoid: Short circuit
Trouble
Contents of • When the 1st clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 1st clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st),
machine
(Code: 31602, ECMV 1 DIR).
Related
information
shift selector switch in the MANUAL position, and select 1st using the shift down switch or move the
gear shift lever to 1st.

Defective 1st clutch ECMV 1.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
1.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
52 WA500-6R
WA500-6R 53
SEN02941-00

© 2007 KOMATSU
All Rights Reserved
54
SEN02942-00
WA500-6R

WA500-6R 60001 and up
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ............................. 4
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)............................................................. 6
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) ................................................................ 8
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) .......................... 10
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) ........................................................... 12
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) ............................................................... 14
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) ........................... 16
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) .............................................................. 18
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit).................................................................. 20
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) ............................. 22
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) .............................................................. 24
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) .................................................................. 26
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) .............................. 28
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) ........................................................... 30
WA500-6R 1
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)............................................................... 32

Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)........................... 34
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection) ............................................. 36
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit) ................................................. 37
Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line)............. 38
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) ............................................. 39
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) ................................................. 40
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line)............. 41
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)............................................ 42
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) ............................................... 44
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) ........... 46
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) ............................................. 48
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) ................................................ 50
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) ............ 52
2 WA500-6R
WA500-6R 3
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with
Action code Failure code 1st clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • When the 1st clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 1st clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 2nd, 3rd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF.
Problem that
appears on • The transmission does not shift into 2nd, 3rd, nor 4th (the machine can travel at 1st).
machine
Related
(Code: 31602 ECMV 1 DIR).
information

Defective 1st clutch ECMV 1.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
1.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
4 WA500-6R
WA500-6R 5
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1
Action code Failure code 2nd clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the 2nd clutch ECMV solenoid system is disconnected, no current flows when 2nd clutch
trouble ECMV solenoid output is ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
Related
information
shift selector switch in the MANUAL position, and select 2nd using the shift down switch or move the
gear shift lever to 2nd.

Defective 2nd clutch ECMV without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (6) and (3) 5 – 15 z
6 WA500-6R
Circuit diagram related to 2nd clutch ECMV solenoid
WA500-6R 7
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1
Action code Failure code 2nd clutch ECMV solenoid: Short circuit
Trouble
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 2nd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
Related
information
shift selector switch in the MANUAL position, and select 2nd using the shift down switch or move the
gear shift lever to 2nd.

Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
8 WA500-6R
WA500-6R 9
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with
Action code Failure code 2nd clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 2nd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 3rd, and 4th clutch ECMV solenoids.
Problem that
appears on • The transmission does not shift into 1st, 3rd, nor 4th (the machine can travel at 2nd).
machine
Related
information

Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
10 WA500-6R
WA500-6R 11
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1
Action code Failure code 3rd clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the 3rd clutch ECMV solenoid system is disconnected, no current flows when 3rd clutch
trouble ECMV solenoid output is ON.
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
Related
information
shift selector switch in the MANUAL position, and select 3rd using the shift down switch or move the
gear shift lever to 3rd.

Defective 3rd clutch ECMV without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (16) and (3) 5 – 15 z
12 WA500-6R
Circuit diagram related to 3rd clutch ECMV solenoid
WA500-6R 13
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1
Action code Failure code 3rd clutch ECMV solenoid: Short circuit
Trouble
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 3rd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
Related
information
shift selector switch in the MANUAL position, and select 3rd using the shift down switch or move the
gear shift lever to 3rd.

Defective 3rd clutch ECMV 3.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
14 WA500-6R
WA500-6R 15
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with
Action code Failure code 3rd clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 3rd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 4th clutch ECMV solenoids.
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 4th (the machine can travel at 3rd).
machine
Related
information

Defective 3rd clutch ECMV 3.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
16 WA500-6R
WA500-6R 17
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1
Action code Failure code R clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the R (Reverse) clutch ECMV solenoid system is disconnected, no current flows when R
trouble (Reverse) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
machine
Related toring function (Code: 31606 ECMV R DIR).
information • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR

Defective R (Reverse) clutch without turning starting switch ON.
1 ECMV solenoid
R.PS (male) Resistance
Between (1) and (2) 5 – 15 z
state (Disconnection or defective R.PS (female) (2) tance
Max. 1 z
R.PS (female) (1) tance
3
Between (15) and (13) 5 – 15 z
18 WA500-6R
Circuit diagram related to R (Reverse) clutch ECMV solenoid
WA500-6R 19
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1
Action code Failure code R clutch ECMV solenoid: Short circuit

Trouble
Contents of • When the R (Reverse) clutch ECMV solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when R (Reverse) clutch ECMV solenoid output was ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
machine
Related toring function (Code: 31606 ECMV R DIR).

Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
R.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
20 WA500-6R
WA500-6R 21
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with

Action code Failure code R clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the R (Reverse) ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when the R (Reverse) ECMV solenoid output was OFF.
• Outputs the signal to the R (Reverse) clutch ECMV solenoid when the directional lever or directional
switch is in R (Reverse).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or F (Forward).
Problem that
appears on • The machine can travel only at R (reverse).
machine
Related
toring function (Code: 31606 ECMV R DIR).
information

Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
Hot short in wiring harness without turning starting switch ON.
value in normal 2
Voltage Max. 1 V
R.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
22 WA500-6R
WA500-6R 23
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1
Action code Failure code F clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the F (Forward) clutch ECMV solenoid system is disconnected, no current flows when F (For-
trouble ward) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
Related (Code: 31608 ECMV F DIR).

Defective F (Forward) clutch without turning starting switch ON.
1 ECMV solenoid
F.PS (male) Resistance
Between (1) and (2) 5 – 15 z
state (Disconnection or defective F.PS (female) (2) tance
Max. 1 z
F.PS (female) (1) tance
3
Between (5) and (3) 5 – 15 z
24 WA500-6R
Circuit diagram related to F (Forward) clutch ECMV solenoid
WA500-6R 25
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1
Action code Failure code F clutch ECMV solenoid: Short circuit

Trouble
Contents of • When the F (Forward) clutch ECMV solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when F (Forward) clutch ECMV solenoid output was ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
machine
Related (Code: 31608 ECMV F DIR).

Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
F.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
26 WA500-6R
WA500-6R 27
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with

Action code Failure code F clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the F (Forward) ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when the F (Forward) ECMV solenoid output was OFF.
• Outputs the signal to the F (Forward) clutch ECMV solenoid when the directional lever or directional
switch is in F (Forward).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or R (Reverse).
Problem that
appears on • The machine can travel only at F (forward).
machine
Related
(Code: 31608 ECMV F DIR).
information

Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
Hot short in wiring harness without turning starting switch ON.
value in normal 2
Voltage Max. 1 V
F.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
28 WA500-6R
WA500-6R 29
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1
Action code Failure code 4th clutch ECMV solenoid: Disconnection

Trouble
E03 DXHHKA (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system is disconnected, no current flows when 4th clutch ECMV
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
Related
information
shift selector switch in the MANUAL position, and select 4th using the shift down switch or move the
gear shift lever to 4th.

Defective 4th clutch ECMV without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (26) and (13) 5 – 15 z
30 WA500-6R
Circuit diagram related to 4th clutch ECMV solenoid
WA500-6R 31
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1
Action code Failure code 4th clutch ECMV solenoid: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 4th clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
Related
information
shift selector switch in the MANUAL position, and select 4th using the shift down switch or move the
gear shift lever to 4th.

Defective 4th clutch ECMV 4.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
32 WA500-6R
WA500-6R 33
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with
Action code Failure code 4th clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 4th clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 3rd clutch ECMV solenoids.
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 3rd (the machine can travel at 4th).
machine
Related
information

Defective 4th clutch ECMV 4.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
34 WA500-6R
WA500-6R 35
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection)1
Action code Failure code 3-spool valve extract EPC solenoid: Disconnection
Trouble
E03 DXHJKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) extract EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) extract EPC solenoid output is ON.
• Continues outputting.
Action of
controller
Problem that
appears on • The 3-spool valve (attachment) cylinder is not extracted.
machine
code is displayed, select “None” in the EPC 3-spool lever setting on the optional setting of the
machine monitor.)
Related
information
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract
Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F21 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
value in normal 2 (Disconnection in wiring Max. 1 z
state F21 (female) (2) tance
harness and defective
contact) Wiring harness between L07 (female) (25) – Resis-
Max. 1 z
3
Between (25) and (3) 5 – 15 z
Circuit diagram related to 3-spool valve (attachment) extract EPC solenoid
36 WA500-6R
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)1
Action code Failure code 3-spool valve extract EPC solenoid: Short circuit
Trouble
E03 DXHJKB (Work equipment controller system)
• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the
Contents of
chassis ground, abnormal current flowed when the 3-spool valve (attachment) extract EPC solenoid
trouble
output was ON.
• The output to the 3-spool valve (attachment) extract EPC solenoid is stopped.
Action of • Stops outputting the signal to all work equipment detent.
Problem that
• The 3-spool valve (attachment) cylinder is not extracted.
appears on
machine
machine monitor.)
Related
information
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract
1
Possible causes
Min. 1 Mz
3
Between (25) and (3) 5 – 15 z
WA500-6R 37
Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short

Action code Failure code 3-spool valve extract EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHJKY (Work equipment controller system)
• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the
Contents of
power source, abnormal voltage was applied when the 3-spool valve (attachment) extract EPC sole-
trouble
noid output was OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not extracted.
appears on
• The 3-spool valve (attachment) extract EPC solenoid may be burnt out.
machine
machine monitor.)
Related
information
1
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Between (25) and (3) 5 – 15 z
38 WA500-6R
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)1
Action code Failure code 3-spool valve retract EPC solenoid: Disconnection
Trouble
E03 DXHKKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) retract EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) retract EPC solenoid output is ON.
• Continues outputting.
Action of
controller
Problem that
appears on • The 3-spool valve (attachment) cylinder is not retracted.
machine
machine monitor.)
Related
information
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
(attachment) retract EPC without turning starting switch ON.
1
value in normal 2 (Disconnection in wiring Max. 1 z
state F22 (female) (2) tance
harness and defective
contact) Wiring harness between L07 (female) (35) – Resis-
Max. 1 z
3
Between (35) and (3) 5 – 15 z
Circuit diagram related to 3-spool valve (attachment) retract EPC solenoid
WA500-6R 39
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)1
Action code Failure code 3-spool valve retract EPC solenoid: Short circuit
Trouble
E03 DXHKKB (Work equipment controller system)
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with the
Contents of
chassis ground, abnormal current flowed when the 3-spool valve (attachment) retract EPC solenoid
trouble
output was ON.
• The output to the 3-spool valve (attachment) retract EPC solenoid is stopped.
Action of • Stops outputting the signal to all work equipment detent.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
machine
machine monitor.)
Related
information
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
1
Possible causes
Min. 1 Mz
3
Between (35) and (3) 5 – 15 z
40 WA500-6R
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit
with power supply line) 1
Action code Failure code 3-spool valve retract EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHKKY (Work equipment controller system)
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with the
Contents of
power source, abnormal voltage was applied when the 3-spool valve (attachment) retract EPC sole-
trouble
noid output was OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
• The 3-spool valve (attachment) retract EPC solenoid may be burnt out.
machine
machine monitor.)
Related
information
1
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Between (35) and (3) 5 – 15 z
WA500-6R 41
Failure code [DXHLKA] (Joystick steering right EPC solenoid:

Disconnection) 1
Action code Failure code Joystick steering right EPC solenoid: Disconnection
Trouble
E03 DXHLKA (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is disconnected, no current flows when the joy-
trouble stick steering right EPC solenoid output is ON.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
Problem that
appears on • Joystick steering is inoperable. (Operable in handle mode.)
machine
• The output state (current) to the joystick steering right EPC solenoid can be checked with the moni-
toring function (Code: 41904 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to right.
Related
• Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring func-
information
tion (Code: 40953, D-OUT-8).
• If failure code of joystick steering solenoid cut relay system (D193KA, D193KB or D193KY) is dis-
played, carry out troubleshooting for joystick steering solenoid cut relay system first.

Defective joystick steering without turning starting switch ON.
1 right EPC solenoid
Between (1) and (2) 5 – 15 z
L118 (male) Resistance
Defective joystick cut-off Between (1) and (2) 200 – 400 z
2 relay (L118) a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection) and carry out troubleshooting.
When joystick cut-off relay (L118) is replaced with a relay of the
same type, if the condition becomes normal, the joystick cut-off
relay is defective.
Possible causes
value in normal without turning starting switch ON.
3
(Disconnection or defective Wiring harness between JS5 (female) (2) – Resis-
contact of connector) Max. 1 z
Max. 1 z
Joystick steering
lever operation
4 Joystick steering
controller Max. 1 V
lever in neutral
Between (28) and (23) Joystick steering
lever at right 5 – 10 V
stroke end
42 WA500-6R
Circuit diagram related to joystick steering right EPC solenoid
WA500-6R 43
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short

circuit) 1
Action code Failure code Joystick steering right EPC solenoid: Short circuit
Trouble
E03 DXHLKB (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is short with the chassis ground, no current
trouble flows when the joystick steering right EPC solenoid output is ON.
Problem that
machine
• Method of reproducing failure code: Start engine and operate joystick steering to right.
Related
information

Defective joystick steering JS5 (male) Resistance
Min. 1 Mz
chassis ground
and standard L118 (male) Resistance
value in normal
state
(Internal short circuit) and carry out troubleshooting.
relay is defective.
3 harness
Min. 1 Mz
44 WA500-6R

Min. 1 Mz
chassis ground
Possible causes
value in normal Defective work equipment and carry out troubleshooting.
4
state controller Joystick steering
lever operation
Joystick steering
Max. 1 V
lever in neutral
stroke end
WA500-6R 45
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short

Action code Failure code Joystick steering right EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHLKY (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system was shorted with the power source, abnormal
trouble voltage was applied when the joystick steering right EPC solenoid output was OFF.
Problem that
machine
Related
information

Min. 1 Mz
chassis ground
state 3
Voltage Max. 1 V
Min. 1 Mz
chassis ground
Defective work equipment and carry out troubleshooting.
4
controller Joystick steering
lever operation
Joystick steering
Max. 1 V
lever in neutral
stroke end
46 WA500-6R
WA500-6R 47
Failure code [DXHMKA] (Joystick steering left EPC solenoid:

Disconnection) 1
Action code Failure code Joystick steering left EPC solenoid: Disconnection
Trouble
E03 DXHMKA (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is disconnected, no current flows when the joy-
trouble stick steering left EPC solenoid output is ON.
Problem that
machine
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitor-
ing function (Code: 41905 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to left.
Related
information

Defective joystick steering without turning starting switch ON.
1 left EPC solenoid
Between (1) and (2) 5 – 15 z
(Internal disconnection) and carry out troubleshooting.
relay is defective.
Possible causes
value in normal without turning starting switch ON.
3
(Disconnection or defective Wiring harness between JS6 (female) (2) – Resis-
contact of connector) Max. 1 z
Max. 1 z
Joystick steering
lever operation
4 Joystick steering
controller Max. 1 V
lever in neutral
lever at left 5 – 10 V
stroke end
48 WA500-6R
Circuit diagram related to joystick steering left EPC solenoid
WA500-6R 49
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)1
Action code Failure code Joystick steering left EPC solenoid: Short circuit
Trouble
E03 DXHMKB (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is short with the chassis ground, no current
trouble flows when the joystick steering left EPC solenoid output is ON.
Problem that
machine
• Method of reproducing failure code: Start engine and operate joystick steering to left.
Related
information

1 left EPC solenoid
Min. 1 Mz
chassis ground
and standard L118 (male) Resistance
value in normal
state
relay is defective.
3 harness
Min. 1 Mz
50 WA500-6R

Min. 1 Mz
chassis ground
Possible causes
value in normal Defective work equipment and carry out troubleshooting.
4
state controller Joystick steering
lever operation
Joystick steering
Max. 1 V
lever in neutral
lever at left 5 – 10 V
stroke end
WA500-6R 51
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short

Action code Failure code Joystick steering left EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHMKY (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system was shorted with the power source, abnormal
trouble voltage was applied when the joystick steering left EPC solenoid output was OFF.
Problem that
machine
Related
information

1 left EPC solenoid
Min. 1 Mz
chassis ground
state 3
Voltage Max. 1 V
Min. 1 Mz
chassis ground
Defective work equipment and carry out troubleshooting.
4
controller Joystick steering
lever operation
Joystick steering
Max. 1 V
lever in neutral
stroke end
52 WA500-6R
WA500-6R 53
SEN02942-00

© 2007 KOMATSU
All Rights Reserved
54
SEN02944-02
WA500-6R

WA500-6R 60001 and up
Troubleshooting of electrical system 
(E-mode)
Fuse locations................................................................................................................................................. 3
Information in troubleshooting table ................................................................................................................ 6
E-1 Engine does not start ............................................................................................................................... 7
E-2 Wiper does not operate .......................................................................................................................... 12
E-3 Windshield washer does not operate ..................................................................................................... 16
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off................................... 19
E-5 Working lamp does not light up or go off ................................................................................................ 27
E-6 Turn signal lamp and hazard lamp do not light up or go off ................................................................... 32
E-7 Brake lamp does not light or it keeps lighting up .................................................................................... 38
E-8 Backup lamp does not light or it keeps lighting up ................................................................................. 40
E-9 Backup buzzer does not sound or it keeps sounding ............................................................................. 42
E-10 Horn does not sound or it keeps sounding ........................................................................................... 44
E-11 Alarm buzzer does not sound or it keeps sounding.............................................................................. 47
E-12 Air conditioner does not operate or stop .............................................................................................. 49
WA500-6R 1
E-13 KOMTRAX system does not work properly .......................................................................................... 52

E-14 Electric priming pump does not operate or does not stop automatically .............................................. 54
2 WA500-6R
Fuse locations 1
Connection table of fuse box and slow blow fuse
a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is
supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
slow blow fuse to see if the power is supplied normally.
Fuse box A
Capacity of
Type of power supply Fuse No. Destination of power
fuse
Switch power supply
1 5A Engine controller circuit
Starting switch ACC
2 10 A Starting switch terminal B circuit
3 30 A Engine controller cut circuit
Constant power  4 10 A Hazard lamp circuit
supply
5 10 A Radio, auto grease circuit
slow blow fuse SBF1
(50 A) 6 10 A Transmission controller (B) circuit
7 10 A Work equipment controller (B) circuit
8 10 A Machine monitor (B) circuit
9 10 A Horn circuit
10 20 A Air conditioner circuit
Switch power supply 11 5A Air conditioner compressor circuit

slow blow fuse CBF2 12 20 A Rear glass heater circuit
(80 A) 13 10 A Radio, auto grease circuit
14 20 A Air suspension seat, 12 V converter circuit
15 10 A KOMTRAX circuit
WA500-6R 3
Fuse box B
Capacity of
Type of power supply Fuse No. Destination of power
fuse
1 10 A Turn signal lamp circuit
2 10 A Back-up lamp and brake lamp circuit
3 20 A Front working lamp circuit
4 20 A Rear working lamp circuit
Switch power supply 5 10 A Transmission controller (A) circuit

slow blow fuse SBF2 6 10 A Parking brake circuit
(120A) 7 10 A Work equipment controller (A) circuit
8 10 A Machine monitor (A) circuit
9 20 A Wiper and washer circuit
10 10 A Spare
11 20 A Main lamp circuit
Switch power supply 12 10 A Clearance lamp (right) circuit
lamp switch 13 10 A Clearance lamp (left) circuit
Switch power supply 14 10 A Headlamp (right) circuit
head lamp relay 15 10 A Headlamp (left) circuit
Slow blow fuse
Slow blow fuse Capacity of

Type of power supply Destination of power
No. fuse
Starting switch B terminal circuit, engine controller cut circuit,
Constant power  hazard lamp circuit, radio, auto grease circuit, transmission con-
SBF1 50 A
supply troller (B) circuit, work equipment controller (B) circuit, machine
monitor (B) circuit
Horn circuit, air conditioner circuit, air conditioner compressor cir-
80 A cuit, rear glass heater circuit, radio, auto grease circuit, air sus-
pension seat, 12 V converter circuit, KOMTRAX circuit
SBF2 Turn signal lamp circuit, back-up lamp, brake lamp circuit, front
Switch power supply working lamp circuit. rear working lamp circuit, transmission con-
120 A troller (A) circuit, parking brake circuit, work equipment controller
(A) circuit, machine monitor (A) circuit, wiper, washer circuit,
spare, main lamp circuit
SBF3 250 A Heater relay circuit
4 WA500-6R
Locations and numbers of fuse boxes and slow blow fuse
WA500-6R 5

diagram. Before carrying out troubleshooting, understand that information fully.
Contents of
Problem that appears on machine
trouble
Related
Information related to detected trouble or troubleshooting
information

<Described contents>
• Standard value in normal state required to judge the
assumed cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24V) circuit.
• Short circuit
Possible Causes by which a trouble A harness of an independent circuit abnormally comes into
causes and is assumed to be defected contact with one of another circuit.
standard value (The order number indi-
in normal state cates a serial number, not <Notes on troubleshooting>
a priority sequence.) (1) Method of indicating connector numbers and handling of
T-junction
For troubleshooting, insert or connect T-junction adapter
3 shown below unless especially specified.
• When “male” or “female” is not indicated for a connec-
tor number, disconnect the connector, and insert the T-
junction adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-junction
adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated
in the front.
• Connect the minus (–) lead to a pin or harness indicated
in the rear.
• This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins).
• “Connector No. and pin No.” from each branching/merging point:
indicate the ends of branch or source of merging within the parts
of the same wiring harness
Arrow (io ): Roughly indicates mounting place on machine.
6 WA500-6R
E-1 Engine does not start 1
Contents of
• The engine does not start.
trouble
• The engine does not start, because the starting motor does not run due to troubles in the starting
motor system and starting switch terminal C signal system.
• Check that No. 2 fuse of fuse box A is normal.
(If it is broken, check the related wiring harness for grounding fault.)
• The input state (ON/OFF) from starting switch terminal C to the machine monitor can be checked with
Related the monitoring function (Code: 40900, D-IN-7).
information • The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked
• The input state (ON/OFF) from starting switch terminal C to work equipment controller can be
checked with the monitoring function (Code: 40912, D-IN-17).
• If failure code [D5ZHKA], [D5ZHKB], [D5ZHKZ], [DDK3KA], [DDK3KB], [DDK4KA], [DDK4KB],
[DDK6KA], or [DDK6KB] is displayed, carry out troubleshooting for it first.

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective battery relay (BTR1) • The battery is normal if any operating sound is output at the bat-
2 (Internal disconnection or tery relay contact by operating the starting switch.
short circuit) Operate the starting switch OFFoONoOFF.
3
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch START and carry out trouble-
shooting
Starting motor Voltage
Between terminals
Possible Power supply input 20 – 30 V
Defective starting motor B and E
causes and 4
(Internal defect) Between terminals
standard value Battery input Max. 1 V
R and E
in normal state
Between terminals
Starting input 20 – 30 V
C and E
If the starting motor does not run even if power supply input, battery
input and starting input is normal, the starting motor is defective.
Defective alternator and carry out troubleshooting.
5
(Internal short circuit) Between alternator terminal R (E03) and
Voltage Max. 1 V
chassis ground
2. Disconnect connector LS4 and connect T-adapter to male side.
Defective starting switch LS4 (male) Position of switch Resistance
6
OFF Min. 1 Mz
Between (1) and (3)
START Max. 1 z
WA500-6R 7

D02 (male) Diode range Continuity
Measure in diode
Between (1) and (2) range with (1) as pos-
itive (+).
Continue
Measure in diode
itive (+).
Measure in diode
Between (2) and (1) range with (2) as pos- Continue
Defective diode (D02, D03, itive (+).
7
D04) (Internal disconnection) a Prepare with starting switch OFF, then carry out troubleshooting
Measure in diode
Between (2) and (1) range with (2) as pos- Continue
itive (+).
Possible a Prepare with starting switch OFF, then perform troubleshooting

causes and with starting switch still OFF.
standard value DAD (male) Diode range Continuity
in normal state Measure in diode
itive (+).
Continue
Measure in diode
itive (+).
Defective neutral safety relay
Between (1) and (2) 200 – 400 z
8 (L103)
(Internal defect) a Prepare with starting switch OFF, then turn starting switch to ON
Check that horn sounds, and replace horn relay with neutral safety
relay (L103). If horn does not sound, neutral safety relay is defective.
a Prepare with starting switch OFF, then perform troubleshooting
with starting switch still OFF.
Defective start neutral hold Between (1) and (2) 200 – 400 z
9 relay (L121) a Prepare with starting switch OFF, then perform troubleshooting
(Internal defect) with starting switch ON.
Check that horn sounds, and replace horn relay with start neutral
hold relay (L121). If horn does not sound, start neutral hold relay is
defective.
8 WA500-6R

Defective lever neutral cut-off Between (1) and (2) 200 – 400 z
10 relay (L104) a Prepare with starting switch OFF, then turn starting switch to ON
(Internal defect) and carry out troubleshooting.
Check that horn sounds, and replace horn relay with lever neutral
cut-off relay (L104). If horn does not sound, lever neutral cut-off
relay is defective.
Defective KOMTRAX engine Between (1) and (2) 200 – 400 z
11 cut relay (L120) a Prepare with starting switch OFF, then turn starting switch to ON
(Internal defect) and carry out troubleshooting.
Check that horn sounds, and replace horn relay with KOMTRAX
engine cut-off relay (L120). If horn does not sound, KOMTRAX
engine cut-off relay is defective.
2. Disconnect each connector, and connect T-adapters to their
female side.
Between battery relay BTR1 D04 and start- Resis-
Max. 1 z
ing motor terminal B (E08) tance
Possible Between starting motor terminal E and chas- Resis-
Max. 1 z
causes and sis ground tance
standard value Between LS4 (female) (3) and L120 (female) Resis-
in normal state Max. 1 z
(3) tance
Max. 1 z
(5) tance
Max. 1 z
(1) tance
Max. 1 z
(3) tance
Disconnection in wiring  Between L103 (female) (3) and L121 (female) Resis-
harness Max. 1 z
12 (3) tance
(3) tance
Between L63 (female) (3) and DAD (female) Resis-
Max. 1 z
(3) tance
Max. 1 z
(2) tance
Max. 1 z
(1) tance
Between L104 (female) (3) and D04 (female) Resis-
Max. 1 z
(2) tance
Between D04 (female) (2) and D03 (female) Resis-
Max. 1 z
(2) tance
Between D04 (female) (1) and D03 (female) Resis-
Max. 1 z
(1) tance
Between D03 (female) (1) and E01 (female) Resis-
Max. 1 z
(1) tance
WA500-6R 9

Max. 1 z
(1) tance
Disconnection in wiring  Between L103 (female) (2) and chassis Resis-
Max. 1 z
harness ground tance
12
(Disconnection or defective Between L121 (female) (2) and chassis Resis-
ground tance
Max. 1 z
ground tance
2. Disconnect battery relay BTR1 D04 terminal and starting motor B
terminal (E08).
3. Disconnect connectors shown below and connectors L80, L02,
L52, and L10, and connect T-adapter to female side of one of
them.
Between battery relay BTR1 D04 or starting Resis-
Min. 1 Mz
motor terminal B (E08) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
(5) or L121 (female) (1) and chassis ground tance
Between L104 (female) (6) or L103 (female)
Ground fault in wiring harness (3) or L06 (female) (25) or L121 (female) (3) Resis-
13 Min. 1 Mz
(Short circuit with ground circuit) and chassis ground tance
Possible Between L63 (female) (3) or L03 (female) Resis-

Min. 1 Mz
causes and (26) or DAD (female) (3) and chassis ground tance
standard value Between L103 (female) (1) or DAD (female) Resis-
in normal state Min. 1 Mz
Between L121 (female) (5) or DAD (female) Resis-
Min. 1 Mz
Between L104 (female) (3) or D04 (female) Resis-
Min. 1 Mz
(2) or D03 (female) (2) and chassis ground tance
Min. 1 Mz
Between D04 (female) (1) or D03 (female) Resis-
Min. 1 Mz
(1) or E01 (female) (1) and chassis ground tance
2. Disconnect alternator R terminal.
14 Defective alternator 3. Turn starting switch to ON position.
Between alternator R terminal and chassis
Voltage Max. 1 V
ground
Hot short in wiring harness 2. Disconnect alternator R terminal.
Between E03 and chassis ground Voltage Max. 1 V
2. Disconnect connector L104 and connect T-adapter to female side.
16 L104 (female) Directional lever Voltage
controller
Neutral Max. 1 V
Between (1) and (2)
Other than above 20 – 30 V
10 WA500-6R
WA500-6R 11
E-2 Wiper does not operate 1
Contents of
(1) Front wiper does not operate.
trouble
Related
• Since the front wiper switch, timer, or wiring harness is defective, the front wiper does not operate.
information

1
C12 Front wiper switch Voltage
Defective front wiper motor
2 Between (2) and (3) Lo 20 – 30 V
(Internal defect)
Between (1) and (3) Hi 20 – 30 V
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C12 (5) and chassis ground until wiper motor
stops.
L21 Front wiper switch Voltage
Possible Between (3) and (1) Constant 20 – 30 V
causes and Defective wiper timer (relay)
3 Between (4) and (1) INT 20 – 30 V
standard value (Internal defect)
in normal state Between (2) and (1) Washer side 20 – 30 V
INT (If wiper switch is
Repeat
Between (5) and (1) set in INT, voltage is
20 to 30 V o 0 V
output intermittently.)
L22 Voltage
Between (7) and chassis ground 20 – 30 V
Defective front wiper switch
4 L22 Front wiper switch Resistance
(Internal defect)
Between (7) and (5) Lo Max. 1 z
Between (7) and (4) Hi Max. 1 z
Between (7) and (2) INT Max. 1 z
Between (3) and (5) INT Max. 1 z
12 WA500-6R

Max. 1 z
Max. 1 z
Disconnection in wiring  C12 (female) (2) tance
harness Wiring harness between L22 (female) (7) – Resis-
5 Max. 1 z
(Disconnection or defective fuse No. 9 of fuse box B, – circuit branch end tance
Max. 1 z
C12 (female) (1) tance
Possible Wiring harness between C12 (female) (3) Resis-
Max. 1 z
causes and and chassis ground tance
standard value Wiring harness between L21 (female) (1) Resis-
Wiring harness between L22 (female) (3) - Resis-
Min. 1 Mz
Wiring harness between L22 (female) (5) Resis-
Ground fault in wiring harness Min. 1 Mz
6 –C12 (female) (2) and chassis ground tance
(Short circuit with ground circuit)
Resis-
fuse No. 9 of fuse box B, – circuit branch end Min. 1 Mz
tance
and chassis ground
Min. 1 Mz
–C12 (female) (1) and chassis ground tance
WA500-6R 13
Contents of
(2) Rear wiper does not operate.
trouble
Related
• Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
information

C15 Rear wiper switch Voltage
Defective rear wiper motor Between (1) and (4) Constant 20 – 30 V
1
(Internal defect) Between (2) and (4) ON 20 – 30 V
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C15 (1) and chassis ground until wiper motor
stops.
L22 Voltage
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal defect)
L22 Rear wiper switch Resistance
Between (7) and (9) ON Max. 1 z
Possible
causes and Between (8) and (9) OFF Max. 1 z
standard value Other than above Min. 1 Mz
in normal state
Max. 1 z
Disconnection in wiring  C15 (female) (1) tance
3 Max. 1 z
(Disconnection or defective C15 (female) (3) tance
Max. 1 z
Wiring harness between C15 (female) (4) – Resis-
Max. 1 z
Min. 1 Mz
Ground fault in wiring harness C15 (female)(1), – circuit branch end tance
4
(Short circuit with ground circuit) Wiring harness between L22 (female) (8) – Resis-
Min. 1 Mz
Min. 1 Mz
14 WA500-6R
Circuit diagram related to wiper
WA500-6R 15
E-3 Windshield washer does not operate 1
Contents of
Windshield washer does not operate
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-2 Wiper does not operate” first.)

Defective front washer motor and carry out troubleshooting.
1
(Internal defect) B09 Voltage
Between (1) and (2) 20 – 30 V
Defective rear washer motor and carry out troubleshooting.
2
(Internal defect) B11 Voltage
Between (1) and (2) 20 – 30 V
L22 Voltage
Defective front wiper switch without turning starting switch ON.
3
(Internal defect) Front wiper washer
switch
ON Max. 1 z
Between (7) and (6)
OFF Min. 1 Mz
Possible
causes and Between (7), (6) and
Constant Min. 1 Mz
standard value chassis ground
in normal state a Prepare with starting switch OFF, then turn starting switch ON
L22 Voltage
Rear wiper washer
switch
ON Max. 1 z
Defective rear wiper switch OFF Min. 1 Mz
4
(Internal defect)
Constant Min. 1 Mz
chassis ground
Rear wiper washer
switch
Between
ON Max. 1 z
(7) and (9), (10)
Between (7), (9), (10)
Constant Min. 1 Mz
and chassis ground
16 WA500-6R

Front wiper washer
Defective wiper timer (relay) L21 (male) Voltage
5 switch
(for only front wiper)
Between (2) and (1) ON 20 – 30 V
Between (5) and (1) 0.2 – 0.8 sec after ON 20 – 30 V
Max. 1 z
B09 (female) (1), L21 (female) (2) tance
Possible Disconnection in wiring  Wiring harness between L22 (female) (7) – Resis-
Max. 1 z
causes and harness fuse No. 9 of fuse box B tance
6
standard value (Disconnection or defective Wiring harness between L22 (female) (10) – Resis-
in normal state B11 (female) (1) tance
Wiring harness between B09 (female) (2), Resis-
Max. 1 z
–B11 (female) (2) – chassis ground tance
Max. 1 z
Resis-
B09 (female) (1), L21 (female) (2) and chas- Min. 1 Mz
Ground fault in wiring harness sis ground tance
7
(Short circuit with ground circuit)
Min. 1 Mz
fuse No. 9 of fuse box B and chassis ground tance
Min. 1 Mz
–B11 (female) (1) and chassis ground tance
WA500-6R 17
Circuit diagram related to windshield washer
18 WA500-6R
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light
up or go off 1
Contents of
(1) None of headlamp, clearance lamp, tail lamp, and license lamp lights up.
trouble
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
lamps lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp
light up.
• Headlamp at HEAD position: Above lamps and headlamp light up.
Related
• The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
information
with the monitoring function (Code: 40200, SMALL LAMP).
• The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked
• The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be
checked with the monitoring function (Code: 40904 D-IN-34).

1
L61 (male) Lamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 z
2 (Internal disconnection or
short circuit) OFF Min. 1 Mz
Possible Between (1) and (2) SMALL Min. 1 Mz
causes and
HEAD Max. 1 z
standard value
in normal state Between (1), (2), (5)
Constant Min. 1 Mz
and chassis ground
Disconnection in wiring  a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between fuse No. 11 of fuse Resis-
Ground fault in wiring harness
4
(Short circuit with ground circuit) Wiring harness between fuse No. 11 of fuse Resis-
box B – L61 (female) (1), – circuit branch Min. 1 Mz
tance
end and chassis ground
WA500-6R 19
Contents of
(2) Either of headlamp low and high beams does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective.
• When the clearance lamp, tail lamp, and license lamp light up and go off normally.
Related • The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked
information with the monitoring function (Code: 40900 D-IN-0).

Defective fuse No. 14 or No. If the fuse is burn, the circuit probably has a grounding fault, etc.
1
15 of fuse box B (See cause 6.)
Defective head lamp relay Between (1) and (2) 200 – 400 z
2
(L115) a Prepare with starting switch OFF, then turn starting switch ON
When head lamp relay (L115) is replaced with a relay of the same type,
if the condition becomes normal, the head lamp relay is defective.
Possible
L61 (male) Headlamp switch Resistance
causes and
Defective lamp switch OFF Min. 1 Mz
standard value
in normal state Between (1) and (2) SMALL Min. 1 Mz
short circuit)
HEAD Max. 1 z
Constant Min. 1 Mz
chassis ground
L61 (male) Dimmer switch Resistance
Defective dimmer switch Low Min. 1 Mz

Between (6) and (3)
4 (Internal disconnection or High Max. 1 z
short circuit) Low Max. 1 z
Between (6) and (4)
High Min. 1 Mz
Constant Min. 1 Mz
chassis ground
20 WA500-6R

Max. 1 z
Max. 1 z
Disconnection in wiring  Wiring harness between fuse No. 11 of fuse Resis-
Max. 1 z
harness box B – L115 (female) (3) tance
5
fuse No. 14 or No. 15 of fuse box B tance
Max. 1 z
box B – right HEAD (female) (B) tance
Max. 1 z
box B – left HEAD (female) (B) tance
Max. 1 z
Resis-
Possible tance
chassis ground
causes and
standard value Wiring harness between L115 (female) (5) –
Resis-
in normal state Ground fault in wiring harness fuse No. 14 or No. 15 of fuse box B and Min. 1 Mz
6 tance
(Short circuit with ground circuit) chassis ground
Resis-
box B – right HEAD (female) (B) and chassis Min. 1 Mz
tance
ground
Resis-
box B – left HEAD (female) (B) and chassis Min. 1 Mz
tance
ground
and carry out troubleshooting.
Headlamp switch is OFF
L115 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground
7 fuse No. 14 or No. 15 of fuse box B and Voltage Max. 1 V
chassis ground
box B – right HEAD (female) (B) and chassis Voltage Max. 1 V
ground
box B – left HEAD (female) (B) and chassis Voltage Max. 1 V
ground
WA500-6R 21
Contents of
(3) Headlamp low beam does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
chassis ground.
• When the high beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.

Between (6) and (3)
Possible short circuit) Low Max. 1 z
causes and Between (6) and (4)
High Min. 1 Mz
standard value
in normal state Between (3), (4) and
Constant Min. 1 Mz
chassis ground
3
(Disconnection or defective Wiring harness between HEAD (female) (A) Resis-
– L61 (female) (4) tance
Ground fault in wiring harness without turning starting switch ON.
4
(Short circuit with ground circuit) Wiring harness between HEAD (female) (A) Resis-
Min. 1 Mz
– L61 (female) (4) and chassis ground tance
22 WA500-6R
Contents of
(4) Headlamp high beam does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
chassis ground.
• When the low beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb

Between (6) and (3)
short circuit) Low Max. 1 z
Possible Between (6) and (4)
causes and High Min. 1 Mz
standard value Between (3), (4) and
in normal state Constant Min. 1 Mz
chassis ground
3
(Disconnection or defective Wiring harness between HEAD (female) (C) Resis-
– L61 (female) (3) tance
Ground fault in wiring harness
4
(Short circuit with ground circuit) Wiring harness between HEAD (female) (C) Resis-
– L61 (female) (3), – circuit branch end and Min. 1 Mz
tance
chassis ground
WA500-6R 23
Contents of (5) Clearance lamp does not light up or go off.

trouble (6) Tail lamp does not light up or go off.
• The switch, lamp, or wiring harness of the clearance lamp or tail lamp system is defective.
Related • When the headlamp and turn signal lamp light up:
information The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
with the monitoring function (Code: 40200, SMALL LAMP).

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuse No. 12 or No. If the fuse is burn, the circuit probably has a grounding fault, etc.
2
13 of fuse box B (See cause 5.)
L61 (male) Headlamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 z
short circuit) OFF Min. 1 Mz
Between (1) and (2) SMALL Min. 1 Mz
HEAD Max. 1 z
Between (1), (2), (5)
Constant Min. 1 Mz
and chassis ground
Possible Wiring harness between L61 (female) (5) – Resis-
Max. 1 z
causes and fuse No. 12 or No. 13 of fuse box B tance
standard value
in normal state Disconnection in wiring  Wiring harness between fuse No. 12 of fuse Resis-
Max. 1 z
harness box B – right COMBI (female) (A) tance
4
(Disconnection or defective Wiring harness between fuse No. 12 of fuse Resis-
box B – G01 (female) (6) tance
Max. 1 z
box B – left COMBI (female) (A) tance
Max. 1 z
box B – G02 (female) (6) tance
Resis-
box B – right COMBI (female) (A) and chas- Min. 1 Mz
tance
sis ground
Ground fault in wiring harness Wiring harness between fuse No. 12 of fuse Resis-
5 Min. 1 Mz
(Short circuit with ground circuit) box B – G01 (female) (6) and chassis ground tance
Resis-
box B – left COMBI (female) (A) and chassis Min. 1 Mz
tance
ground
Min. 1 Mz
box B – G02 (female) (6) and chassis ground tance
24 WA500-6R

and carry out troubleshooting.
Headlamp switch is OFF
fuse No. 12 or No. 13 of fuse box B and Voltage Max. 1 V
chassis ground
Possible
causes and
Hot short in wiring harness box B – right COMBI (female) (A) and chassis Voltage Max. 1 V
standard value 6
in normal state
Voltage Max. 1 V
box B – G01 (female) (6) and chassis ground
box B – left COMBI (female) (A) and chassis Voltage Max. 1 V
ground
Voltage Max. 1 V
box B – G02 (female) (6) and chassis ground
WA500-6R 25
Circuit diagram related to headlamp, clearance lamp and tail lamp
26 WA500-6R
E-5 Working lamp does not light up or go off 1
Contents of
(1) Either of front working lamp and rear working lamp does not light up
trouble
• The working lamp system power supply wiring harness is disconnected or shorted with the chassis
Related ground.
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.

Possible
causes and
standard value 1
in normal state (Disconnection or defective Wiring harness between L61 (female) (5) Resis-
–S67 (female) (5), S68 (female) (5) tance
Contents of
(2) Front working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the front working lamp system is defective
Related • When the rear working lamp lights up (goes off).
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
2
Between (5) and (6) 200 – 400 z
Defective front working lamp
Possible 3 a Prepare with starting switch OFF, then turn starting switch ON
relay (L109)
causes and and carry out troubleshooting.
standard value When front working lamp relay (L109) is replaced with a relay of the
in normal state same type, if the condition becomes normal, the front working lamp
relay is defective.
Front working lamp
Defective front working lamp S67 (male) Resistance
switch
4 switch (Internal disconnection
ON Max. 1 z
or short circuit) Between (5) and (6)
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
WA500-6R 27

Max. 1 z
and S67 (female) (5) tance
Wiring harness between S67 (female) (6) Resis-
Max. 1 z
and L109 (female) (5) tance
Max. 1 z
Disconnection in wiring  chassis ground tance
harness Wiring harness between fuse No. 3 of fuse Resis-
5 Max. 1 z
(Disconnection or defective box B – L109 (female) (2), (4) tance
Max. 1 z
C04 (female) (1), C05 (female) (1) tance
Wiring harness between C04 (female) (2), Resis-
Max. 1 z
C05 (female) (2) – chassis ground tance
Max. 1 z
RS1 (female) (1), RS2 (female) (1) tance
Wiring harness between RS1 (female) (1), Resis-
Max. 1 z
RS2 (female) (1) – chassis ground tance
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and without turning starting switch ON.
standard value
in normal state Wiring harness between S67 (female) (6) – Resis-
Min. 1 Mz
Wiring harness between fuse No. 3 of fuse box Resis-
Min. 1 Mz
Ground fault in wiring harness B – L109 (female) (2), (4) and chassis ground tance
6
(Short circuit with ground circuit) Wiring harness between L109 (female) (1) –
Resis-
C04 (female) (1), C05 (female) (1), – circuit Min. 1 Mz
tance
branch end and chassis ground
Wiring harness between L109 (female) (3)
Resis-
–RS1 (female) (1), RS2 (female) (1) and Min. 1 Mz
tance
chassis ground
• Front working lamp switch OFF
Wiring harness between S67 (female) (6) –
Voltage Max. 1 V
C04 (female) (1), C05 (female) (1), – circuit Voltage Max. 1 V
RS1 (female) (1), – RS1 (female) (1) and Voltage Max. 1 V
chassis ground
28 WA500-6R
Contents of
(3) Rear working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the rear working lamp system is defective.
Related • When the front working lamp and side working lamp (if equipped) light up (goes off).
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (5) and (6) 200 – 400 z
Defective rear working lamp
3 a Prepare with starting switch OFF, then turn starting switch ON
relay (L110)
When rear working lamp relay (L110) is replaced with a relay of the
same type, if the condition becomes normal, the rear working lamp
relay is defective.
Possible Defective rear working lamp Rear working lamp
causes and switch switch
4
standard value (Internal disconnection or ON Max. 1 z
in normal state short circuit) Between (5) and (6)
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Max. 1 z
and S68 (female) (5) tance
Wiring harness between S68 (female) (6) Resis-
Max. 1 z
Disconnection in wiring  and L110 (female) (5) tance
5 Max. 1 z
(Disconnection or defective chassis ground tance
contact in connector) Wiring harness between fuse No. 4 of fuse Resis-
Max. 1 z
Max. 1 z
G03 (female) (1), G04 (female) (1) tance
Wiring harness between G03 (female) (2) or Resis-
Max. 1 z
G04 (female) (2) – chassis ground tance
WA500-6R 29

Wiring harness between S68 (female) (6) – Resis-
Max. 1 z
Ground fault in wiring harness Wiring harness between fuse No. 4 of fuse box
6 Resis-
(Short circuit with ground circuit) B – L110 (female) (2), – circuit branch end and Max. 1 z
tance
chassis ground
Possible
causes and Wiring harness between L110 (female) (1) –
Resis-
standard value G03 (female) (1), G04 (female) (1) and chassis Max. 1 z
tance
in normal state ground
• Front working lamp switch OFF
Hot short in wiring harness Wiring harness between S68 (female) (6) –
7 Voltage Max. 1 V
(Contact with 24 V circuit) L110 (female) (5) and chassis ground
G03 (female) (1), G04 (female) (1) and chassis Voltage Max. 1 V
ground
30 WA500-6R
Circuit diagram related to working lamp
WA500-6R 31
E-6 Turn signal lamp and hazard lamp do not light up or go off 1
Contents of
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
• The input state (ON/OFF) from turn signal lamp and hazard lamp switch (right turn signal lamp) to
Related
machine monitor can be checked with the monitoring function (Code: 40901, D-IN-12).
information
• The input state (ON/OFF) from turn signal lamp and hazard lamp switch (left turn signal lamp) to

Defective fuse No. 4 of fuse
If the fuse is burn, the circuit probably has a grounding fault, etc.
1 box A and fuse No. 1 of fuse
(See cause 6.)
box B
Between (1) and (2) 200 – 400 z
2 Defective hazard relay (L113)
Possible
causes and When hazard relay (L113) is replaced with a relay of the same type,
standard value if the condition becomes normal, the hazard relay is defective.
in normal state a Prepare with starting switch OFF, then turn starting switch ON
L19 (male) Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit
Between (4) and (1) Repeat 20 to 30 V io 0 V
short circuit) a Prepare with starting switch OFF, then carry out troubleshooting
Min. 1 Mz
chassis ground
32 WA500-6R

Turn signal lamp and
hazard lamp switches
Turn signal lever: Left Min. 1 Mz
Turn signal lever:
Min. 1 Mz
Neutral
Between (2) and (3) Turn signal lever:
Max. 1 z
Right
Hazard lamp switch:
Max. 1 z
ON
Defective turn signal lamp and Turn signal lever: Left Max. 1 z
hazard lamp switches  Turn signal lever:
4 Min. 1 Mz
(Internal disconnection or Neutral
short circuit) Between (2) and (4) Turn signal lever:
Min. 1 Mz
Right
Hazard lamp switch:
Max. 1 z
ON
Hazard lamp switch:
Max. 1 z
ON
Between (1) and (5)
Hazard lamp switch:
Min. 1 Mz
OFF
Possible
causes and Between (1), (2), (3),
Constant Min. 1 Mz
standard value (4) and chassis ground
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
Max. 1 z
Disconnection in wiring  L19 (female) (3) tance
5 Max. 1 z
(Disconnection or defective L62 (female) (2) tance
Max. 1 z
Max. 1 z
Ground fault in wiring harness Wiring harness between L113 (female) (3) Resis-
6 Min. 1 Mz
(Short circuit with ground circuit) –L19 (female) (3) and chassis ground tance
Min. 1 Mz
–L62 (female) (2) and chassis ground tance
Hot short in wiring harness Wiring harness between L113 (female) (3)
7 Voltage Max. 1 V
(Contact with 24 V circuit) –L19 (female) (3) and chassis ground
Wiring harness between L19 (female) (4)
Voltage Max. 1 V
–L62 (female) (2) and chassis ground
WA500-6R 33
Contents of
(2) Turn signal lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
When the hazard lamp blinks.
Related • The input state (ON/OFF) from turn signal lamp and hazard lamp switch (right turn signal lamp) to
information machine monitor can be checked with the monitoring function (Code: 40901, D-IN-12).
• The input state (ON/OFF) from turn signal lamp and hazard lamp switch (left turn signal lamp) to

If a specific turn signal lamp does not light up, its bulb may be bro-
1 Broken bulb
ken or may have a defective contact. Check the bulb directly.
Turn signal lamp and
hazard lamp switches
Turn signal lever: Left Min. 1 Mz
Turn signal lever:
Min. 1 Mz
Neutral
Max. 1 z
Right
Defective turn signal lamp and Hazard lamp switch:
Max. 1 z
hazard lamp switches  ON
2
(Internal disconnection or Turn signal lever: Left Max. 1 z
short circuit)
Turn signal lever:
Min. 1 Mz
Neutral
Min. 1 Mz
Right
Hazard lamp switch:
Max. 1 z
ON
Possible Between (2), (3), (4)

Constant Min. 1 Mz
causes and and chassis ground
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch ON.
Max. 1 z
G01 (female) (1), – right COMBI (female) (C) tance
Max. 1 z
Disconnection in wiring  G02 (female) (1), – left COMBI (female) (C) tance
harness Wiring harness between G01 (female) (4) – Resis-
3 Max. 1 z
(Disconnection or defective chassis ground tance
contact in connector) Wiring harness between G02 (female) (4) – Resis-
Max. 1 z
Wiring harness between right COMBI Resis-
Max. 1 z
(female) (B) – chassis ground tance
Wiring harness between left COMBI (female) Resis-
Max. 1 z
(B) – chassis ground tance
Resis-
Ground fault in wiring harness G01 (female) (1), – right COMBI (female) (C) Min. 1 Mz
4 tance
(Short circuit with ground circuit) and chassis ground
Resis-
G02 (female) (1), – left COMBI (female) (C) Min. 1 Mz
tance
and chassis ground
34 WA500-6R

Possible
standard value Hot short in wiring harness G01 (female) (1), – right COMBI (female) (C) Voltage Max. 1 V
5
in normal state (Contact with 24 V circuit) and chassis ground
G02 (female) (1), – left COMBI (female) (C) Voltage Max. 1 V
and chassis ground
WA500-6R 35
Contents of
(3) Hazard lamp does not light up or go off.
trouble
Related • The switch or lamp of the hazard lamp is defective.
information When the turn signal lamp flashes normally.

1
Between (1) and (2) 200 – 400 z
2 Defective hazard relay (L113)
When hazard relay (L113) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
L62 (male) Hazard lamp switch Resistance
Between ON Max. 1 z
Defective hazard lamp switch (2) and (3), (4) OFF Min. 1 Mz
short circuit) ON Max. 1 z
Between (1) and (5)
OFF Min. 1 Mz
Between (1), (2), (3),
(4), (5) and Constant Min. 1 Mz
chassis ground
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state
Disconnection in wiring  Wiring harness between fuse No. 4 of fuse Resis-
Max. 1 z
harness box A – L113 (female) (1), (5) tance
4
Max. 1 z
Ground fault in wiring harness Resis-
5 box A – L113 (female) (1), (5) and chassis Min. 1 Mz
(Short circuit with ground circuit) tance
ground
Min. 1 Mz
• The harnesses in the following two systems are shorted with the
power source simultaneously.
6
(Contact with 24 V circuit) G01 (female) (1), – right COMBI (female) (C) Voltage Max. 1 V
and chassis ground
G02 (female) (1), – left COMBI (female) (C) Voltage Max. 1 V
and chassis ground
36 WA500-6R
Circuit diagram related to turn signal lamp and hazard lamp
WA500-6R 37
E-7 Brake lamp does not light or it keeps lighting up 1
Contents of
Brake lamp does not light or it keeps lighting up.
trouble
Related
• The lamp or wiring harness of the brake lamp system is abnormal.
information

If a specific brake lamp does not light up, its bulb may be broken or
1 Broken bulb
2
Defective brake lamp relay
Between (1) and (2) 200 – 400 z
(L102)
3 a Prepare with starting switch OFF, then turn starting switch ON
short circuit) and carry out troubleshooting.
When brake lamp relay (L102) is replaced with a relay of the same
type, if the condition becomes normal, the brake lamp relay is defec-
tive.
Defective brake lamp switch L16 (male) Brake pedal Resistance

4 (Internal disconnection or Pressed Max. 1 z
short circuit) Between (1) and (2)
Released Min. 1 Mz
Possible Between (1), (2) and
Constant Min. 1 Mz
causes and chassis ground
Max. 1 z
box B – L102 (female) (2), – L16 (female) (1) tance
Disconnection in wiring  Wiring harness between L16 (female) (2) – Resis-
Max. 1 z
harness L102 (female) (5) tance
5
Max. 1 z
G01 (female) (5), – G02 (female) (5) tance
Wiring harness between G01 (female) (4), Resis-
Max. 1 z
G02 (female) (4) – chassis ground tance
Wiring harness between fuse No. 2 of fuse box
Resis-
B – L102 (female) (2), – L16 (female) (1),  Min. 1 Mz
tance
Ground fault in wiring harness – circuit branch end and chassis ground
6
(Short circuit with ground circuit) Wiring harness between L16 (female) (2) Resis-
Min. 1 Mz
Resis-
G01 (female) (5), – G02 (female) (5) and Min. 1 Mz
tance
chassis ground
38 WA500-6R

Possible and carry out troubleshooting.
standard value Hot short in wiring harness Voltage Max. 1 V
7 L102 (female) (5) and chassis ground
in normal state (Contact with 24 V circuit)
G01 (female) (5), – G02 (female) (5) and Voltage Max. 1 V
chassis ground
Circuit diagram related to brake lamp
WA500-6R 39
E-8 Backup lamp does not light or it keeps lighting up 1
Contents of
Backup lamp does not light or it keeps lighting up
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
Related
(If disconnection or short circuit occurs in the primary side of the backup lamp relay, failure code
information
[D160KA] or [D160KZ] is displayed. Carry out troubleshooting for it first.)

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
2
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L101) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
When backup lamp relay (L101) is replaced with a relay of the same
type, if the condition becomes normal, the backup lamp relay is
defective.
Max. 1 z
Max. 1 z
Possible G01 (female) (2), – G02 (female) (2) tance
standard value Disconnection in wiring  L101 (female) (1) Resis-
harness • If any abnormality is detected, failure code tance
4
(Disconnection or defective [D160KA] is displayed.
contact in connector) Wiring harness between L101 (female) (2) –
chassis ground Resis-
Max. 1 z
• If any abnormality is detected, failure code tance
[D160KA] is displayed.
Wiring harness between G01 (female) (4) – Resis-
Max. 1 z
Max. 1 z
Wiring harness between fuse No. 2 of fuse box Resis-
Min. 1 Mz
B – L101 (female) (5) and chassis ground tance
Ground fault in wiring harness Wiring harness between L101 (female) (3) – Resis-
5
(Short circuit with ground circuit) G01 (female) (2), – G02 (female) (2) and tance
Min. 1 Mz
chassis ground
L101 (female) (1) and chassis ground Resis-
Min. 1 Mz
[D160KZ] is displayed.
40 WA500-6R

Possible a Prepare with starting switch OFF, then turn starting switch ON
standard value Hot short in wiring harness
G01 (female) (2), – G02 (female) (2), – circuit Voltage Max. 1 V
WA500-6R 41
E-9 Backup buzzer does not sound or it keeps sounding 1
Contents of
Backup buzzer does not sound or it keeps sounding
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
Related
(If disconnection or short circuit occurs in the primary side of the backup lamp relay, failure code
information
[D160KA] or [D160KZ] is displayed. Carry out troubleshooting for it first.)

Defective backup buzzer
1 (Internal disconnection or G06 Gear shift lever Voltage
short circuit) R 20 – 30 V
Between (1) and (2)
Other than R Max. 1 V
2
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L101) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
When backup lamp relay (L101) is replaced with a relay of the same
type, if the condition becomes normal, the backup lamp relay is
defective.
Possible Wiring harness between fuse No. 2 of fuse Resis-
causes and Max. 1 z
standard value
G06 (female) (1) tance
Disconnection in wiring  Wiring harness between L04 (female) (18) –
harness L101 (female) (1) Resis-
4
contact in connector) [D160KA] is displayed.
chassis ground Resis-
Max. 1 z
[D160KA] is displayed.
Max. 1 z
Min. 1 Mz
Ground fault in wiring harness Wiring harness between L101 (female) (3) – Resis-
5 Min. 1 Mz
(Short circuit with ground circuit) G06 (female) (1) and chassis ground tance
L101 (female) (1) and chassis ground Resis-
Min. 1 Mz
[D160KZ] is displayed.
42 WA500-6R

Possible a Prepare with starting switch OFF, then turn starting switch ON
standard value Hot short in wiring harness
G06 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground
WA500-6R 43
E-10 Horn does not sound or it keeps sounding 1
Contents of
Horn does not sound or it keeps sounding (Steering wheel specification)
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information

1
Defective horn relay (L108)
Between (1) and (2) 200 – 400 z
short circuit) a Prepare with starting switch OFF, then turn starting switch ON
When horn relay (L108) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
Defective steering wheel horn
switch Steering wheel horn
3 L64 (male) Resistance
Possible (Internal disconnection or switch
causes and short circuit) Between (1) and ON Max. 1 z
standard value chassis ground OFF Min. 1 Mz
in normal state
Defective joystick lever horn
switch Joystick lever horn
4 JL2 (male) Resistance
(Internal disconnection or switch
short circuit) ON Max. 1 z
OFF Min. 1 Mz
and carry out troubleshooting. (Disconnect connector and mea-
sure on female side.)
Defective horn F03, F05 Horn switch Voltage
5 (Internal disconnection or OFF Max. 1 V
Between
short circuit)
F03 (2) and (1) ON 20 – 30 V
Between OFF Max. 1 V
F05 (2) and (1) ON 20 – 30 V
44 WA500-6R

Resis-
box A – L108 (female) (1), – F03 (female) Max. 1 z
tance
(2), – F05 (female) (2)
Max. 1 z
Disconnection in wiring  Wiring harness between L108 (female) (2) – Resis-
harness Max. 1 z
6 JL2 (female) (9) tance
Max. 1 z
Possible F03 (female) (1), – F05 (female) (1) tance
causes and Wiring harness between steering wheel horn Resis-
standard value Max. 1 z
switch – chassis ground tance
in normal state
Wiring harness between JL2 (female) (10) – Resis-
Max. 1 z
Resis-
box A – L108 (female) (1), – F03 (female) Min. 1 Mz
tance
(2), – F05 (female) (2) and chassis ground
Ground fault in wiring harness Wiring harness between L108 (female) (2) Resis-
7 Min. 1 Mz
(Short circuit with ground circuit) –L64 (female) (1) and chassis ground tance
Min. 1 Mz
Resis-
F03 (female) (1), F05 (female) (1) and chassis Min. 1 Mz
tance
ground
WA500-6R 45
Circuit diagram related to horn
46 WA500-6R
E-11 Alarm buzzer does not sound or it keeps sounding 1
Contents of
• Alarm buzzer does not sound or it keeps sounding
trouble
• The alarm buzzer output circuit is disconnected or shorted with the chassis ground.
Related • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
information monitoring function (Code: 40952, D-OUT-0).
• If failure code [DV00KB] (Alarm buzzer: Short circuit) is displayed, carry out troubleshooting for it first.

1
• Check 2 seconds after starting switch is turned ON.
Defective alarm buzzer 
2 L20 (female) Alarm buzzer Normal/Defective
Sounds Buzzer is normal
Ground (2)
Does not sound. Buzzer is defective
Disconnection in wiring  without turning starting switch ON.
harness Wiring harness between fuse No. 8 of fuse Resis-
3 Max. 1 z
(Disconnection or defective box B – L20 (female) (1) tance
Possible Max. 1 z
causes and L51 (female) (14) tance
Ground fault in wiring harness Resis-
4 box B – L20 (female) (1), – circuit branch end Min. 1 Mz
(Short circuit with ground circuit) tance
and chassis ground
Min. 1 Mz
L51 Starting switch Voltage
For 2 sec after ON
5 Defective machine monitor 20 – 30 V
(Alarm buzzer sounds)
Between (14) and For 3 sec
chassis ground from 2 sec after ON
Max. 1 V
(Alarm buzzer does
not sound)
WA500-6R 47
Circuit diagram related to alarm buzzer
48 WA500-6R
E-12 Air conditioner does not operate or stop 1
Contents of
Air conditioner does not operate or stop.
trouble
• The following is troubleshooting for only the power supply or ground circuit between the air condi-
Related
tioner and operator's cab. For troubleshooting for the other item, see "Air conditioner" on chapter 80,
information
"Appendix".

Defective fuse No. 10 or No.11
of fuse box A and fuse 5A or If the fuse is burn, the circuit probably has a grounding fault, etc.
1
15A in main circuit in air condi- (See cause 2.)
tioner unit
• When fuse No. 10 of fuse box A is broken
box A – fuse 5A of main circuit in air condi- Resis-
Min. 1 Mz
tioner unit, – fuse 15 A in air conditioner unit tance
and chassis ground
• When fuse No. 11 of fuse box A is broken
Resis-
box A – compressor clutch relay and chassis Min. 1 Mz
Grounding fault in power sup- ground tance
2 ply wiring harness
(Contact with ground circuit) a Prepare with starting switch OFF, then carry out troubleshooting
Possible • When fuse 5 A of main circuit in air conditioner unit is broken
causes and
standard value Wiring harness between fuse 5 A of main cir-
in normal state cuit in air conditioner unit – C48 (female) (7), Resis-
Min. 1 Mz
– pressure switch, – primary side of blower tance
OFF relay and chassis ground
• When fuse 15 A in air conditioner unit is broken
Wiring harness between fuse 15A in air con-
Resis-
ditioner unit – blower OFF relay and chassis Min. 1 Mz
tance
ground
C48 Starting switch Voltage
Disconnection in air conditioner Between (7) and (1) ON 20 – 30 V

control panel power supply or OFF Max. 1 V
3 ground wire harness  a Prepare with starting switch OFF, then carry out troubleshooting
(Disconnection or defective without turning starting switch ON.
Max. 1 z
box A – C48 (female) (7) tance
Wiring harness between C48 (female) (1) – Resis-
Max. 1 z
WA500-6R 49

Blower OFF relay,
Starting switch Voltage
pressure switch
Between blower OFF ON 20 – 30 V
relay (15 A fuse line)
– chassis ground OFF Max. 1 V
Between blower OFF ON 20 – 30 V

relay (5 A fuse line of
main circuit) – chas- OFF Max. 1 V
sis ground
Possible Between pressure ON 20 – 30 V
causes and Disconnection in relay wiring switch (5 A fuse line of
standard value harness  main circuit) – chassis
4 OFF Max. 1 V
in normal state (Disconnection or defective ground
Max. 1 z
box A – blower OFF relay (15 A fuse line side) tance
Resis-
box A – blower OFF relay (5 A fuse line side Max. 1 z
tance
of main circuit)
Resis-
box A – pressure switch (5 A fuse line side of Max. 1 z
tance
main circuit)
Wiring harness between pressure switch – Resis-
Max. 1 z
compressor clutch relay tance
50 WA500-6R
Circuit diagram related to air conditioner
WA500-6R 51
E-13 KOMTRAX system does not work properly 1
Contents of
• KOMTRAX system does not work properly.
trouble
• If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
Related
system, carry out the following troubleshooting.
information
• A defect in KOMTRAX system, if any, does not appear especially as a defective phenomenon.

1 Defective power supply L80 Signal Voltage
Between (39), (40) Constant
20 – 30V
and (37), (38) power supply
a Turn the starting switch ON, then start engine and carry out trou-
bleshooting.
LED(6) Normal state
LED-C1 ON
Defective starting switch a Prepare with starting switch OFF, then start engine and carry out
2 ACC signal and alternator R troubleshooting.
signal L80 Signal Voltage
Between
Starting switch ACC 20 – 30V
(36) and (37), (38)
Between
Alternator R 20 – 30V
(28) and (37), (38)
Possible and carry out troubleshooting.
causes and Defective starting switch C
standard value 3 L80 Signal Voltage
signal
in normal state Between
Starting switch C 20 – 30V
(27) and (37), (38)
a Turn the starting switch ON, and carry out troubleshooting.
LED(4) Normal state
LED-C4 ON
Defective CAN connection
4
L80 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 z
5 Number of unsent mails LED(7) Normal state
7 segments 0–9
LED(8) Normal state
Defective GPS positioning Dot ON
6
status
One or more minute may be taken until GPS positioning is completed
after the starting switch was turned ON even in an outdoor service
area.
52 WA500-6R
Lamp display section of KOMTRAX terminal L80 connector
LED for communication module

1. LED-A1 (power indicator lamp)
2. LED-A2 (within communication range lamp)
3. LED-A3 (on communicating lamp)
4. LED-A4 (internal transmission lamp)
5. LED-A (internal reception lamp)
CPU LED
6. LED-C1 (R signal and ACC signal status)
7. LED-C2 (starting output status)
8. LED-C3 (S-NET, C signal status)
9. LED-C4 (CAN status)
10. LED-C5 (download writing condition)
11. LED-C6 (download writing condition)
7 segments and dot for CPU
12. 7 segments (number of mails not yet sent)
13. Dot (GPS positioning in progress)
WA500-6R 53
E-14 Electric priming pump does not operate or does not stop
automatically
Contents of
• Electric priming pump does not operate or does not stop automatically.
trouble
Related
information

1 Low battery charge level Battery charge level may be low. Check battery directly.
Defective fuse No. 13 of If the fuse is burn, circuit probably has ground fault, etc.
2
fuse box A (See cause No. 5.)
Disconnection in wiring a Prepare with starting switch OFF, then turn starting switch ON and
harness carry out troubleshooting.
3 (Disconnection or defective
contact in connector) Wiring harness between E24 (1) – (2) Voltage 20 – 30 V
(Power supply system)
a Prepare with starting switch OFF, then turn starting switch ON.
a Turn electric priming pump switch ON and carry out troubleshoot-
ing.
Disconnection in wiring
harness • Lamp blinks but stops in about 5 seconds.
4 (Disconnection or defective Wiring harness between E23 (1) – (2) Voltage 20 – 30 V
contact in connector) a Prepare with starting switch OFF, then carry out troubleshooting
(Drive power supply system) without turning starting switch ON.
Wiring harness between E24 (female) (2) – Resis-

Max. 1 z
Possible
causes and
standard value Wiring harness between E24 (female) (1) – Resis-
Min. 1 Mz
in normal state Ground fault in wiring fuse (13) and chassis ground tance
harness Wiring harness between E24 (female) (3) – Resis-
5 Min. 1 Mz
(Short circuit with ground E23 (female) (1) and chassis ground tance
circuit) Wiring harness between E24 (female) (4) – Resis-
Min. 1 Mz
E23 (female) (2) and chassis ground tance
Wiring harness between E23 (female) (1) – Resis-
1–3z
a Prepare with starting switch OFF, then turn starting switch ON.
a Turn electric priming pump switch ON and carry out troubleshoot-
ing.
Defective electric priming Between E24 (3) – (4) Voltage 20 – 30 V
pump switch • Lamp blinks but output voltage is improper.
6
(Malfunction or automatic • Results of troubleshooting steps 1 – 4 are normal and lamp does
stop failure) not blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective. (Turn toggle switch OFF to
stop pump and then replace switch.)
• Lamp blinks but stops in about 5 seconds.
Overload on electric priming
7 a If pump is overloaded, power supply is turned OFF automatically
pump
to protect circuit (Priming pump switch is reset automatically).
54 WA500-6R

Possible
Resis-
causes and Between E23 (male) (1) – (2) 1–3z
Trouble in electric priming tance
standard value 8
in normal state pump Resis-
Between E23 (male) (1) – pump body Min. 1 Mz
tance
Resis-
Between E23 (male) (2) – pump body Min. 1 Mz
tance
Circuit diagram related to electric priming pump
WA500-6R 55
SEN02944-02

© 2018 KOMATSU
All Rights Reserved
56
SEN02945-00
WA500-6R

WA500-6R 60001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Method of using troubleshooting chart............................................................................................................ 3
Table of failure modes and causes ................................................................................................................. 6
H-1 Machine does not start ........................................................................................................................... 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)] ................................................................................................ 12
H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)] ....................... 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak,
and gear is not shifted............................................................................................................................... 14
H-5 Shocks are large at the times of starting and shifting gear .................................................................... 16
H-6 Time lag is large at the times of starting and shifting gear ..................................................................... 18
H-7 Torque converter oil temperature is high................................................................................................ 20
H-8 Steering does not turn ............................................................................................................................ 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)] .................................................... 22
H-10 Steering response is low ...................................................................................................................... 23
WA500-6R 1
H-11 Turning response of steering is poor [machine with joystick steering (if equipped)]............................. 24
H-12 Steering is heavy .................................................................................................................................. 25
H-13 When machine turns, it shakes or makes large shocks ....................................................................... 26
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)]............................................................................................ 27
H-15 Wheel brake does not work or does not work well ............................................................................... 28
H-16 Wheel brake is not released or it drags................................................................................................ 29
H-17 Parking brake does not work or does not work well ............................................................................. 30
H-18 Parking brake is not released or it drags (including emergency release system) ................................ 31
H-19 Lift arm does not rise............................................................................................................................ 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient................................................................. 33
H-21 When rising, lift arm comes to move slowly at specific height.............................................................. 34
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats) ................................................................... 34
H-23 Hydraulic drifts of lift arm occur often ................................................................................................... 34
H-24 Lift arm wobbles during operation ........................................................................................................ 34
H-25 Bucket does not tilt back ...................................................................................................................... 35
H-26 Bucket speed is low or tilting back force is insufficient ......................................................................... 36
H-27 Bucket comes to operate slowly in the midst of tilting-back ................................................................. 37
H-28 Bucket cylinder cannot hold down the bucket ...................................................................................... 37
H-29 Hydraulic drifts of bucket occur often ................................................................................................... 37
H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”) ............................ 37
H-31 During operation of machine, engine speed lowers remarkably or engine stalls ................................. 38
H-32 Large shocks are made when work equipment starts and stops.......................................................... 38
H-33 When work equipment circuit is relieved singly, other work equipment moves .................................... 38
H-34 ECSS does not operate, and pitching and bouncing occur.................................................................. 39
2 WA500-6R
Method of using troubleshooting chart 1

This troubleshooting chart determines the location from the problem occurring on the machine and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.
Step 1. Ask operator questions Step 3. Method of reading matrix

q The questions to ask the operator are given 1. Operate the machine when carrying out trou-
under the problem. If the answer to the ques- bleshooting of the items in the Diagnosis col-
tion matches the content given, the cause umn. If any problems occur as the result of the
given after the arrow is the probable cause. troubleshooting, put a check against the item.
Keeping the content of the questions in mind, a When carrying out the troubleshooting,
read the matrix and proceed with Step 2 and check the easier items first. It is not neces-
Step 3 to pinpoint the correct cause. sary to follow the number order.
[Example]
Example: Steering does not turn
Diagnosis
Ask the operator and check the following points. No.
Remedy
q Did the problem suddenly start?
Steering does not turn in both directions (left
o Related equipment broken 1 and right)
q Was the steering wheel heavy before?
Steering turns only in one direction (left or
o Wear of related parts, defective seal 2 right)
Steering is heavy when turned in both direc-
Step 2. Checks before troubleshooting 3 tions (left and right)
q Before measuring the oil pressure or starting Steering wheel is heavy in one direction (left
4
the troubleshooting, confirm the checks before or right)
starting items, check for leakage of oil, or for 5 Work equipment moves
loose bolts. This will prevent wasting time
when troubleshooting. The items given under 2. Find the matching cause in the Cause column.
“Checks before troubleshooting” are checks If a problem is found, the Q marks on the same
that are particularly important to make about line as the troubleshooting are the causes. (In
the condition of the machine before starting the Diagnosis item 2 in the same diagram below
actual troubleshooting. the cause is c or e.)
When there is one Q mark:
Example: Checks before starting troubleshooting Carry out troubleshooting for the other items
q Is oil level and type of oil in hydraulic tank cor- marked with Q in the same Cause column to
rect? check if the problem occurs, then make
q Is there any oil leakage from steering valve or repairs.
demand valve? When there are two or more Q marks:
q Is steering linkage adjusted properly? Go to Step 3 to narrow down the cause.
WA500-6R 3
3. Operate the machine and carry out trouble- 6. Repeat the operation in Steps 3, 4, and 5 until
shooting of the items not checked in Step 1. the cause is narrowed down to 1 item (1 com-
Operate the machine in the same way as in mon item).
Step 1, and if any problem occurs, put a check a If cause items are 2 or more, continue until
against the item. (In Troubleshooting item 5 in number of items becomes minimum.
the diagram below, the problem was re-
enacted.) 7. Remedy
After narrowing down the common causes,
4. Find the matching cause in the cause column. taken the action given in the remedy line.
In the same way as in Step 2, if a problem is Marks and remedies in remedy line
found, the Q marks on the same line for the ×: Replace E: Repair A: Adjust C: Clean
troubleshooting item are the causes. (In Diag-
nosis item 5 in the diagram below the cause is
b or e.)
5. Narrow down the causes.

Of the causes found in Step 2 and Step 4,
there are common items (Q marks on the line
for each Diagnosis item and in the same
Cause column as each other) that have
causes common with the problem items found
in the troubleshooting in Step 1 and Step 3.
a The items that are not common (items that
do not have Q marks in the same cause
common as each other) are probably not
the cause, so they can be eliminated. (The
causes for Diagnosis item 2 in the dia-
gram below are c or e, and the causes in
Diagnosis item 5 are b or e, so Cause e is
the common cause.)
4 WA500-6R
WA500-6R 5
Table of failure modes and causes 1
Clogging of torque converter charging pump strainer

Part that can cause failure
Clogging or air intake on torque converter charging
Drop of transmission main relief valve set pressure

Defective operation of torque converter relief valve
Clogged or broken torque converter oil cooler
Defective torque converter charging pump
Internal breakage of torque converter
Defective regulator valve
The PTO is defective
pump suction side

Defective engine
Failure mode
Machine does not start Q Q Q Q Q Q Q

Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]
Power train
Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] Q
Travel speed is slow, thrusting force is weal, uphill traveling power is weak, and gear is not shifted Q Q Q Q Q Q Q Q Q
Shocks are large at the times of starting and shifting gear Q Q Q Q
Time lag is large at the times of starting and shifting gear Q Q Q Q
Torque converter oil temperature is high Q Q Q Q Q Q Q
Steering does not turn Q
Steering does not turn [Machine with joystick steering (if equipped)] Q
Steering response is low Q
Steering
Turning response of steering is poor [machine with joystick steering (if equipped)] Q
Steering is heavy
When machine turns, it shakes or makes large shocks
When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]
Wheel brake does not work or does not work well Q
Wheel brake is not released or it drags
Brake
Parking brake does not work or does not work well

Parking brake is not released or it drags (including emergency release system)
Lift arm does not rise Q
Lift arm speed is low or rising force of lift arm is insufficient
When rising, lift arm comes to move slowly at specific height
Lift arm cylinder cannot hold down bucket (Bucket floats)
Hydraulic drifts of lift arm occur often
Lift arm wobbles during operation
Work equipment
Bucket does not tilt back Q

Bucket speed is low or tilting back force is insufficient
Bucket comes to operate slowly in midst of tilting-back
Bucket cylinder cannot hold down bucket
Hydraulic drifts of the bucket occur often
The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD“)
Engine speed lowers remarkably or engine stalls during work equipment control Q
Large shocks are made when work equipment starts and stops
When work equipment circuit is relieved singly, other work equipment moves
ECSS does not operate, and pitching and bouncing occurs
6 WA500-6R
Clogging of last chance filter
Q Q
Q Q
Q Q
Q
Q Q
Defective operation of relevant ECMV
Q Q Q
Defect of transmission controller system
Q
Q
Internal breakage of transmission
WA500-6R
Q Q
Q
Q Q
Wear or seizure of relevant clutch disc
Defective clutch piston
The relevant clutch piston seal is defective
40 Troubleshooting
Q Q
Q Q Q
Q Q
Q Q
Defective seal of relevant clutch shaft
Q
Q Q Q
Clogging of transmission breather
Q
Q
Defective transmission oil temperature sensor
Q
Defective transmission output shaft speed sensor
Defective seal of work equipment and steering
Q
Q
system hydraulic pump shaft
Clogging or air intake on steering pump suction side
Q Q
Q Q
Defective steering pump
Q Q
Defective steering pump servo
Defective Orbit-roll
Q Q
Defective steering stop valve
Defective steering main relief valve
Defective demand spool
Q
Defective steering spool of steering valve
Defective safety-suction valve
Q Q Q Q Q
Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q
Defective seal of steering cylinder piston
Clogging of joystick steering solenoid valve line filter
Defective joystick steering solenoid valve
Q Q
Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q
Defective actuation of rotary valve
Q
Defective steering wheel or steering shaft
Defective seal of brake piston
Q
Defective operation of brake piston
Internal breakage of wheel brake
Q Q Q Q
Wear of wheel brake disc
Q
Seized wheel brake disc plate
Q
Q
Q
Defective brake pump

Q Q
Q Q
Q Q
Q Q
Clogging or air intake on brake pump suction side

Air in wheel brake circuit
Q
Q Q Q Q
Defective brake valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
7
SEN02945-00
Defective operation of check valve (between last chance

Part that can cause failure
Gas leakage from accumulator, defective seal of piston

Defective operation of wheel brake emergency switch
Defective operation of parking brake solenoid valve

Defective parking brake emergency release valve
Defective operation of parking brake piston

Defective accumulator charge valve
filter and parking brake solenoid)
Defective parking brake spring

Defective slack adjuster
Defective axle oil
Failure mode
Machine does not start Q Q Q

Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]
Power train
Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]
Travel speed is slow, thrusting force is weal, uphill traveling power is weak, and gear is not shifted
Shocks are large at the times of starting and shifting gear
Time lag is large at the times of starting and shifting gear
Torque converter oil temperature is high
Steering does not turn Q
Steering does not turn [Machine with joystick steering (if equipped)] Q
Steering response is low Q
Steering
Turning response of steering is poor [machine with joystick steering (if equipped)] Q
Steering is heavy Q
When machine turns, it shakes or makes large shocks Q
When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)] Q
Wheel brake does not work or does not work well Q Q Q Q
Wheel brake is not released or it drags Q
Brake
Parking brake does not work or does not work well Q Q Q Q

Parking brake is not released or it drags (including emergency release system) Q Q Q
Lift arm does not rise
Lift arm speed is low or rising force of lift arm is insufficient
When rising, lift arm comes to move slowly at specific height
Lift arm cylinder cannot hold down bucket (Bucket floats)
Hydraulic drifts of lift arm occur often
Lift arm wobbles during operation
Work equipment
Bucket does not tilt back

Bucket speed is low or tilting back force is insufficient
Bucket comes to operate slowly in midst of tilting-back
Bucket cylinder cannot hold down bucket
Hydraulic drifts of bucket occur often
Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD“)
Engine speed lowers remarkably or engine stalls during work equipment control
Large shocks are made when work equipment starts and stops
When work equipment circuit is relieved singly, other work equipment moves
ECSS does not operate, and pitching and bouncing occur Q
8 WA500-6R
Q
Q
Q
Q
The parking brake piston seal is defective
Q
Wear of parking brake disc
Q
Seizure of parking brake disc and plate
Defective harness of parking brake switch line
WA500-6R
Clogging or air intake on work equipment pump
Q
Q
Q
Q
Q
Q
Q
Q
Q
suction side
Q
Defective work equipment controller
40 Troubleshooting
Defective work equipment pump
Q Q
Defective work equipment pump servo
Q
Q
Defective work equipment valve body
Defective work equipment main relief valve
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Defective work equipment unload valve
Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Defective lift arm spool of work equipment valve
Q Q
Q Q
Q
Q
Q
Q
Q
Defective bucket spool of work equipment valve
Defective lift arm load check valve of work
Q
Q
Q
Q
Q
Q
equipment valve
Defective safety-suction valve on bucket head side
Q
Q
of work equipment valve
Defective safety-suction valve on bucket bottom side
Q
Q
Q
Q
Q
of work equipment valve
Q
Q
Q
Defective lift arm cylinder
Q
Defective bucket cylinder
Q
Q
Q
Q
Q
Defective seal of lift arm cylinder piston
Q
Q
Q
Q
Q
Q
Defective seal of bucket cylinder piston
Q
Defective stroke of lift arm EPC lever
Q
Defective stroke of bucket EPC lever
Defect in electrical system of lift arm or bucket EPC
Q
lever
Clearance error of pin or bush of working equipment
Q
linkage
Q
Defective ECSS solenoid valve
Q
Q
Q
Q
Q
Q
Q
Defective ECSS charge valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
9
SEN02945-00
H-1 Machine does not start 1

Ask the operator about the following: Cause
q Has the machine come not to start sud-
Parking brake emergency

denly?
Torque converter
Torque converter
Main relief valve

charging pump
Parking brake
o Seizure of clutch, breakage of parts
Transmission
release valve
Check valve
ECMV
Did the machine cause any abnormal noise
at the time and where?
Checks before troubleshooting

q Does the machine monitor function nor-
mally? a b c d e f g h i j k l m n o p q
(between last chance filter and parking brake solenoid)

q Has the machine monitor displayed any fail-
Defective operation of parking brake solenoid valve

ure code of the electrical system?

q Are the transmission oil level and the oil type
Defective operation of spool of parking brake

appropriate?

The relevant clutch shaft seal is defective
q Did you smell deteriorated or burnt transmis-

sion oil?
Set pressure drop of main relief valve

Clogging or air intake on suction side
Defective operation of check valve

q Have the transmission filter and strainer
Wear or seizure of relevant clutch

been clogged? The charging pump is defective

q Can you find any damage or oil leak from
emergency release valve

the appearance?
q Has the drive shaft been broken?

Clogging of strainer
q Have the wheel brake and the parking brake

been locked?
Remedy E E E E E E E E E
No.
Diagnosis x C x
x
x x x
x * x
* * x
x x
x x
1 The machine does not start at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q

2 The machine does not start at specific gear speeds Q Q Q Q Q
When the transmission oil temperature is low, the charg-
3 ing pump or the transmission filter causes any abnormal Q Q
noise (s)
When the transmission oil temperature rises, the machine
4 Q Q Q Q
comes not to start
Metal (Aluminum, copper, iron, etc.) powders are adhered
5 Q Q Q
to the transmission filter or the strainer
The speed is higher at all gear
6 When the stall speed of Q Q Q Q Q Q Q Q
speeds
the torque converter is
The speed is higher at specific
7 measured Q Q Q Q Q
gear speeds
The oil pressure is low at all
8 Q Q Q Q Q Q Q
gear speeds
When the ECMV output The oil pressure is low at spe-
9 Q Q Q Q
(Clutch) oil pressure is cific gear speeds
measured
The oil pressure does not
10 become stable as the gauge Q Q
fluctuates
When the torque converter relief (Inlet) oil pressure is
11 Q Q Q Q Q Q
measured, the oil pressure is low.
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
10 WA500-6R
* Defective clutch and ECMV specifying method

(Check by failure code)
a For the checking method of failure code display, see the
paragraph of “Special functions of machine monitor.”
a When replacing the ECMV for diagnosis, remove mud and
dust around the ECMV completely and clean it, and then
tighten the mounting bolt with the specified torque.
Cause
a For the following diagnoses, start the engine and select the
Transmission ECMV
manual mode:
a b c d e f g h i j k l
Clutch
Table of applicable clutches
F R 1st 2nd 3rd 4th
In the automatic mode q
N
Wear or seizure of 2nd clutch disc or wear of piston seal

Q Q Q Q
Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
In the manual mode
Wear or seizure of R clutch disc or wear of piston seal

Wear or seizure of F clutch disc or wear of piston seal
q q
Defective operation of 2nd clutch ECMV (Fill switch)

F1
Defective operation of 3rd clutch ECMV (Fill switch)

Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
a When the gear speed is N in the manual mode, the clutch of

the gear speed (Marked with Q), to which the gear shift lever
is set, is ON.
q Even if the gear shift lever is used when the gear speed is N,
the clutch position cannot be changed.
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA500-6R 11
H-2 Torque converter lockup is not switched off (engine stalls) [Machine
with lockup clutch (if equipped)] 1
Checks before troubleshooting Cause
q Is the oil level of transmission case appropriate? a b
Defective operation of lockup clutch ECMV
Wear or seizure of lockup clutch disc

Remedy
No. x x
Diagnosis
1 Lockup oil pressure does not drop to 0 Q
2 Lockup cannot be turned off even when the lockup oil pressure is 0 Q
12 WA500-6R
H-3 Torque converter lockup is not switched ON [Machine with lockup

clutch (if equipped)] 1
Ask the operator about the following:
q Has the lockup come not to turn on suddenly? Cause
o Seizure or breakage inside torque converter a b c d e f g
q Did any abnormal noise occur at the time? o Breakage of parts
Drop of transmission main relief valve set pressure

q Is the oil level of transmission case appropriate?
Defective operation of lockup clutch ECMV

q Is there any external oil leakage?
Defective seal of lockup clutch piston

Wear or seizure of lockup clutch disc
Defective seal of lockup clutch shaft

Check of abnormality
q Main relief oil pressure

Crack on lockup clutch case
q Lockup oil pressure
q Travel speed
Remedy
E
No. Diagnosis Transmission x x x x C x
x
controller self-diagnosis code
1 Main relief oil pressure is low Q
2 Main relief oil pressure is normal, but lockup oil pressure is low or 0 Q Q Q Q Q
3 Main relief oil pressure and oil pressure is normal, but lockup oil pressure is low or 0 Q
4 Time to lockup actuation takes long 15SJLH Q
WA500-6R 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power
is weak, and gear is not shifted 1
q Has the abnormality occurred suddenly?
Torque converter
Torque converter
Torque converter
Main relief valve

Regulator valve
charging pump
o Breakage of related equipment
Parking brake
Transmission
oil cooler
Others
ECMV
Did any abnormal noise occur at the time and
where?
q Have any abnormal signs come to occur gradually?
o Wear of related equipment, defective seal
a b c d e f g h i j k l m n o p q r s
q Execute digging and measure traveling speeds on
a level ground and on a slope to check whether the
Defective seal of work equipment and steering system hydraulic pump

abnormality actually occurs or is a matter of opera-
tor's sense
Breakage of oil cooler and piping (After torque converter outlet)

Clogging of oil cooler and piping (After torque converter outlet)
q Is any failure code of the electrical system dis-
played on the machine monitor?
q Are the transmission oil level and the oil type
shaft (Mixing of hydraulic oil in transmission case)

appropriate?
q Haven't the transmission filter and strainer been
Clogging or air intake on pump suction side
clogged?
Defective seal of relevant clutch piston

q Is any external oil leak found on the mating faces of
Defective seal of parking brake piston

Drop of main relief valve set pressure
Defective operation of regulator valve

pipings and valves around the torque converter and

the transmission?
The charging pump is defective
Oil leak inside torque converter

q Isn't the wheel brake or the parking brake being

dragged?
q Are the tire air pressure and the tread shape appro-
Clogging of breather
priate?
Note Engine degradation

q Is the operating method correct?
NOTE: When the inspection result was “Engine degra-
dation,” proceed to Troubleshooting of engine
(S-mode).
Remedy C E E E E E E E E C E
No. x x x * * x x
Diagnosis x x x x x x x x x x x
1 Any abnormality occurs at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Any abnormality occurs at specific gear speeds Q Q Q Q
When the transmission oil temperature is low, the charging
3 Q Q
pump or the transmission filter causes any abnormal noise
4 The torque converter oil temperature is heated abnormally high Q Q Q Q Q Q Q Q Q Q Q Q
5 The transmission oil level rises and falls Q Q Q Q Q Q
Metal (Aluminum, copper, iron, etc.) powders are adhered to the
6 Q Q Q
transmission filter or the strainer
The engine low idle and high idle speeds are measured to be
7 Q Q Q
abnormal
8 When the stall speed of the The speed is high Q Q Q Q Q Q Q Q Q Q
9 torque converter is measured The speed is low Q
The oil pressure drops as the
10 Q Q Q Q
oil temperature rises
The oil pressure is low at all
11 Q Q Q Q Q Q Q Q Q
gear speeds
When the ECMV output (Clutch)
The oil pressure is low at spe-
12 oil pressure is measured Q Q Q Q
cific gear speeds
The oil pressure does not
13 become stable as the gauge Q Q
fluctuates
When the torque converter relief (Inlet) oil pressure is mea-
14 Q Q Q
sured, the oil pressure is low. (No. 11 - 13 are normal.)
When the oil pressure at the torque converter outlet is mea-
15 Q
sured, the oil pressure is low. (No. 14 is normal.)
14 WA500-6R

dust around the ECMV completely and clean it, and then Cause
tighten the mounting bolt with the specified torque. Transmission ECMV
a For the following diagnoses, start the engine and select the a b c d e f g h i j k l
manual mode:
Clutch
F R 1st 2nd 3rd 4th
N

Q Q Q Q

In the manual mode

q q

F1

F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
Diagnosis code
1
2
ECMV
clutch ECMV
ECMV
ECMV
WA500-6R 15
H-5 Shocks are large at the times of starting and shifting gear 1
q Did shocks become large suddenly?
Torque converter
Main relief valve

charging pump
Parking brake
Transmission
Sensor
ECMV
Did any abnormal noise occur at the time and where?
q Did shocks become large gradually?
Checks before troubleshooting a b c d e f g h i j k l

q Did any of the following abnormal phenomena occur at the same
Defective return (Release) of relevant clutch piston

time: The traveling speed is slow, the braking is weak, the uphill
travelling power is weak, the gear is not shifted. o Execute H-4


Defective operation of relevant ECMV a
Defect of transmission controller system
Defective operation of main relief valve

q Is any failure code of the electrical system displayed on the
machine monitor?

q Are the transmission oil level and the oil type appropriate?

q Haven't the transmission filter and strainer been clogged?
q Is any external oil leak found on the mating faces of pipings and
valves around the torque converter and the transmission?
q Isn't the engine speed high at the time of low idle?
q Isn't play of each drive shaft large?
Remedy C E E
No.
Diagnosis x x
x
x
x * ** * * x x **
1 Shocks are large at all gear speeds Q Q Q Q Q Q Q Q
2 Shocks are large at specific gear speeds Q Q Q Q Q Q
3 When the ECMV output The oil pressure is low at all gear speeds Q Q Q Q Q Q
4 (Clutch) oil pressure is The oil pressure is low at specific gear speeds Q Q Q
5 measured The oil pressure is high at all gear speeds Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
*: Proceed to the paragraph of "Defective clutch and ECMV specifying method (Check by failure code)."
**: See "Troubleshooting by failure code (Display of code)."
16 WA500-6R

manual mode:
Clutch
F R 1st 2nd 3rd 4th
N

Q Q Q Q

In the manual mode

q q

F1

F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
Diagnosis code
1
2
ECMV
clutch ECMV
ECMV
ECMV
WA500-6R 17
H-6 Time lag is large at the times of starting and shifting gear 1
q Did the time lag become large suddenly?
Torque converter
Main relief valve

charging pump
Parking brake
Transmission
Sensor
ECMV
q Has the time lag become large gradually?
Check of abnormality a b c d e f g h i j
q Did any of the following abnormal phenomena occur at the same time:

The traveling speed is slow, the braking is weak, the uphill travelling

power is weak, the gear is not shifted. o Execute H-4

Defective operation of relevant ECMV a

q Is any failure code of the electrical system displayed on the machine

monitor?

q Are the transmission oil level and the oil type appropriate?
q Haven't the transmission filter and strainer been clogged?
q Is any external oil leak found on the mating faces of pipings and valves
around the torque converter and the transmission?
Remedy C E E
No. x x
Diagnosis x x x * * x x **
1 Time lag is large at all gear speeds Q Q Q Q Q Q Q
2 Time lag is large at specific gear speeds Q Q Q Q
When the transmission oil temperature is low, any abnormal noise occurs from the
3 Q Q
charging pump or the transmission filter
4 The torque converter oil temperature is heated abnormally high Q Q Q Q
5 When the ECMV output (Clutch) The oil pressure is low at all gear speeds Q Q Q Q Q
6 oil pressure is measured The oil pressure is low at specific gear speeds Q Q Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
**: See Troubleshooting by failure code (Display of code)
18 WA500-6R

manual mode:
Clutch
F R 1st 2nd 3rd 4th
N

Q Q Q Q

In the manual mode

q q

F1

F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
Diagnosis code
1
2
ECMV
clutch ECMV
ECMV
ECMV
WA500-6R 19
H-7 Torque converter oil temperature is high 1

q Does the oil temperature rise when the torque converter
Torque converter
Torque converter
Torque converter
Main relief valve

charging pump
Transmission
stalls and does the temperature fall at the time of no
oil cooler
Others
load? o Selection of improper gear speed
q Does the oil temperature rise only at the time of lifting?
o Improvement of operating method
a b c d e f g h i j k l
Defective seal of work equipment and steering

q Measure the torque converter oil temperature to find if
(Mixing of hydraulic oil in transmission case)

the oil temperature is really high.
o The torque converter oil temperature gauge is defective


Breakage of oil cooler and piping

Clogging of oil cooler and piping
Oil leak inside torque converter

q Are the coolant level in the radiator and the belt tension
(After torque converter outlet)
(After torque converter outlet)
system hydraulic pump shaft

appropriate?
q Are the oil level in the transmission and the oil type
appropriate?
Clogging of breather
Note Engine degradation

q Haven't the transmission filter and strainer been
clogged?
NOTE:When the inspection result was “Engine degradation,”
proceed to Troubleshooting of engine (S-mode).
Remedy C E E EEEE C E
No. x x
Diagnosis x x x x x x x x x
When the transmission oil temperature is low, the charging
1 Q Q
pump or the transmission filter causes any abnormal noise
Traveling speed, braking force and uphill travelling power do not
2 Q Q Q Q Q Q Q Q Q Q Q
occur at all gear speeds
Traveling speed, braking force and uphill travelling power do not
3 Q
occur at specific gear speeds
4 The transmission oil level rises and falls Q Q Q
Metal powders (Aluminum, copper, iron, etc.) are adhered to the
5 Q Q Q
transmission filter and the strainer
The engine low idle and high idle speeds are measured to be
6 Q Q Q
abnormal
When the stall speed of the torque converter is measured, the
7 Q Q Q Q Q Q Q Q Q
speed is high
The oil pressure drops as the oil tem-
8 Q
perature rises
The oil pressure is low at all gear
9 When the ECMV output speeds Q Q Q Q Q
(Clutch) oil pressure is
The oil pressure is low at specific gear
10 measured Q
speeds
The oil pressure does not become sta-
11 Q Q
ble as the gauge vibrates
When the torque converter relief (Inlet) oil pressure is mea-
12 Q Q Q
sured, the oil pressure is low. (No. 9 - 11 are normal.)
When the oil pressure at the torque converter outlet is mea-
13 Q
sured, the oil pressure is low. (No. 12 is normal.)
20 WA500-6R
H-8 Steering does not turn 1

Did the problem suddenly start? o Breakage of related equipment
Hydraulic cylinder
q
Hydraulic pump
Steering valve
Charge valve
Did the machine cause any abnormal noise at the time and where?
Stop valve
Orbit-roll
q Is oil level in hydraulic tank correct? Is the type of oil correct?
q Is the steering shaft broken?
q Is the steering stop valve properly adjusted? a b c d e f g h i j k
q Has the lock bar been removed from the frame?
Defect in steering cylinder (defective piston seal)

Defective actuation of demand spool

Defective actuation of steering spool

Defective stop valve

Defective PTO
Remedy E EEEEEEE
No. E x x
Diagnosis x x x x x x x x
1 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q
2 Steering turns only in one direction (left or right) Q Q
3 Steering is heavy when turned in both directions (left and right) Q Q Q Q
4 Steering wheel is heavy in one direction (left or right) Q
5 Work equipment moves Q Q Q Q Q Q Q
6 Work equipment does not move Q Q Q Q
7 Abnormal noise comes from around PTO Q
8 Abnormal noise comes from around hydraulic tank Q Q
Oil pressure is low, or there is no pressure in both
9 Q Q Q Q Q Q Q Q Q
When steering relief directions (left and right)
pressure is measured Oil pressure is low, or there is no pressure in one direc-
10 Q Q
tion (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be low or
11 Q Q Q Q Q
there is no oil pressure
12 When Orbit-roll basic Oil pressure is low Q Q Q Q
13 pressure is measured There is no oil pressure Q Q Q
a There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is left in the steering, check the operation of the work equipment also.
WA500-6R 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)] 1
Hydraulic cylinder
Joystick steering
Hydraulic pump
solenoid valve
Steering valve
Charge valve
Rotary valve

q Is the steering shaft broken? a b c d e f g h i j k l
q Has the lock bar been removed from the frame?

q Are the steering mode switch and steering operations proper?


Clogged line filter

Remedy E EEE C EEE
No. E x x x
1 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q
2 Steering turns only in one direction (left or right) Q
3 Joystick steering is heavy when turned in both directions (left and right) Q Q Q
4 Joystick steering is heavy in one direction (left or right)
5 Work equipment moves Q Q Q Q Q Q Q Q
Oil pressure is low, or there is no pressure in both
When steering relief directions (left and right)
pressure is measured Oil pressure is low, or there is no pressure in one
10 Q
direction (left or right)
When joystick steering solenoid valve output pressure is measured, oil pres-
11 Q Q Q Q Q Q Q
sure is found to be low
12 When Orbit-roll basic Oil pressure is low Q Q Q Q
13 pressure is measured There is no oil pressure Q Q Q
22 WA500-6R
H-10 Steering response is low 1

Hydraulic cylinder
Hydraulic pump
Steering valve
Charge valve
Stop valve
Orbit-roll
Did the machine cause any abnormal noise at the time and
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal
a b c d e f g h i j k l m



Defective main relief valve
Defective steering spool


Remedy E EEEEEEEEE E
No. E x
Turning response of steering wheel is poor in both directions (left and
right)
2 Turning response of steering wheel is poor in one direction (left or right) Q Q
3 Steering wheel is heavy in both directions (left and right) Q Q Q Q
5 Work equipment moves Q Q Q Q Q Q Q Q Q
Oil pressure is low, or there is no pressure in
9 Q Q Q Q Q Q Q Q Q Q
When steering relief both directions (left and right)
pressure is measured Oil pressure is low, or there is no pressure in
10 Q Q
one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be
11 Q Q Q Q Q
low
When Orbit-roll basic pressure is measured, oil pressure is found to be
12 Q Q Q Q
low or there is no pressure
When steering pump servo assembly is replaced, oil pressure is found to
13 Q
be normal
WA500-6R 23
H-11 Turning response of steering is poor [machine with joystick

steering (if equipped)] 1
Hydraulic cylinder
Joystick steering
Steering pump
solenoid valve
Steering valve
Charge valve
Rotary valve
Did the machine cause any abnormal noise at the time and
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal
a b c d e f g h i j k l m n



Defective rotary valve

Clogged line filter

Remedy E EEEE C EEEE E
No. E x x
Turning response of steering wheel is poor in both directions (left and
1 Q Q Q Q Q Q Q Q Q Q Q Q Q
right)
Turning response of steering wheel is poor in one direction (left or
2 Q
right)
3 Steering wheel is heavy in both directions (left and right) Q Q Q
4 Work equipment moves Q Q Q Q Q Q Q Q Q Q
Oil pressure is low, or there is no pressure in
8 Q Q Q Q Q Q Q Q Q Q Q Q
When steering relief both directions (left and right)
pressure is measured Oil pressure is low, or there is no pressure in
9 Q
one direction (left or right)
When joystick steering solenoid valve output pressure is measured, oil
10 Q Q Q Q Q Q Q
pressure is found to be low
When steering pump servo assembly is replaced, oil pressure is found
11 Q
to be normal
24 WA500-6R
H-12 Steering is heavy 1

Check of abnormality Cause
Is the steering difficult to turn? o See H-8 or H-9
Hydraulic pump
Steering valve
Charge valve
Stop valve
Orbit-roll
Others
Measure the operating effort and turning speed, and check the “Standard value table” to
see if they are abnormal.

a b c d e f
q Did the problem suddenly start? o Breakage of related equipment
Defective actuation of steering wheel or steering shaft

q Was there previously any symptom that may lead to heavy steering?

q Is the tire inflation pressure correct?


Remedy E E E E E E
No.
Diagnosis x x x x x x
1 Steering is heavy when turned in both directions (left and right) Q Q Q Q Q
3 Steering is heavy even when joint between steering shaft and Orbit-roll is disconnected Q
Oil pressure is low, or there is no pressure in both directions (left and
4 When steering relief Q Q Q Q
right)
pressure is measured
5 Oil pressure is low, or there is no pressure in one direction (left or right) Q
6 When Orbit-roll output pressure is measured, oil pressure is found to be low Q Q Q Q
7 When Orbit-roll basic Oil pressure is low Q Q
8 pressure is measured There is no oil pressure Q
WA500-6R 25
H-13 When machine turns, it shakes or makes large shocks 1

Is the steering difficult to turn? o See H-8
Hydraulic pump
q
Steering valve
Charge valve
Stop valve
q Is there any abnormal noise from around the steering equipment
Orbit-roll
Cylinder
q Is the steering wheel play correct?
q Is there any abnormality in the connection between the steering shaft and
a b c d e f g h i
the Orbit-roll?




Remedy E E E E E E EE
No. E
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in one direction (left or right) Q Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
Machine jerks or there is excessive shock when steering is operated to end of its
4 Q
stroke
5 Work equipment also jerks Q Q
6 When steering relief Oil pressure is unstable in both directions (left and right) Q Q Q Q Q Q Q
7 pressure is measured Oil pressure is unstable in one direction (left or right) Q Q
8 When Orbit-roll output Oil pressure is unstable in both directions (left and right) Q Q Q
9 pressure is measured Oil pressure is unstable in one direction (left or right) Q
10 When Orbit-roll basic pressure is measured, oil pressure is found to be unstable Q Q
26 WA500-6R
H-14 When machine turns, it shakes or makes large shocks [machine

with joystick steering (if equipped)] 1
Is the steering difficult to turn? o See H-9
Joystick steering solenoid valve

q
q Is there any abnormal noise from around the steering equipment
Hydraulic pump
Steering valve
Charge valve
Rotary valve
Cylinder
q Has the machine monitor displayed any failure code?
o See Troubleshooting by failure code (Display of code)
q Is the steering play proper?
q Is there any abnormality in the connection between the steering shaft and
the Orbit-roll?
a b c d e f g h i
Defective operation in joystick steering solenoid valve



Remedy E E EEE EE
No. x E
Diagnosis x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in one direction (left or right) Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
4 Work equipment also jerks Q Q
5 When steering relief Oil pressure is unstable in both directions (left and right) Q Q Q Q Q Q Q Q
6 pressure is measured Oil pressure is unstable in one direction (left or right) Q
7 When Orbit-roll output Oil pressure is unstable in both directions (left and right) Q Q Q Q
8 pressure is measured Oil pressure is unstable in one direction (left or right)
9 When Orbit-roll basic pressure is measured, oil pressure is found to be unstable Q Q
WA500-6R 27
H-15 Wheel brake does not work or does not work well 1
Slack adjuster
q Test the effectiveness of the brake referring to “Measuring brake
Charge valve
Wheel brake
Accumulator
Brake pump
Brake valve
performance” in “Testing and adjusting” to check whether the
Others
abnormality actually occurs or is a matter of operator's sense

q Has the brake come not to work suddenly? a b c d e f g h i j k l m
Gas leakage from accumulator, defective seal of piston

q Did any abnormal noise occur at the time and where?
q Has the brake come not to work gradually?

q Is oil level and type of oil in hydraulic tank correct?

q Is the play of brake pedal appropriate?
The brake piston seal is defective

q Isn't the oil leaked from brake piping or tube deformed?
q Are the tire air pressure and the tread state appropriate?
Internal breakage of brake

Air intake on suction side
Defective slack adjuster


Wear of brake disc

Air in brake circuit
Improper axle oil
Remedy E EE EEEEEE
No. E x E x
Diagnosis x x x x x x x x x
1 When the brake pedal is stepped on, only a little resistance is felt Q Q Q Q Q Q Q
2 When the brake pedal is stepped on, a heavy resistance is felt Q
To get the specified braking force, an extremely strong leg-power is
3 Q Q Q Q
required
4 When the brake works, an abnormal noise occurs from the brake Q Q Q
5 Work equipment and steering wheel does not move Q Q
6 Work equipment and steering wheel move slowly Q Q Q
8 Abnormal noise comes from around hydraulic tank or brake pump Q Q
Much metal powders are mixed in the oil when it is drained from the axle
9 Q
case
When the accumulator charge pressure is measured, the oil pressure is
10 Q Q Q
low.
11 The brake does not work immediately when the engine is stopped Q
12 The brake works after some time lag Q Q
13 When brake pressure is measured, the oil pressure is low Q
When brake piston pressure effect is measured, the pressure effect is
14 Q Q
large
15 When wear of brake disc is measured, the amount of wear is large Q Q
16 Air is discharged when the air is bled from the brake system Q
28 WA500-6R
H-16 Wheel brake is not released or it drags 1

Was the brake locked suddenly? o Breakage of related equipment
Slack adjuster
q
Wheel brake
Brake valve

q Has the brake pedal returned completely?
q Isn't the parking brake turned ON? a c d e
Defective operation of slack adjuster

Seizure of brake disc plate
Remedy E E E
No. x
Diagnosis x x x
1 The machine does not travel at all Q
2 The machine travels a little Q Q Q
When residual pressure in the brake accumulator circuit is released using only the brake pedal, the
3 Q
brake is released
4 When air bleeder at wheel is opened, oil leaks out and the brake is released Q
5 When air bleeder is opened, large amount of oil flows out Q
6 When wear of brake disc is measured and the brake pedal is released, the piston returns Q
7 When wear of brake disc is measured and the brake pedal is released, the piston does not return Q Q
WA500-6R 29
H-17 Parking brake does not work or does not work well 1
Has the brake come not to work suddenly? o Breakage of related equipment
Parking brake
q
Solenoid
Valve
q Has the brake come not to work gradually?
Checks before troubleshooting a b c d e

q Isn't the parking brake emergency release switch turned ON?

q Hasn't the mechanical release of parking brake performed?
Defective operation of parking brake piston

Defective parking brake solenoid valve
Defective parking brake spring
Wear of parking brake disc

Remedy E E
No. x x x
Diagnosis x x
1 The parking brake is not applied even if the engine stops Q Q Q
2 When wear of parking brake disc is checked, the disc thickness is lower than standard value Q
With the parking brake switch ON, there is no oil pressure
3 When the parking brake inlet Q Q
(Normal)
pressure is measured
4 With the parking brake switch ON, there is a oil pressure Q Q Q
With the parking brake switch ON, there is no oil pressure
5 When the parking brake solenoid (Normal) Q Q
valve output pressure is measured
6 With the parking brake switch ON, there is a oil pressure Q
30 WA500-6R
H-18 Parking brake is not released or it drags (including emergency

release system) 1
Parking brake
q Is there any abnormality in the power train system?
o See H-1, H-4, H-5 and H-6 (Power train hydraulic system)
Solenoid
Wheel
Valve
a b c d e
Defective operation of wheel brake emergency brake switch

Seizure of parking brake disc and plate

Defective parking brake solenoid valve
Defective seal of parking brake piston

Remedy EE
No. x x
Diagnosis x x
The parking brake is released when the emergency release switch is turned ON
1 Q Q
(The parking brake switch does not release the brake)
The parking brake is released, when “Method of releasing parking brake manually” is executed
2 Q Q Q
(The parking brake switch and emergency release switch does not release the brake)
3 When the parking brake inlet pressure is measured Oil pressure is normal Q Q
4 (While operating the parking switch) Oil pressure is low Q Q
5 When the parking brake output pressure is measured Oil pressure is normal Q Q
6 (While operating the emergency release switch) Oil pressure is low Q Q
7 When the parking brake solenoid valve output pressure is measured, the oil pressure is low Q
When the wheel brake piping oil pressure is measured, the oil pressure is lower than the emer-
8 Q
gency brake working pressure (3.6 ± 0.49 MPa {37 ± 5 kg/cm2})
a If any abnormality is left in releasing of the parking brake, check the operation of the power train also,
because the power train main relief pressure is used as the parking brake release pressure. (The
emergency release circuit uses the wheel brake circuit oil pressure.)
WA500-6R 31
H-19 Lift arm does not rise 1

Did the bucket stop suddenly?
equipment pump
q
Work equipment
Bypass valve
Tank – Work
o Seizure or breakage of each component
Cylinder
valve
Did abnormal sound come out when the lift arm stopped?
(From what part)
q Has the speed lowered? o Wear of parts and fatigue of springs
Checks before troubleshooting a b c d e f g h i j

q Is the oil level in the hydraulic tank proper?
Defective operation of lift arm load check valve

Internal breakage of valve body (lift arm spool)
q Is the stroke of the lift arm control lever proper?

q Is the engine speed proper?

Damaged lift arm cylinder piston seal

Defective operation of unload valve

Defective operation of spool

Remedy C E E E E E E
No. x x x
Diagnosis E x x x x x x
1 Bucket does not move and lift arm does not rise Q Q Q Q Q
2 Lift arm can raise chassis but does not rise Q Q
3 Bucket moves but lift arm does not rise Q Q
4 Lift arm can rise when not loaded but cannot when loaded Q Q Q Q Q
5 Work equipment pump is making abnormal sound Q Q
6 Hydraulic drifts of the lift arm cylinder occur often Q Q Q Q
7 When lift arm and bucket are operated simultaneously, lift arm does not rise Q
When work equipment pump and servo assembly are replaced, lift arm moves nor-
8 Q
mally
32 WA500-6R
H-20 Lift arm speed is low or rising force of lift arm is insufficient 1
Is the stroke of the lift arm control lever proper?
equipment pump
q
Work equipment
Tank – Work
Cylinder
valve
q The troubles of the rising force and rising speed are strongly related to each
other. The rising speed lowers first. Measure the lift arm rising speed while it
is loaded and check abnormality with the “Standard value table.” a b c d e f g h i
Defective operation and defective adjustment of main relief valve
Internal wear or breakage of valve body (lift arm spool)

Defective operation of lift arm load check valve
Defective operation of ECSS charge valve

Damaged lift arm cylinder piston seal

A C
Remedy C E E EE
No. E E x x
Diagnosis E x x x x
x x
1 Tilting force and speed of bucket are abnormal and rising speed of lift arm is low Q Q Q Q Q Q
2 Tilting force and speed of bucket are normal and rising speed of lift arm is low Q Q Q
3 After oil temperature rises, rising speed lowers more in step 1. Q
5 Hydraulic drift of the cylinder is large Q Q Q
6 Relief oil pressure of relief valve of work equipment valve is low Q Q Q Q Q
When work equipment pump and servo assembly are replaced, lift arm moves nor-
7 Q
mally
WA500-6R 33
H-21 When rising, lift arm comes to move slowly at specific height 1
q Deformation of lift arm cylinder in appearance
Cause
q Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see “H-20 Lift arm speed is low or rising force of lift
arm is insufficient“
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats) 1
See “H-20 Lift arm speed is low or rising force of lift arm is insufficient.”

q Is the stroke of the lift arm control lever appropriate?
Cause
q Defective seat of suction valve on the lift arm cylinder head side of work equipment valve
q Oil leak from lift arm cylinder piston seal
H-23 Hydraulic drifts of lift arm occur often 1

q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts
q Is the lift arm spool at the neutral holding position? o The spool detent is defective
q Check the hydraulic drift of the lift arm with the “Standard values table.”
Cause
q Oil leakage in lift arm cylinder
q Imperfect fitting of load check valve on bottom side
q Imperfect fitting of lift arm spool
H-24 Lift arm wobbles during operation 1

The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm
control lever in the HOLD position.
Diagnosis and Cause
Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see “H-23 Hydraulic drifts of the lift arm occur
often.”
2. If the lift arm cylinder can lift the machine, see “H-20 Lift arm speed is low or rising force of lift arm is
insufficient.”
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times
with the normal hydraulic drift and after the lift arm cylinder operates to full stroke
o The cause is vacuum generated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder head side is defective
34 WA500-6R
H-25 Bucket does not tilt back 1

Did the bucket stop suddenly?
equipment pump
q
Work equipment
Tank – Work
o Seizure or breakage of each component
Cylinder
valve
Did abnormal sound come out when the bucket stopped?
(From what part)
q Has the speed lowered? o Wear of parts and fatigue of springs
Checks before troubleshooting a b c d e f g h i j

q Is the oil level in the hydraulic tank proper?
Defective operation of bucket bottom suction valve (Suction safety valve)

Defective operation of bucket bottom safety valve (Suction safety valve)
q Is the stroke of the bucket control lever proper?
o See Troubleshooting by failure code (Display of code).
Internal breakage of valve body (bucket spool)


Damaged bucket cylinder piston seal

C
Remedy C E E E E E E
No. E x x
Diagnosis E x x x x x x
x
1 Lift arm does not move and bucket does not tilt back Q Q Q Q Q
2 Bucket can raise chassis but does not tilt back Q Q
3 Lift arm moves but bucket does not tilt back Q Q
4 Bucket can tilt back when not loaded but cannot when used for digging or scooping Q Q Q Q Q Q
6 Hydraulic drift of bucket cylinder is large Q Q Q Q
7 When lift arm and bucket are operated simultaneously, bucket does not tilt back Q
When work equipment pump and servo assembly are replaced, bucket moves nor-
8 Q
mally
WA500-6R 35
H-26 Bucket speed is low or tilting back force is insufficient 1

Is the stroke of the bucket control lever proper?
equipment pump
q
Work equipment
Tank – Work
Cylinder
valve
q Check by actual operation that the tilting back force is insufficient.
q Measure the operating speed of the bucket and check it with the “Stan-
dard value table.” a b c e f g h i j k
Defective operation of bucket bottom suction valve (Suction safety valve)

Defective operation of bucket bottom safety valve (Suction safety valve)
Defective operation and defective adjustment of main relief valve
Internal wear or breakage of valve body (bucket spool)

Defective operation of ECSS charge valve

Damaged bucket cylinder piston seal

A C
Remedy C E E EEE
No. E E x x
Diagnosis E x x x x x
x x
Rising force and speed of lift arm are abnormal and tilting back force and speed of
1 Q Q Q Q Q Q
bucket are low
Rising force and speed of lift arm are normal and tilting back force and speed of
2 Q Q Q Q
bucket are low
3 After oil temperature rises, tilting back speed lowers more in step 1. Q
5 Hydraulic drift of the cylinder is large Q Q Q Q
6 Relief oil pressure of relief valve of work equipment valve is low Q Q Q Q Q Q Q
When work equipment pump and servo assembly are replaced, bucket moves nor-
7 Q
mally
36 WA500-6R
H-27 Bucket comes to operate slowly in the midst of tilting-back 1

q Deformation of bucket cylinder in appearance
Cause
q Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see “H-26 Bucket speed is low or tilt-back
force is insufficient.”
H-28 Bucket cylinder cannot hold down the bucket 1

See “H-26. Bucket speed is low or tilting back force is insufficient.”
q Is the stroke of the bucket control lever appropriate?
Cause
q Defective seat of safety valve (with suction valve) on the bucket cylinder head side of work equipment
valve
q Oil leak from bucket cylinder piston seal
H-29 Hydraulic drifts of bucket occur often 1

q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts
q Is the bucket spool at the neutral holding position? o The spool detent is defective
q Refer to the “Standard value table” and check if the hydraulic drift of the bucket occurs often practically
Cause
q Oil leak in bucket cylinder
q Improper adhesion of safety valve (With suction valve) on the bottom side
q Improper oil tight of bucket spool
H-30 Bucket wobbles during travel with cargo (Work equipment valve is
set to “HOLD”) 1
Cause
q Defective seal of bucket cylinder piston
q Defective operation of safety valve (With suction valve) on bucket cylinder head side. For other abnor-
mal phenomena, refer to diagnoses for relevant abnormal phenomena.
WA500-6R 37
H-31 During operation of machine, engine speed lowers remarkably or

engine stalls 1
Is the working equipment main relief pressure normal?
Cause
q Defective work equipment pump servo
q Defective working equipment pump unit
q Defective working equipment pump servo EPC input voltage
q Defective engine system
H-32 Large shocks are made when work equipment starts and stops 1
Cause
q Defective operation of control valve spool
q Defective working equipment electric lever system
H-33 When work equipment circuit is relieved singly, other work

equipment moves 1
Cause
q Pressure is not released properly from main spool of moving equipment o Replace main spool
38 WA500-6R
H-34 ECSS does not operate, and pitching and bouncing occur 1
Did pitching and bouncing occur suddenly? o Breakage of related equipment
Solenoid valve
q
Accumulator
Controller
Sensor
q Has pitching and bouncing occurred gradually? o Wear of related equipment, defective seal

q Is the state of ECSS switch proper? a b c d
Defective transmission output shaft speed sensor

Defective operation of work equipment controller
Gas leakage from accumulator, defective seal
Defective ECSS solenoid valve
Remedy A
No. x x x
Diagnosis x
1 The ECSS actuation speed (5 km/h) largely fluctuates Q Q
2 The ECSS does not operate under no load Q Q
3 When the ECSS operates under load, the lift arm lowers to the maximum distance (30 cm or more) Q
4 The ECSS does not operate at all Q Q Q Q
WA500-6R 39
SEN02945-00

© 2007 KOMATSU
All Rights Reserved
40
SEN02946-02
WA500-6R

WA500-6R 60001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Engine does not start easily...................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operation.................................................................................................................11
S-5 Engine does not rotate smoothly (Engine hunts.)................................................................................... 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (Incomplete combustion) ................................................................................. 14
S-8 Oil is consumed much (or exhaust gas color is blue)............................................................................. 15
S-9 Engine oil becomes contaminated quickly ............................................................................................. 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Coolant contains oil (blows back or reduces) ....................................................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Water, fuel in oil) ........................................................................................................... 20
S-14 Coolant temperature rises too high (Overheating) ............................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
WA500-6R 1
S-16 Vibration is excessive ........................................................................................................................... 23

S-17 Air cannot be bled from fuel circuit ....................................................................................................... 24
2 WA500-6R
Method of using troubleshooting chart 1

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspection without using
troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
Questions:
Sections A + B in the right corresponds to the items
were answers can be obtained from the user or
operator.
A is the basic content. B is the items that can be
obtained from the user or operator depending on
their level.
Check items:
Simple items checked by the serviceman to deter-
mine the causes. C in the chart to the right corre-
sponds to them.
Causes:
The contents to be determined after asking ques-
tions and checking items.
The serviceman determines causes of high proba-
bility from A, B, and C.
Troubleshooting:
The content for ultimately verifying whether the
determined causes are truly the defective factors
by using troubleshooting tools or making direct
checking starting with probable causes of higher
order.
This troubleshooting chart marks the content of the
questions and check items with E, Q or w accord-
ing to their closer relationship with the causes.
E : A cause that can be referred to in relation to

the question or check item.
Q : A cause that is related the question or check
item.
w : A cause particularly probable among those
marked with Q above.
a Count the priority level of each marking as w > Q
when determining the cause.
Don't count E when determining the cause.
The item with this marking may be counted,
however, if no difference is present than this
and the cause cannot be determined.
WA500-6R 3
<Example of troubleshooting> Exhaust smoke is black

Let us assume that the questions and item check were conducted when a defect of black exhaust gas is
detected. Now suppose that three symptoms have causal relationship with this problem: namely, [Exhaust
gas gradually became black], [Power was lost gradually], and [Dust indicator turned red].
4 WA500-6R
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes.
Procedure for determining the causes from these relationship and leading to the troubleshooting will be
explained in step 1 to 3 in the following diagram.
WA500-6R 5
S-1 Engine does not start easily. 1

General causes for poor startability include the following Cause
q Electrical system is not normal
Clogged air breather hole in fuel tank cap

Defective contact of valve or valve seat
q Insufficient supply of fuel
Stuck or seized supply pump plunger

Leakage, clogging, air in fuel piping
q Insufficient intake of air
Defective intake air heater system

Clogged of feed pump gauze filter
Defective or deteriorated battery

Defective alternator (generator)
q Improper selection of fuel
Defective alternator (regulator)

Clogged air cleaner element
a Common rail type fuel injection system (CRI) recog-
Wear of piston ring, cylinder
Clogged fuel filter, element

nizes the fuel injection timing electrically. Therefore,
there are cases where the engine does not start
Defective injector
before the crankshaft makes two revolutions maxi-
mum after starting operation. This is not an abnormal
state, however.
Check recent repair history

Degree of machine
Machine operated for long period E E E E
operation
Gradually became worse Q w w Q Q
Ease of starting
Starts when warm w w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters has not been carried out according to Operation & Maintenance
w w w Q Q
Manual
Engine oil replenishment increasing w
Preheat monitor dose not indicate normal operation during preheating or at low tem-
w
perature (With monitor installed)
Charge level monitor indicates abnormal charging during operation (with monitor
w w
installed)
Dust indicator is red (with indicator installed) w
Clogged air breather hole in fuel tank cap w
Leakage from fuel piping w Q
No response or heavy resistance felt when operating priming pump w Q Q
Starting motor cranks engine slowly w
and air breathing plug is removed from fuel filter, fuel fails to
When engine is cranked discharge w w
with starting motor,
w
Check items
When spill hose is separated from injector, spill flow drops

When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low
Engine does not pick up smoothly, and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, the oil pressure is low q q
Air is discharged when air is bled from fuel system q
Troubleshooting
Inspect fuel filter, strainer directly q

Inspect fuel feed pump gauze filter directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q
Speed of some cylinders does not change when operated in reduced cylinder mode q
Intake air heater mount does not warm up during preheating operation q
Is voltage 26 – 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? None q
Specific gravity of electrolyte and voltage of battery are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
6 WA500-6R
S-2 Engine does not start 1

a) Engine does not crank Cause
Defective starting motor (Safety relay section)

General causes why engine does not turn
Defective starting motor (Motor section)

q Seizure inside engine
Defective battery terminal connection

o See the troubleshooting for “S-4 Engine stops during opera-
Defective wiring of starting circuit

tions”.

q Coolant mixing inside cylinder causing water hammer
Damaged flywheel ring gear

q Electrical system is not normal
Defective starting switch

q Defective drive unit on applicable machine side
Defective battery relay

o Carry out troubleshooting on applicable machine side

Questions
Degree of machine
Machine operated for long period EE
operation
Condition of horn when Does not sound. Q Q w
starting switch is turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
No operating sound from battery relay when starting switch is turned ON Q w
When starting switch is turned to START, pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is set Makes grating noise w w
to START, the starting pin-
ion comes out, but Soon disengages pinion again w
Makes rattling noise and does not turn Q Q w
Inspect flywheel ring gear directly q
Carry out troubleshooting on

applicable machine side

Troubleshooting
There is no voltage (20 – 30 V) between battery relay

q
terminal B and terminal E
Turn the starting switch When terminal B and terminal C of starting switch are
q
OFF, connect the cord, then connected, engine starts
turn starting switch ON and When the safety relay outlet terminal B and terminal C
carry out troubleshooting q
are connected, engine starts
When the safety relay outlet terminal B and terminal C
q
are connected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
WA500-6R 7
b) Engine turns but no exhaust smoke comes out Cause
Defective operation of overflow valve (not closing)

General causes why engine turns but no exhaust smoke
comes out

q Fuel is not being supplied
Seizure or abnormal wear of feed pump
Wrong connection of supply pump PCV

q Supply of fuel extremely small

Defective operation of flow damper

q Improper selection of fuel (particularly in winter)
Clogged feed pump gauze filter
Broken supply pump shaft, key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Improper fuel used
Degree of machine
Questions
Machine operated for long period EEE

operation
Exhaust smoke suddenly stops coming out (when starting again) w Q w w w EE
Replacement of filters has not been carried out according to Operation
w w E Q
& Maintenance Manual
Fuel tank is found to be empty w
Clogged air breather hole in fuel tank cap Q w
Rust and water are detected when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, no fuel is inside the fuel filter w w
Leakage from fuel piping w
Check items

and the air breathing plug is removed from
Q Q w Q
When engine is cranked the fuel filter, fuel fails to discharge
with starting motor, Spill flow drops, when spill hose is separated
Q w w w w Q
from injector
Air is discharged when the air is bled from the fuel system q
q
Troubleshooting
Inspect the fuel filter directly

Inspect feed pump directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q q q
Carry out troubleshoot by “PCV1 Error (*2) or PCV2 Error (*3)” q
Inspect overflow valve directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Add
Remedy
8 WA500-6R
c) Exhaust smoke comes out but engine does not start Cause
Defective coolant temperature sensor or defective wiring harness

(Fuel is being injected)
General causes why exhaust smoke comes out but engine

does not start
q Rotating force in short due to defective electrical system
Wear of valve system (valve, rocker lever, etc.)

q Supply of fuel small
q Small air intake
Clogged injection nozzle, defective spray


Defective intake air heater system

Worn piston ring, cylinder liner
Clogged fuel filter, strainer

Improper fuel used
Degree of machine
operation
w w Q
Questions
Suddenly failed to start

Non-specified fuel is being used Q Q
w w w
Manual
Preheat monitor not indicating normal operation during preheating or at low temper-
w
ature (when monitor installed)
Dust indicator turned red (with indicator installed) w
Clogged air breather hole in fuel tank cap Q
Rust and water are detected when fuel tank is drained w w
When fuel filter is removed, no fuel is inside the fuel filter w
Starting motor cranks engine slowly w
When engine is cranked, abnormal noise is heard from around cylinder head w
Check items
When engine is and the air breathing plug is removed from the fuel filter, fuel
Q w w
cranked with starting fails to discharge
motor, Spill flow drops, when spill hose is separated from injector w
w

Inspect valve system directly q
When compression pressure is measured, the oil pressure is low q
Troubleshooting
Inspect the fuel filter, strainer directly q
Testing a single unit injector indicates defective spraying q
Coolant temperature gauge indication is not normal (when the gauge is installed) q
Intake air heater mount does not warm up during preheating operation q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WA500-6R 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Cause
Defective operation of flow damper (excessive injector leakage)

q Fuel injection condition not normal
q Controller in derate control mode
(Controlling injection capacity (output) due to an error in

the electrical system)
Clogged injection nozzle, defective spray

Defective contact of valve and valve seat
Seizure or interference of turbocharger



Improper valve clearance
Degree of machine
Machine operated for long period E E E E E
operation
Questions
Engine pick-up suddenly became poor w Q Q Q

Non-specified fuel is being used w w w w
w w w
Manual
Q w
Blue under light load w
Color of exhaust gas
Check items
Black w Q w w
When engine is cranked, abnormal noise is heard from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

q
Troubleshooting
Inspect valve clearance directly

When turbocharger is rotated by hand, it is found to be heavy q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
10 WA500-6R
S-4 Engine stops during operation 1

General causes why engine stops during operations Cause
q Seizure inside engine
Broken auxiliary equipment (pump, compressor, etc.)

Breakage of valve system (valve, rocker lever, etc.)
q Overheating
q Defective drive unit on applicable machine side:

o Carry out troubleshooting on applicable machine
Broken, seized piston or connecting rod

side.
Broken, seized crankshaft metal
Leakage, clogging in fuel piping
Broken supply pump shaft, key

Broken, seized feed pump

Broken, seized gear train
Defective power train

Degree of machine
Machine operated for long period E E
operation
Abnormal noise was heard and engine stopped sud-
w w w w Q w Q w w
denly
Questions
Condition when Engine overheated and stopped w Q Q

engine stopped
Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation &
w w
Maintenance Manual
Fuel level monitor indicates low fuel level (with monitor installed) w
w w Q Q
Check items
Metal particles are found when oil pan is drained

Does not turn at all w w
When engine is Turns in opposite direction w
cranked manually Moves by the amount of gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when loaded on the machine side w

Carry out troubleshooting
Inspect piston and connecting rod directly. q

q
Troubleshooting
Inspect crankshaft metal directly

in the H-mode.
Inspect gear train directly q

Inspect feed pump directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q
Engine rotates when auxiliary equipment (pump, compressor) is removed q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Add
Remedy
WA500-6R 11
S-5 Engine does not rotate smoothly (Engine hunts.) 1

General causes why engine does not rotate smoothly Cause
q Mixing of air in the fuel system
Defective operation of flow damper (excessive injector leakage)

q Rotation sensor is not normal (abnormality where it fails to
make error indication)
Defective Bkup speed sensor or defective wiring harness

Defective Ne speed sensor or defective wiring harness
Clogged fuel injector, defective injection

Low idle speed setting is too low

Degree of machine operation Machine operated for long period EE
Occurs at a certain speed range Q Q Q
Questions
Occurs at low idle w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slope w Q Q
Replacement of filters has not been carried out according to Operation & Main-
w w
tenance Manual
Check items
Rust and water are detected when fuel tank is drained Q Q

Troubleshooting

Carry out troubleshoot by “Eng Ne Speed Sensor Error (*1)” q
Carry out troubleshoot by “Eng Ne Speed Sensor Error (*2)” q
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Add
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA689]

*2: Troubleshooting by failure code (Display of code), Code [CA778]
12 WA500-6R
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Cause
Defective fuel temperature sensor or defective wiring harness

Defective charge pressure sensor or defective wiring harness
Defective mounting of charge pressure sensor (air leak)

q Overheating
Defective drive of injector (signal or solenoid)

o See the troubleshooting for “S-14 Coolant

Defective contact of valve and valve seat
Clogged fuel injector, defective injection

temperature too high (Overheat)”

Leakage, clogging in fuel piping

(Controlling injection capacity (output) due to an
Air leakage from air intake pipe

error in the electrical system)

Confirm recent repair history
Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Replacement of filters not carried out according to Operation & Maintenance
w
Manual
Engine oil must be added more frequently Q Q Q
Output reduces after a break w
Black w w
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Check items
When engine is cranked, interfering noise is heard from around turbocharger w

High idle speed of engine is low Q
High idle speed under no load is normal, but speed suddenly drops when load
w w Q
is applied
Engine does not pick up smoothly, and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q

Inspect intake air piping directly q
When boost pressure is measured, the oil pressure is low q q q
Troubleshooting
Inspect valve clearance directly q

Inspect fuel filter, strainer directly q
Check the mount of boost pressure sensor directly q
Carry out troubleshoot by “Chg Air Press Sensor Error (*2)” q
Carry out troubleshoot by “Fuel Temp Press Sensor Error (*3)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
WA500-6R 13
S-7 Exhaust smoke is black (Incomplete combustion) 1

General causes why exhaust smoke is black Cause

Air leakage between turbocharger and cylinder head
Clogged fuel spill piping (on the cylinder head side)

q Overheating
o See the troubleshooting for “S-14 Coolant
temperature too high (Overheat)”
Defective contact of valve or valve seat


(Controlling injection capacity (output) due to an
error in the electrical system)

Improper injection pressure

Abnormal wear of injector
Crushed, clogged muffler
Improper injection timing

Clogged, seized injector
Degree of machine
operation
Suddenly became black w Q Q
Questions
Color of exhaust gas Gradually became black w Q Q Q

Engine oil must be added more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Leakage of air between turbocharger and cylinder head, loose clamp w
Operated in low-temperature mode during normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine,
Q w
temperature of some cylinders is low
Check items

Torque converter stall or high pump relief speed (excessive fuel injection) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly, and combustion is irregular Q Q Q Q Q w
Spill flow is excessive when spill hose is separated from injector w
q q
Troubleshooting
When compression pressure is measured, the oil pressure is low

When muffler is removed, exhaust color returns to normal q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q
Speed of some cylinders does not change when operated in reduced cyl-
q
inder mode
Inspect fuel spill piping (on the cylinder head side) directly q
Carry out troubleshoot by “Coolant Temp Sensor Error (*2)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
14 WA500-6R
S-8 Oil is consumed much (or exhaust gas color is blue) 1

General causes why oil consumption is excessive Cause
q Abnormal oil combustion
Turbocharger
Worn or damaged valve (stem, guide, and seal)
q Extended operation for long hours in low or high
idle (continuous no load operation for 20 minutes
Leakage from oil pan, cylinder head, etc.

and longer inhibited)
q Oil leakage to outside
Clogged breather or breather hose

Dust sucked in from intake system
Worn, damaged rear seal surface

q Wear of lubricating system
Leakage from oil drain plug

Wear of seal at blower end
Worn seal at turbine end
Leakage from oil cooler
Leakage from oil piping

Leakage from oil filter
Broken piston ring
Broken oil cooler

Degree of machine
Questions
Machine operated for long period EEE E

operation
Oil consumption suddenly increased w Q
Engine oil must be added more frequently w Q
Engine oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
Pipe clamps for intake system are loose w
Inside of turbocharger air intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
There is oil in the coolant w

Oil level in clutch or damper chambers on increasing w
Color of exhaust gas blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is contaminated abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Inspect breather, breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA500-6R 15
S-9 Engine oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Cause
q Entry of exhaust gas due to internal wear
Clogged lubricating drain tube of turbocharger

q Clogging of lubrication route
Defective seal at turbocharger turbine end

q Improper fuel is being used
q Improper oil is being used
q Operated under excessive load
Clogged breather, breather hose

Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is black

Clogged oil cooler
Clogged oil filter
Degree of machine
Machine operated for long period EEE
Questions
operation
Non-specified fuel is being used Q
Oil filter clogging monitor indicates clogging when the oil temperature rises (with the
w Q
monitor installed)
Metal particles are found when oil is drained in oil filter Q Q w
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
w
Check items
Blue under light load

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

q q
Troubleshooting
When compression pressure is measured, the oil pressure is low

q
(See S-7)
Inspect breather, breather hose directly

Inspect oil cooler directly q
Inspect oil filter directly q
There is catching or breakage to the oil filter safety valve spring q
Inspect turbocharger lubricating drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
—
Remedy
16 WA500-6R
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Cause
q Leakage of fuel

q Fuel injection condition (fuel pressure and injection timing) not nor-
mal
q Excessive fuel injection
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Leakage of fuel inside head cover
Defective supply pump plunger

Defective feed pump oil seal
Defective injector operation

Defective injector spray
Questions
Degree of machine operation Machine operated for long period EE E

More than for other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
Fuel leakage to outside w
There is irregular combustion w
Oil increasing of smelling of diesel oil w w
w
Check items
Low idle speed is too high Q

Torque converter stall or hydraulic pump relief speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

q
Troubleshooting
Inspect feed pump oil seal directly

Speed of some cylinders does not change when operated in reduced cylinder mode q
Spill flow is excessive when spill hose is separated from injector q
Carry out troubleshoot by “Coolant Temp Sensor Error (*2)” q
Check by the monitoring function q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
WA500-6R 17
S-11 Coolant contains oil (blows back or reduces) 1

General causes why oil in coolant Cause
q Internal leakage of lubricating system
Hole drilled by damages or pitching of cylinder liner O-ring

q Internal leakage of cooling system
Broken hydraulic oil cooler, power train oil cooler

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Questions
Degree of machine operation Machine operated for long period E E

Suddenly increased Q Q Q
Oil level
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
w w
Check items
Excessive air bubbles inside radiator, coolant spurts back

Hydraulic oil or power train oil is milky w
When hydraulic oil or power train oil is drained, water is discharged w
q
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage

Carry out
Inspect cylinder block, liner directly q q troubleshooting
Inspect cylinder liner directly q on applicable
machine side
Pressure-tightness test of cylinder head shows there is leakage q
Replace
Replace
Replace
Replace
Replace
Remedy
18 WA500-6R
S-12 Oil pressure drops 1

General causes why oil pressure drops Cause
q Leakage, clogging, wear of lubrication system
Defective hydraulic sensor or defective wiring harness

Defective oil level sensor or defective wiring harness
q Hydraulic control is not normal
Leakage, crushing or clogging of hydraulic piping

q Selection of oil by the temperature etc. specified in the
"Operation and Maintenance Manual" is not observed.
Clogging or breakage of pipe inside oil pan

q Oil deteriorated by overheating
Clogged strainer inside oil pan
Defective oil pump relief valve

Wear of metal journal
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Water, fuel in oil
Degree of machine
Machine operated for long period E E E
Questions
operation
Oil pressure monitor indicates low pressure level (with monitor installed) Q w
Replacement of filters has not been carried out according to Operation &
w
Maintenance Manual
Indicates a drop of hydraulic pressure during low idle w Q
Oil pressure monitor Indicates a drop of oil pressure during low and high Q w w w Q
(With monitor idle
installed) Indicates a drop of oil pressure on a slope w
Indicates a drop of oil pressure occasionally w Q Q
Oil level monitor indicates low level (with monitor installed) w w
Oil pan oil level is in short w
w
Check items
Leakage or crushing with external hydraulic piping

Oil is cloudy white or smells of diesel oil w
Metal particles are found when oil pan is drained w
Metal particles are found when oil is drained from oil filter w Q
Metal particles are detected in oil filter q

Inspect oil pan strainer, pipe directly q q
Troubleshooting
Oil pump rotation is heavy, there is play q

See S-13
Oil pump relief valve, spring is fatigued or damaged q

Inspect oil filter directly q
Carry out troubleshoot by “Eng Oil Press Sensor Error (*1)” q
Replacing the oil level sensor will cause the oil pressure monitor to be dis-
q
played normally.
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
—
Remedy
WA500-6R 19
S-13 Oil level rises (Water, fuel in oil) 1

General causes why oil level rises Cause
q Coolant mixing in the oil (oil turns cloudy)
Clogging of water pump drain hole (breather hole) or defective seal

q Fuel in oil (smells diluted diesel fuel)
a If oil mixes with the coolant, carry out troubleshooting by “S-11
Defective seal of auxiliary equipment (pump or compressor)

Coolant contains oil”

Leakage of fuel inside head cover
Worn, damaged rear seal surface

Internal cracks in cylinder block
Broken oil cooler core, O-ring
Defective thermostat sheet

Defect inside supply pump
Questions
Degree of machine operation Machine operated for long period EE E E

Fuel must be added more frequently w w
Coolant must be added more frequently Q w
There is oil in the coolant Q Q Q w
Engine oil smells of diesel fuel w w
Oil is milky Q w
After starting engine, drops of water come from muffler Q
Leave radiator cap open. When engine is run at idle, an abnormal number of bub-
w Q
bles appear or water spurts back
Check items
Exhaust gas is white Q Q

Clogged water pump drain hole (breather hole) w
Water comes out when water pump drain hole (breather hole) is cleaned w
Oil level in clutch or damper chambers on applicable machine side decreasing w
Hydraulic tank oil level is decreasing w

Remove head cover and inspect directly q
Troubleshooting
Inspect cylinder block, liner directly q q

Inspect rear oil seal directly q
Pressure-tightness test of cylinder head shows there is leakage q
Remove water pump and inspect directly q
Remove thermostat cover and inspect directly q
Remove supply pump and inspect directly q
Inspect the seal of auxiliary machine directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20 WA500-6R
S-14 Coolant temperature rises too high (Overheating) 1

General causes why coolant temperature becomes too high Cause
q Lack of cooling air (deformation, damages of fan)

q Drop in heat dissipation efficiency
q Defect in the coolant circulation system
q Power train oil temperature on applicable machine side
is rising:
o Carry out troubleshoot on applicable machine side
Defective radiator cap (pressure valve)

Defective coolant temperature gauge
Rise of power train oil temperature

Defective operation of thermostat
Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of machine
Questions
operation
Suddenly increased Q w
Condition of overheating
Always tends to overheat Q w w
Coolant temperature gauge Rises quickly Q w

(when installed) Does not go down from red range w
Radiator coolant level monitor indicates low level (with monitor installed) w
Engine oil level has risen, oil is cloudy white w Q
Turning the fan pulley causes a looseness. w
Cloudy white oil is floating on coolant w
Excessive air bubbles inside radiator, coolant spurts back w
Check items
When light bulb is held behind radiator, no light passes through w

Radiator shroud and inside of underguard are clogged with dirt or mud w
Coolant leakage from cracks in the radiator hose or loose clamps w
Coolant flows out from radiator overflow hose w
Power train oil temperature gauge enters red range faster than engine coolant
temperature gauge (when oil temperature and coolant temperature gauge are w
installed)

Inspect cylinder liner directly q
Carry out troubleshooting on
q
applicable machine side
Inspect oil cooler directly

Troubleshooting
Temperature difference between top and bottom radiator tanks is excessive q

When function test is carried out on thermostat, it does not open even at cracking
q
temperature
Temperature difference between top and bottom radiator tanks is slight q
Inspect radiator core directly q
When function test is carried out on the radiator cap, cracking pressure is low q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Add
Remedy
WA500-6R 21
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Cause
q Abnormality due to defective parts
Defective fuel injection timing (abnormal low coolant temperature sensor)

q Abnormal combustion
q Air sucked in from intake system
a Judge if noise is from inside or outside before proceed-
ing with troubleshooting
a When engine is not fully warmed up, engine noise rises
Air leakage between turbocharger and cylinder head

slightly because of operation in the low temperature
Defect inside muffler (dividing board out of position)

Breakage of valve system (valve, rocker lever, etc.)
mode. This is not abnormal, however.
a When engine is accelerated, it enters acceleration mode,
Deformed fan, loose fan belt or interference

Excessive wear of piston ring, cylinder liner
where engine noise remains slightly higher for about 5

seconds maximum. This is not abnormal, however.
Missing, seized gear train bushing

Improper gear train backlash
Dirt caught in the injector

Clogged, seized injector
Degree of machine operation Machine operated for long period E
Questions
Condition of abnormal noise
Suddenly increased Q Q Q
Non-specified fuel is being used Q
Engine oil must be added more frequently w
Metal particles are found when oil is drained in oil filter w w
Leakage of air between turbocharger and cylinder head w
When engine is cranked, abnormal noise is heard from around EGR gas piping
When engine is cranked, abnormal noise is heard from around cylinder head w w
When engine is cranked, abnormal noise is heard from around muffler w
Check items

w Q
Black Q w Q
Engine pickup is poor and combustion is abnormal w
Abnormal noise is loud when accelerating engine Q Q Q Q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
Abnormal noise is emitted only when starting engine q
Check by the realtime monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
22 WA500-6R
S-16 Vibration is excessive 1

General causes why vibration is excessive Cause
q Defective parts (abnormal wear, breakage, etc.)
Breakage of damper or power train output shaft

Loose engine mounting bolts, broken cushion
q Alignment with applicable machine side is not normal
Stuck valve system (valve, rocker lever, etc.)

q Abnormal combustion
a If there is abnormal noise together with the vibration, carry out trou-
Worn main metal, connecting rod metal

bleshooting also for “S-15 Abnormal noise is made”.
Center of engine and power train

Improper gear train backlash

Worn camshaft bushing
Questions
Degree of machine operation Machine operated for long period E E E

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Metal particles are found when oil is drained in oil filter w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke color is black w

Inspect main metal, connecting rod metal directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Check by the realtime monitoring function q
Inspect engine mount bolt, cushion directly. q
When face runout and radial runout are inspected, they are found to be incorrect q
Inspect inside of output shaft or damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
WA500-6R 23
S-17 Air cannot be bled from fuel circuit 1

(After filter is replaced or fuel is used up and then air is bled, engine does not start
or it starts but stalls.)
General causes why air cannot be bled Cause
q Electric priming pump does not operate.
Defective wiring harness of electric priming pump

Improper setting of air bleeding valve (Closed)
q Fuel is not supplied or is supplied very little.
Malfunction of electric priming pump switch

q Fuel valve or air bleeding valve is not set properly.
Leaking or clogged fuel piping or air in it

q Air bleeding piping is clogged.
Improper setting of fuel valve (Closed)
Malfunction of electric priming pump

q Fuel return piping is clogged.
Clogged fuel tank cap breather hole
Clogged water separator screen

Clogged air bleeding piping
Low battery charge level

Clogged fuel filter
Low fuel level
Confirm recent repair history
Questions
Degree of use of
machine Operated for long period E E
Non-specified fuel is used Q Q

Fuel tank is empty w
Fuel tank cap breather hole is clogged Q w
Fuel is leaking from fuel piping w
Switch lamp does not blink w w Q
Check
items
When electric priming Lamp blinks but pump operation sound is not heard w w
pump switch is operated
Pump operation sound is heard but fuel does not flow out
of hose soon Q Q w w w Q Q
Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and breakage) q
Check electric priming pump directly q
Check electric priming pump system directly (See E-14 in E-mode) q q
Check water separator screen directly q
Check fuel filter for clogging (See failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Charge
Clean
Add
Remedy
24 WA500-6R
Note 1: Check of air bleeding piping for clogging
q Remove joint bolt (1) and blow clean compressed air into hole (a) of the orifice to check for clogging.
q Remove air bleeding pipings (2), (3) and blow compressed air against its both ends to check for clog-
ging.
WA500-6R 25
SEN02946-02

© 2009 KOMATSU
All Rights Reserved
26
SEN02903-02
WA500-6R

WA500-6R 60001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools ...............................................................................................................................11
WA500-6R 1
SEN02903-02 50 Disassembly and assembly
How to read this manual 1 Installation

q Except where otherwise instructed, installation
1. Removal and installation of assemblies of parts is done in the reverse order of
Special tools
removal.
q As to the special tools needed for removal
q Instructions and precautions for installing parts
and installation, symbols such A1···X1 are
are shown with [*1] mark in the “Removal” sec-
attached in the table along with respective
tion, identifying which step the instructions are
part numbers, part names and quantity.
intended for.
q In addition to the above, the list of special
q As to the multi purpose tools used in installa-
tools contains the following information.
tion, the numbers such [1], [2]··· are given.
1) Necessity
Their part numbers, part names and quantity
t: Special tools that cannot be substi- are not described.
tuted and should always be used
q Marks shown in the “Installation” section stand
(installed). for the following.
k : Precautions related to safety in execution
q: Special tools that will be useful if
available and are substitutable with of work.
commercially available tools.
a : This mark gives guidance or precautions
2) Distinction of new and existing special
when doing the procedure.
2 : Type of coating material
tools
3 : Tightening torque
N: Tools newly developed for this model.
5
They respectively have a new part
number. : Quantity of oil or coolant to be added
R: Tools with upgraded part numbers.
They are remodeled from already Sketches of special tools
available tools for other models. q Various special tools are illustrated for the con-
Blank: Tools already available for other venience of local manufacture.
models. They can be used without
any modification.
3) Circle mark (Q) in sketch column:
q A circle mark means that a sketch of
the special tool is presented in the
section of Sketches of special tools.
q Part No. of special tools starting with
79*T means that they are locally
made parts and as such not inter-
changeable with those made by
Komatsu in Japan, e.g. 79*T-***-****.
Removal
q The “Removal” section contains procedures,
precautions and the amount of oil or coolant to
be drained.
q As to the multi purpose tools used in removal,
the numbers such [1], [2]··· are given. Their
part numbers, part names and quantity are not
described.
q Various symbols used in the “Removal” section
are explained and listed below.
of work.
[*1] : This mark shows that there are instructions
or precautions for installing parts.
6 This mark shows oil or coolant to be drained.
4 : Weight of part or component
2 WA500-6R
2. Disassembly and assembly of assem- Assembly

blies q In “Assembly” section, the work procedures,
Special tools precautions and know-how for carrying out
q As to the special tools needed for disas- those procedures, and quantity of the oil and
sembly and assembly, symbols such coolant added are described.
A1···X1 are attached along with respective q As to the multi purpose tools used in assembly,
part numbers, part names and quantity. the numbers such [1], [2]··· are given. Their
q In addition to the above, the list of special part numbers, part names and quantity are not
tools contains the following information. described.
1) Necessity q Various symbols used in “Assembly” section
t: Special tools that cannot be substi- are explained and listed below.
tuted and should always be used k : Precautions related to safety in execution
(installed). of work
q: Special tools that will be useful if a : This mark gives guidance or precautions
available and are substitutable with when doing the procedure.
commercially available tools. 2 : Type of coating material
2) Distinction of new and existing special 3 : Tightening torque
tools 5 : Quantity of oil or coolant to be added
N: Tools newly developed for this model.
They respectively have a new part
Sketches of special tools
number.
R: Tools with upgraded part numbers. q Various special tools are illustrated for the con-
They are remodeled from already venience of local manufacture.
available tools for other models.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark (Q) in sketch column:
q A circle mark means that a sketch of
the special tool is presented in the
q Part No. of special tools starting with
79*T means that they are locally
made parts and as such not inter-
changeable with those made by
Komatsu in Japan, e.g. 79*T-***-****.
Disassembly
q In “Disassembly” section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q As to the multi purpose tools used in disas-
sembly, the numbers such [1], [2]··· are given.
Their part numbers, part names and quantity
are not described.
q Various symbols used in the “Disassembly”
section are explained and listed below.
of work.
6 This mark shows oil or coolant to be drained.
WA500-6R 3
Coating materials list 1

(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 WA500-6R
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
Molybdenum
• Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
• Feature: Seizure and scuffing prevention com-

compound
prevention
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease  SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
WA500-6R 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses. 
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 WA500-6R
Special tool list 1

a Tool part number 79QT-QQQ-QQQQ indicates an interchangeable part (locally produced)
a Necessity : t············Special tools which cannot be substituted and should be always installed (used)
: q············Special tools which are very useful if available. They can be substituted with com-
mercially available tools.
a Distinction of new and existing special tools.
: N············Tools with new part numbers. They are newly developed for this model.
: R············Tools with upgraded part numbers. They are remodeled from already available
tools for other models.
: Blank······Tools already available for other models and usable without any modification.
a Circle (Q) in sketch column: A circle mark means that a sketch of the special tool is presented in the
New/Remodel
Necessity
Sketch
Q'ty
Work item Symbol Part No. Part name Nature of work, remarks
795-630-5500 Standard puller t 1

Removal of fuel supply
1 01010-81090 • Bolt t 2
pump
01643-31032 • Washer t 2
Angle tightening of head
2 790-331-1110 Wrench t 1
bolt
3 795-931-1100 Seal puller t 1 Removal of oil seal
795T-521-1111 Push tool t 1 N Q
Press fitting of engine
4 01050-31655 Bolt t 3
front seal
01050-31635 Bolt t 3
795T-521-1150 Push tool t 1 N Q Press fitting of engine
A 5
01050-31635 Bolt t 3 front seal (sleeve type)
Removal and installation 795T-421-1260 Push tool t 1 N Q

Press fitting of engine
of engine front seal and 6 01050-31640 Bolt t 4
rear seal (standard type)
engine rear seal 01643-31645 Washer t 8
795T-421-1240 Push tool t 1 N Q
7 01050-31645 Bolt t 4
01643-31645 Washer t 4 Press fitting of engine
795T-421-1231 Push tool t 1 N Q rear seal (sleeve type)
8 01050-31645 Bolt t 4
01643-31645 Washer t 8
Disassembly and assem- 1 795-101-2102 Puller (294 kN {30 ton}) t 1 Removal of turbine boss
bly of torque converter F Removal and installation
assembly 2 793-613-1210 Wrench t 1
of pump nut
WA500-6R 7
New/Remodel
Necessity
Sketch
Q'ty
Operation check of clutch

1 799-301-1500 Oil leak tester t 1
piston
796-514-2000 Remover t 1 Removal of No. 3 plane-
2
796-515-2140 Adapter 1 tary gear shaft
Disassembly and assem-
bly of transmission 790-201-1702 Push tool kit 1
790-201-1741 • Push tool 1 Press fitting of No. 3 and
3
790-101-5021 • Grip 1 No. 4 carrier bushings
01010-50816 • Bolt t 1
790-101-2501 Push puller t 1
790-101-2610 • Leg 1
790-101-2660 • Adapter 1
790-101-2510 • Block 1
4 Removal of output shaft
790-101-2560 • Nut 1
01643-32060 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 2
790-101-1102 Pump t 6
G 790-101-2501 Push puller t 1

790-101-2540 • Washer 1
790-101-2620 • Leg 2
790-101-2510 • Block 1
Disassembly and assem- 790-101-2660 • Adapter 2
bly of transfer assembly
790-101-2560 • Nut 2
Press fitting of output
5 791-112-1180 • Nut 1
shaft bearing
791-520-4140 Screw t 1
793T-615-1630 Adapter t 1 Q
793T-615-1640 Push tool t 1 Q
01643-32060 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
Pre-load adjustment on
6 793-615-1140 Spline wrench t 1 intermediate shaft bear-
ing
Pre-load adjustment on
7 796-720-3800 Wrench assembly t 1
input shaft bearing
8 WA500-6R
New/Remodel
Necessity
Sketch
Q'ty
Disassembly and assem- 790-501-5000 Repair stand t 1

Removal and installation
bly of differential assem- 1 790-901-4110 Bracket t 1
of differential
bly 793T-622-2120 Plate t 1 Q
792T-422-1220 Plate t 1 Q
Press fitting of outer drum
2 790-101-5421 Grip t 1
oil seal
01010-81240 Bolt t 1
Removal and installation
of wheel hub and brake,
3 793T-622-2210 Fixture t 3 Q
disassembly and assem-
bly of brake
792-520-2110 Installer t 1
Disassembly and assem-
791-580-1600 Push tool t 1
bly of final drive assem-
bly 791-580-1610 • Plate 1
791-580-1620 • Arm 4
791-580-1640 • Plate 1 Installation of floating
4
791-580-1650 • Plate 4 seal (gear side)
01010-51425 • Bolt 8
01541-21670 • Nut 4
01640-21426 • Washer 4
792-530-1630 Stud t 4
- 793-605-1001 Brake tester t 1
1 793-605-1200 Stop valve t 1
H 2 793-605-1120 Nipple t 1
8 3 793-605-1130 Tee t 1
4 790-301-1361 Gauge t 1
5 793-605-1140 Nipple t 1
6 790-101-1430 Coupler t 1
Removal and installation 9 790-101-1102 Pump t 1
of brake assembly 10 790-301-1720 Adapter t 1
11 07002-12034 O-ring t 1
12 799-101-5160 Nipple t 1
13 799-401-2220 Hose t 1
14 790-261-1130 Coupling t 1
15 793T-622-2410 Fixture t 3 Q
Commercially
16 Sling q 2
available
792-520-2110 Installer t 1
793T-622-2310 Plate t 1 Q
793T-622-2320 Arm t 4 Q
Disassembly and assem- 791-580-1640 Plate t 1 Installation of floating
5
bly of brake assembly 792-530-1630 Stud t 4 seal (hub side)
01010-61425 Bolt t 4
01640-21426 Washer t 4
01580-01613 Nut t 4
WA500-6R 9
New/Remodel
Necessity
Sketch
Q'ty
1 793-520-2630 Bar t 2
2 793-520-2640 Push puller t 1
3 793-520-2550 Guide t 1
Press fitting of upper 4 790-101-2300 Push puller t 1
1
hinge pin 5 790-101-2310 • Block 1
6 02215-11622 • Nut 2
7 790-101-2102 Puller (294 kN {30 ton}) t 1
K
8 790-101-1102 Pump t 1
1 793-520-2530 Guide t 1
2 01010-31480 Bolt t 2
Press fitting of lower 3 01643-31445 Washer t 2
2
hinge pin 4 793-520-2640 Push puller t 1
5 790-101-2102 Puller (294 kN {30 ton}) t 1
6 790-101-1102 Pump t 1
1 790-502-1003 Repair stand t 1
1
2 790-101-1102 Pump 1
790-102-4300 Wrench assembly t 1 Removal and installation
2
790-102-4310 Pin t 2 of piston
Socket (Width across Removal and installation
3 790-302-1290 t 1
flats: 60 mm) of steering cylinder nut
1 790-201-1500 Push tool kit t 1 Press fitting of dust seal
2 790-201-1590 • Plate t 1 Steering cylinder
4 3 790-201-1680 • Plate 1 Bucket cylinder
4 790-101-5021 • Grip 1
All cylinders
5 01010-50816 • Bolt 1
Disassembly and assem- Press fitting of roll bush-
bly of hydraulic cylinder U 1 790-201-1702 Push tool kit t 1
ing
assembly
2 790-201-1781 • Push tool 1 Steering cylinder
5
3 790-201-1871 • Push tool 1 Bucket cylinder
4 790-101-5021 • Grip 1
All cylinders
5 01010-50816 • Bolt 1
1 790-720-1000 Expander t 1 Expansion of piston ring
2 796-720-1660 Ring t 1
Steering cylinder
3 07281-01159 Clamp t 1
6 4 796-720-1680 Ring t 1
Lift arm cylinder
5 07281-01589 Clamp t 1
6 796-720-1690 Ring t 1
Bucket cylinder
7 07281-01919 Clamp t 1
1 793-498-1120 Clear plate t 2
2 2 793-498-1130 Plate t 2 Installation of operator's
Operator's cab glass X
3 793-498-1110 Magnet t 2 cab glass
3 793-498-1210 Lifter (Suction cup) t 2
10 WA500-6R
Sketches of special tools 1

Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
A4. Push tool
A5. Push tool
WA500-6R 11
drawings.
A6. Push tool
A7. Push tool
12 WA500-6R
drawings.
A8. Push tool
G5. Adapter
WA500-6R 13
drawings.
G5. Push tool
H1. Plate
14 WA500-6R
drawings.
H2. Plate
H3. Fixture
WA500-6R 15
drawings.
H5. Plate
H5. Arm
16 WA500-6R
drawings.
H15. Fixture
WA500-6R 17
SEN02903-02

© 2019 KOMATSU
All Rights Reserved
18
SEN02904-00
WA500-6R

WA500-6R 60001 and up
50 Disassembly and assembly 1
Engine and cooling system

(SAA6D140E-5)
Removal and installation of engine assembly ................................................................................................. 2
Removal and installation of radiator assembly ............................................................................................... 7
Removal and installation of air aftercooler ...................................................................................................... 9
Removal and installation of cooling fan and fan motor assembly ................................................................. 10
Removal and installation of radiator guard and cooling fan motor assembly................................................ 12
Removal and installation of fuel tank assembly ............................................................................................ 15
Removal and installation of hood .................................................................................................................. 17
WA500-6R 1
Removal and installation of

engine assembly
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Drain the coolant.

6 Coolant: Approx. 90 l
2. Drain the hydraulic oil.

6 Hydraulic oil: Approx. 337 l
10. Remove right and left covers (6).

3. Remove the hood. For details, see "Removal
and installation of hood". 11. Remove partition plate (7).
4. Set jack [1] under the transmission.
12. Loosen the clamp and remove air connector

and hose assembly (8).
5. Remove 2 brake tube support U-bolts (1).
13. Loosen the clamp and remove tube (9)
6. Disconnect wiring harness clamp (2). between the turbocharger and air aftercooler.
[*1]
7. Remove bracket (3). 14. Loosen hose clamps (10) between the air
cleaner and turbocharger and remove air
8. Remove cover (4). cleaner lock band (11) and air cleaner assem-
bly (12). [*2]
9. Remove rear brake tube (5).
2 WA500-6R
15. Remove air cleaner bracket (13). 18. Remove pre-filter assembly (17), then move it
outward.
19. Remove bracket (18).
16. Disconnect heater hose (14).
17. Remove partition rubber plates (15) and (16).

a Disconnect partition rubber plate (16) and 20. Disconnect connector E16 (20).
move it to the right.
21. Remove air compressor belt (21) and remove
and move air compressor assembly (22) out-
ward. [*3]
22. Disconnect hose (23) and remove the clamp

and fuel return tube (24). [*4]
WA500-6R 3
23. Disconnect fan drive motor hoses (25) and 28. Remove cover (34) and disconnect engine
(26). drain valve (35).
24. Remove fan drive motor tube clamp (27) and

hose clamp (28) between torque converter
cooler and pump.
25. Remove fan pump tube (29).
29. Remove the 2 clamps and disconnect aeration

hose (36).
30. Loose 4 hose clamps (37) and remove tube,

hose and block assembly (38).
26. Disconnect fuel hoses (30) and (31).
31. Disconnect air bleeder hose (39).
27. Disconnect fuel tank breather (32) and remove 32. Loosen clamps (40) and (41) and remove
crossbar (33). water pump tubes (42) and (43). [*5]
33. Loosen clamp (44) and remove engine oil

cooler tube (45). [*6]
4 WA500-6R
34. Disconnect harness connectors ER1 (46), ER2 39. Remove the U-bolt and bracket (55).
(47) and ER3 (48).
35. Disconnect harness connectors JR1 (49) and

JR2 (50).
40. Remove right and left engine front mounting

bolts (56). [*7]
41. Remove right and left engine rear mounting

36. Disconnect heater cable (49). bolts (57). [*8]
37. Disconnect starter cable (50).
42. Sling the engine assembly and remove mount-

ing bolt (58). [*9]
38. Disconnect harness connectors JE1 (51), JE2
(52), E11 (53) and E17 (54).
WA500-6R 5
43. Lift off engine assembly (59). Installation

a Before lifting off the engine assembly, q Carry out installation in the reverse order to
check that all the wiring harnesses, pipe removal.
clamps, are disconnected.
4
[*1]
3
Engine assembly: 1,870 kg
Hose clamp: 10.5 Nm {1.07 kgm}
[*2]
3 Hose clamp: 10.5 Nm {1.07 kgm}
a When installing clamp (10), direct it down.
[*3]
Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting, "Testing and
adjusting air conditioner compressor belt tension".
[*4]
3 Tube joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*5], [*6]
[*7], [*8]
3 Mounting bolt:
662 – 829 Nm {67.5 – 84.5 kgm}
[*9]
3 Engine and transmission coupling bolt:
98 – 123 Nm {10 – 12.5 kgm}
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
q Refilling with oil (Hydraulic tank)

again.
q Bleeding air
Bleed air from the brake circuit and fan drive
motor circuit. For details, see Testing and
adjusting, "Bleeding air from each part".
6 WA500-6R
Removal and installation of

radiator assembly
Removal
2. Remove rear top hood (1).
10. Remove air bleeder hose clamps (13) and right

and left partition plates (14).
3. Remove rubber cover (2) and covers (3), (4)

and (5).
12. Loosen 4 hose clamps (16) and remove the

tube bolts on the engine side and tube and
hose assembly (17). [*1]
4. Remove the 4 clamps and aeration hoses (6)

and (7).
5. Disconnect hose (8) from the bracket.
6. Remove the 2 clamps and disconnect hose (9)

from the reservoir tank.
7. Remove the clamp and disconnect hose (10)

from the tube.
8. Disconnect air bleeder hose (11).
9. Remove the 4 clamps and move hose (12)

toward the engine.
WA500-6R 7
13. Remove 8 radiator mounting bolts and 12 Installation

bracket mounting bolts and lift off bracket (20). q Carry out installation in the reverse order to
4 Bracket: 30 kg removal.
[*1]
14. Lift off radiator assembly (21) slowly.

4 Radiator assembly (1 piece): 30 kg
a Remove the other radiator assembly
according to the above procedure.
8 WA500-6R
Removal and installation of air 5. Remove 2 reservoir tank hose clamps (7).
aftercooler
6. Remove the 2 bolts and move receiver (8) out-
Removal ward.
and installation of hood".
2. Remove 4 partition plates (1).
7. Sling air aftercooler assembly (9), remove its 6

mounting bolts, and lift it off.
4 Air aftercooler assembly: 30 kg
3. Loosen clamp (2) and remove hose and air
intake connector (3). [*1]
4. Loosen clamps (4) and (5) and remove pipe

(6). [*2]
Installation
q Carry out installation in the reverse order to
removal.
[*1]
[*2]
a When installing clamp (4), direct it down.
WA500-6R 9
Removal and installation of cooling 5. Remove cover (6).

fan and fan motor assembly
6. Remove the 3 wiring harness clamps and dis-
Removal connect wiring harness connector G09 (7).

2. Remove the 2 mounting bolts and open grille

(1).
3. Remove fan guard (2).
7. Remove the 3 support mounting bolts and

open motor, fan, fan guard, and support
assembly (8). [*1]
4. Disconnect motor hoses (3), (4) and (5).
8. Remove lock plate (9) and nut (10). [*2]
9. Sling fan (11). Using the puller, disconnect and

remove the fan from the motor.
4 Fan: 40 kg
10 WA500-6R
10. Remove mounting bolt (12) and remove fan Installation

motor assembly (13). [*3] q Carry out installation in the reverse order to
removal.
[*1]
3 Support mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
[*2]
3 Fan mounting nut:
132.3 – 156.8 Nm {13.5 – 16 kgm}
a When setting the bolt holes of the nut lock
plate, do not rotate the nut in the loosening
direction but rotate it in the tightening direction.
[*3]
3 Fan motor assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a Adjust clearance between the fan and shroud
to 5.5 mm minimum by loosening bolts (14) at
4 locations.
3 Plate mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}

again.
q Bleeding air
Bleed air from the fan motor circuit. For
details, see Testing and adjusting, "Bleeding
air from each part, Bleeding from fan motor cir-
cuit".
WA500-6R 11
Removal and installation of 6. Remove fan guard (4).

radiator guard and cooling fan
motor assembly
Removal


3. Remove right and left door locks (1). 7. Remove wiring harness connector GR1 (5).
4. Remove open-close lock (2) of the grille.
8. Remove wiring harness cover (6).
5. Lift off grille (3). 9. Disconnect wiring harness connector G09 (7)
4
and remove the 3 clamps.
Grille: 28 kg
12 WA500-6R
10. Disconnect fan motor hoses (8), (9) and (10). 15. Remove the 2 of radiator support mounting
bolts (17) from the front. [*2]
11. Remove fan motor hose clamps (11), (12) and
(13).
a The wiring harness clamp is also fixed
with hose clamp (11).
a Move the disconnected hoses to the rear
of the counterweight.
12. Remove the 3 mounting bolts of support (14).

[*1]
16. Remove the 8 of radiator guard mounting bolts

(18) from the right and left.
13. Remove reservoir tank bracket (15).
14. Remove 8 mounting bolts (16) of the right and

left side hoods and guards.
17. While slinging radiator guard and cooling fan

motor assembly (19) slowly, move it toward the
rear to remove.
4 Radiator guard and cooling fan motor
assembly: 320 kg
WA500-6R 13
Installation
removal.
[*1]
3 Support mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
[*2]
3 Radiator support mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}

again.
q Bleeding air
Bleed air from the fan motor circuit. For
details, see Testing and adjusting, "Bleeding
air from each part, Bleeding from fan motor cir-
cuit".
14 WA500-6R
Removal and installation of fuel 5. Disconnect 3 clamps from radiator drain hose
tank assembly (6).
Removal 6. Disconnect harness connector R16 (7).

k Set the lock bar to the frame. Apply the
parking brake and put the chocks to the
wheels.
1. Drain the fuel.

6 Tank capacity (full): 473 l
2. Remove L.H. and R.H. steps (1), covers (2)
and L.H. and R.H. covers (3).
7. Disconnect receiver assembly (8).
3. Disconnect fuel drain valve (4) from the frame.
4. Disconnect the fuel tank breather (5) from the

frame.
8. Disconnect hose (9) between the water sepa-
rator and fuel tank.
WA500-6R 15
9. Disconnect fuel return hoses (10) between the 12. Temporarily lift fuel tank assembly (13) with
fuel tank and block. nylon slings. Support the front bottom side of
the fuel tank with a jack [1] and remove 4
10. Disconnect fuel supply hoses (11) between the mounting bolts. [*1]
fuel tank and block.
13. While adjusting the jack height so that the bot-
tom of fuel tank assembly (13) will be in paral-
lel with the ground, lower the crane slowly.
a Check that all the wiring harnesses, pip-
ings, etc. are disconnected.
4 Fuel tank assembly (Empty): 225 kg
11. .Disconnect fuel return hose (12)
14. Place fuel tank assembly (13) on a palette

truck [2] etc. and pull it out of the machine.
Installation
removal.
[*1]
a Reduce the clearance between the fuel tank
and rear frame to below 0.5 mm with shims.
3 Fuel tank mounting bolt:
785 – 980 Nm {80 – 100 kgm}
16 WA500-6R
Removal and installation of hood 4. Disconnect air conditioner hose clamp (4).
Removal
1. Remove rear hood (1).
5. Disconnect 6 reservoir hose clamps (5).
2. Loosen the pre-cleaner hose clamp, remove

the mounting bolts, and then lift off front hood,
muffler and pre-cleaner assembly (2).
4 Front hood, muffler and pre-cleaner
assembly: 68 kg
6. Remove rubber cover (6).
7. Remove partition covers (7), (8) and (9).
8. Remove covers (10) and (11).
3. Remove right and left side panels (3).
WA500-6R 17
9. Remove support (12). 14. Disconnect dust indicator (18) and block
together.
10. Remove right and left covers (13).
15. Remove right and left intermediate covers (19).

11. Disconnect torque converter cooler air bleeder
hose clamps (14).
16. Disconnect right and left gas springs (20) and

rods (21).
12. Disconnect reservoir tank bracket (15).
13. Disconnect bracket (16) of the pipe between

turbocharger and aftercooler.
18 WA500-6R
17. Sling right and left side hood and door assem- Installation
blies (22), remove their mounting bolts, and lift q Carry out installation in the reverse order to
them off. removal.
4 Right and left side hood and door
assemblies: 77 kg
18. Remove right and left cover and support

assembly (23).
WA500-6R 19
SEN02904-00

© 2007 KOMATSU
All Rights Reserved
20
SEN02905-02
WA500-6R

WA500-6R 60001 and up
Engine (SAA6D140E-5)
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of cylinder head assembly ...................................................................................... 6
Removal and installation of fuel injector assembly ....................................................................................... 17
Removal and installation of engine front seal ............................................................................................... 20
Removal and installation of engine rear seal ................................................................................................ 24
WA500-6R 1
Removal and installation of fuel 5. Disconnect connector E16 (5).

supply pump assembly
6. Remove air compressor belts (6) and discon-
Special tools nect a harness clamp. [*1]
New/Remodel
7. Remove air compressor assembly (7) together
Necessity
Sym- with bracket (8) and shift them toward outside.
Part No. Part name
Sketch
bol
Q'ty
795-630-5500 Standard puller t 1
A 1 01010-81090 • Bolt t 2
01643-31032 • Washer t 2
Removal
1. Open the inspection door on the R.H. side

hood.
2. Remove partition plates (1) and (2). 8. Disconnect harness clamps (9) and plate (10).
Remove bracket (11).
3. Remove fuel prefilter and head assembly (3)

and shift them toward outside. 9. Remove fuel tube (12). [*2]
4. Remove bracket (4). 10. Disconnect fuel tubes (13) and (14), and
remove fuel main filter and head assembly
(15). [*3]
2 WA500-6R
11. Remove engine oil filler port bracket (16). 17. Remove bracket (31), clamps (32), (33) and
(34). [*6]
18. Remove 2 high-pressure pipes (35). [*7]
12. Remove tube clamps and remove oil filler port

(17).
19. Remove cover (36).
13. Disconnect tube clamps (18), (19), (20) and
(21) and remove fuel tubes (22), (23), (24) and
(25). [*4]
14. Remove oil tube (26). [*5]
20. Rotate the crankshaft forward and set interme-

diate point (a) between stamps 2/5 TOP and
3/4 TOP on damper (37) to pointer (38).
a At this time, check that the drive gear forc-
ing tap is set to the bolt hole at the top of
cover (36). (If the drive gear forcing tap is
15. Remove the harness clamps and disconnect not set so, rotate the crankshaft 1 more
connectors PCV1 (27), PCV2 (28) and G (29). turn.)
a At this point, the pump shaft key is at 15°
16. Remove bracket (30). to the right from the top.
WA500-6R 3
21. Remove nut (39). [*8] 23. Remove 4 fuel supply pump mounting bolts
a Take care not to drop the removed parts (41) and fuel supply pump assembly (42).
into the case.
22. Install tool A1 and tighten center bolt to

remove gear (40). [*9]
a Keep tool A1 installed until the gear is
installed again.
4 WA500-6R
Installation 2) Install tube clamps (32), (33) and (34)

q Carry out installation in reverse order of manually then tighten them permanently.
removal. 3 Tube clamp mounting bolts:
8.8 – 10.8 Nm {0.9 – 1.1 kgm}
[*1] 3) Install the splash prevention cover with the
Adjust the tension of air compressor belt by refer- notch on the supply pump side facing the
ring to Testing and adjusting, "Testing and adjusting block and on the common rail side facing
air compressor belt tension." downward.
[*2] [*8], [*9]

3 Fuel tube (12) joint bolt: 1) Remove tool A1. Insert the supply pump
7.8 – 9.8 Nm {0.8 -– 1.0 kgm} along the gear groove with the fuel supply
(filter side) pump (42) key on the top.
2) Tighten fuel supply pump assembly
[*3] mounting bolts (41).
3 Fuel tubes (13) and (14) joint bolt: 2 Supply pump mounting bolts:
24.5 – 34.3 Nm {2.5 – 3.5 kgm} Adhesive (LT-2)
(filter side) 3) Tighten the timing gear nut.
[*4] 3 Nut: 176 – 196 Nm {18 – 20 kgm}
3 Tube clamps (18), (20) and (21) mounting
bolts: k Check that the high-pressure pipe is separated
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} from the surrounding wiring by 10 mm and
3 Fuel tube (22) joint bolt: over.
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Fuel tube (24) joint bolt: q Bleed air
14.8 – 19.6 Nm {1.5 – 2.0 kgm} Bleed air from the fuel circuit by referring to
(supply pump side) Testing and adjusting, "Bleeding air from fuel
3 Fuel tube (23) joint bolt: circuit."
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(supply pump side) q Checking fuel leakage
3 Fuel tube (23) sleeve nut: Check the fuel leakage by referring to Testing
43 – 47 Nm {4.4 – 4.8 kgm} and adjusting, "Checking leakage from fuel
(block side) system."
3 Fuel tube (24) joint bolt:
17.1 – 22.6 Nm {1.8 – 2.3 kgm}
(common rail side)
3 Fuel tube (25) joint bolt:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(supply pump side)
[*5]
3 Oil tube (26) joint bolt:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
(supply pump side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(cylinder block side)
[*6], [*7]
1) Install tube (35) manually then tighten it
permanently.
3 High-pressure pipe sleeve nut:
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
(supply pump side)
39.2 – 58.8 Nm {4.0 – 6.0 kgm}
(common rail side)
WA500-6R 5
Removal and installation of 6. Loosen hose clamps (11) between the air
cylinder head assembly cleaner and turbocharger and remove air
cleaner fixing bands (12) and air cleaner
Special tool assembly (13). [*2]
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
A 2 790-331-1110 Wrench (angle) q 1
Removal

6 Coolant: Approx. 90 l 7. Remove the muffler fixing band and 4 mount-
ing bolts and lift off muffler assembly (14).
2. Remove the hood. For details, see "Removal 4 Muffler assembly: 46 kg
3. Remove partition plates (1), (2), (3) and (4).
4. Remove tube (5) between the turbocharger

and air aftercooler. [*1]
5. Remove covers (6), (7), (8), (9) and (10).
6 WA500-6R
9. Remove fuel prefilter assembly (16) together 15. Disconnect 2 fuel tubes (25) and remove cor-
with the head and shift them toward outside rosion resistor assembly (26). [*6]
16. Disconnect supply pump connectors PCV1

(27), PCV2 (28) and G (29) and remove the
11. Remove fuel tube (18). [*3] harness clamps.
12. Disconnect fuel tubes (19) and (20), and
remove fuel filter and head assembly (21). [*4]
17. Disconnect electrical intake air heater harness

(30).
13. Remove oil tube (22) and remove oil filter and
bracket assembly (23).
a To avoid installation error, mark the top,
bottom, inlet and outlet side of this tube.
14. Remove the clamps and disconnect fuel return

tube (24). [*5]
WA500-6R 7
18. Remove 15 harness clamps (31) and shift har- 25. Remove corrosion resistor mounting bracket
ness assembly (32). (40).
26. Remove plate (41).
19. Remove muffler mounting bracket (33).

27. Lift and remove air intake connector assembly
20. Remove air cleaner mounting bracket (34). (42) together with the joint housing.
4 Air intake connector assembly: 35 kg
21. Remove oil filter mounting bracket (35).
22. Remove fuel filter mounting bracket (36).
28. Disconnect connectors TIM (43), PIM (44) and

TFUEL (45).
23. Remove air connector (37) and electrical
intake air heater (38).
24. Remove blow-by tube (39).
8 WA500-6R
29. Loosen the mounting bolts of high-pressure 32. Remove blow-by connector (51).
pipe clamp (46). Disconnect bracket (47) from
the air intake manifold. [*7] 33. Remove corrosion resistor tube (52). [*9]
30. Loosen 6 mounting bolts of high-pressure pipe 34. Remove fuel return tube (53). [*10]
clamp (48). Remove bracket (49) from the air
intake manifold. [*8]
35. Temporarily lift air intake manifold assembly

(54) and remove the mounting bolts to remove
31. Remove block (50). the air intake manifold assembly. [*11]
a Jointly tighten 2 high-pressure pipe brack-
ets.
4 Air intake connector assembly: 35 kg
WA500-6R 9
36. Remove spill pipe (55). [*12] 38. Remove 4 tube clamps (58) and turbocharger
lubrication tube (59). [*13]
37. Remove 6 wiring harness clamps (56) and dis-
connect 6 injector connectors (57) and move
them toward the hydraulic tank.
39. Remove high-pressure pipe clamp (60), then

remove bracket (61). [*14]
a Insert flat-head screwdriver [3] in shoulder 40. Remove 10 high-pressure pipe clamps (62),
(a). While pressing stopper (b), move the then remove 7 brackets (63). [*15]
screwdriver in direction (X), and connector
(c) is disconnected.
(d): Fuel injector wiring side
41. Disconnect connector (64) and remove dust

indicator hose (65).
42. Remove connector (66) and bracket (67).

[*16]
43. Remove stay (68) and bracket (69).
10 WA500-6R
44. Disconnect turbocharger drain tube (70). 47. Remove air bleeding tube (73). [*18]
48. Remove 12 scatter prevention covers (74)

from the common rail and cylinder head sides,
46. Sling exhaust manifold and turbocharger and remove high-pressure pipes (75). [*19]
assembly (72), remove its mounting bolts, and
lift it off. [*17]
4 Exhaust manifold and turbocharger
assembly: 61 kg
49. Remove head cover (76). [*20]
WA500-6R 11
50. Remove the 3 mounting bolts and rocker arm 53. Remove 2 nuts (82) from the solenoid valve of
and shaft assembly (77). [*21] the fuel injector. [*24]
a Loosen locknut (78), and then loosen a Loosen the nuts alternately.
adjustment screw (79) by 2 – 3 turns so
that an excessive force will not be applied 54. Pull out spring clamp (83).
to the push rod when the rocker arm is
installed. 55. Disconnect clamp (84).
56. Remove the fixing bolt and holder of connector

(85), push in the connector, and remove the
injector wiring harness. [*25]
57. Loosen mounting bolt (87) of holder (86). [*26]
58. Insert a small L-bar under the connector of the

fuel injector and pry out fuel injector assembly
(88) slowly. [*27]
a Do not grip the solenoid valve at the top of
the injector with pliers etc. to pull off the
injector.
51. Remove push rods (80). [*22]
52. Remove crossheads (81). [*23]
59. Remove mounting bolts (89), auxiliary bolts

and cylinder head assembly (90). [*28]
60. Remove cylinder head gasket. [*29]
12 WA500-6R
Installation [*12]
q Carry out installation in the reverse order to 3 Spill pipe joint bolt:
removal. 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*1] [*13]
3 Tube hose clamp: 10.5 Nm {1.07 kgm} 3 Lubrication tube joint bolt:
a When installing the clamp, direct it down. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*2] [*14], [*15]

3 Air cleaner hose clamp: 3 Bracket mounting bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*3] 3 High-pressure pipe clamp mounting bolt:

3 Tube joint bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
[*16]
[*4] 3 Connector hose clamp:
3 Tube joint bolt: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*17]
[*5] Apply heat-resistant sealant to the fitting parts of
3 Tube joint bolt: the exhaust manifold (between ports No. 2 and No.
24.5 – 34.3 Nm {2.5 – 3.5 kgm} 3 and between ports No. 4 and No. 5).
2 Fitting parts:
[*6], [*9] Heat-resistant sealant (HOLTZ MH705)
3 Tube joint bolt: a Tighten the 3 bolts of [1] – [3] shown below
24.5 – 34.3 Nm {2.5 – 3.5 kgm} temporarily in the numeric order and then
tighten other bolts [4] – [24] temporarily in the
[*7], [*8] numeric order. Then, tighten all bolts [1] – [24]
3 High-pressure pipe clamp mounting bolt: to the specified torque in the numeric order.
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} 2 Threads of mounting bolt:
Seizure prevention compound (LC-G)
[*10] (NEVER-SEEZ (Bostik, Inc.) or equivalent)
3 Fuel return tube joint bolt: 3 Exhaust manifold mounting bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm} 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
[*11]
a Install the gasket with the "UP" mark up.
a Tighten the air intake manifold assembly
mounting bolts in the order of [1] – [24] as
shown in the following figure.
3 Air intake manifold mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
[*18]
3 Air bleeding tube joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
WA500-6R 13
[*19] [*21]
k Before installing the high-pressure pipe, a Before tightening the mounting bolts, check
check it for the following defects. If there is that the adjustment screw ball is fitted in the
any of these defects, it can cause fuel leak- push rod socket.
age. Accordingly, replace the high-pres- 3 Rocker arm and shaft assembly mounting
sure pipe. bolt: 93 – 103 Nm {9.5 – 10.5 kgm}
q Check the taper seal of the connecting part a For adjustment of the valve clearance, see
(Part (a): Part of 2 mm from the end) for visible Testing and adjusting, "Adjusting valve clear-
lengthwise slit (b) and dent (c). ance".
q Check part (d) (End of the taper seal: Part at 2
mm from the end) for stepped-type wear [*22]
(fatigue) which your nail can feel. a Check that the push rod is in the cam follower.
[*23]
a Adjust the crosshead according to the follow-
ing procedure.
1) Loosen the locknut and return the adjust-
ment screw.
2) While holding the crosshead top lightly,
tighten the adjustment screw.
3) After the adjustment screw touches the
valve stem, tighten it 20° more.
4) Tighten the locknut.
3 Locknut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
1) Fit the O-ring to the sleeve of high-pres- [*24]

sure pipe (75). While setting the sleeve to a Take up the slack of the wiring harness and
the injector connector, tighten the sleeve press it against injector.
nut temporarily. Tighten the sleeve nut on a Tighten the nuts alternately.
the common rail side temporarily, too. 3 Wiring harness terminal nut:
2 O-ring: Engine oil (EO30) 2.0 ± 0.2 Nm {0.2 ± 0.02 kgm}
2) Tighten the high-pressure pipe sleeve nut
permanently with a spanner-type torque
wrench.
3 Sleeve nut:
39.2 – 49 Nm {4 – 5 kgm}
3) Check that the O-ring is not projected from
the sleeve.
4) Install the scatter prevention cover on the
injector side with the notch down and that
on the common rail side with the notch
directed toward the cylinder block.
[*20]
3 Head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
a Tighten the bolts temporarily which are also
used to fix the wiring harness clamp.
14 WA500-6R
[*25]
a Since the injector wiring harness fitted with the
O-ring is difficult to insert from inside, install it
1) Remove O-ring (102) from connector (96)
and pass the wiring harness out from
inside of the cylinder head and then fit the
O-ring.
2 O-ring: Engine oil (EO30)
2) Install holder (103) to connector (96) and
push the connector into the position where
the O-ring is fitted.
3) Fix the holder with mounting bolt (104).
[*26], [*27]
a Install the injector assembly according to the [*28]
following procedure. a Check the cylinder head mounting bolts for the
1) Check that there is not dirt in the injector following items. If they are out of the standard,
sleeve. do not use them but replace them.
2) Install gasket (105) and O-ring (106) to q Number of tightening times must be 5 or less
fuel injector (99).
2 O-ring: Engine oil (EO30)
(Number of punch marks denoting the number
of tightening times must be 5 or less).
3) Insert holder (97) in the fuel injector and q Using limit length of bolt stem (e)
insert the injector connector, directing it Short bolt: less than 170.8 mm
toward the high-pressure pipe insertion Long bolt: less than 205.8 mm
hole.
4) Install the spherical washer to bolt (98)
and tighten holder (97) temporarily.
2 Spherical washer:
Engine oil (EO30)
5) Insert high-pressure pipe sleeve (107)
through the high-pressure pipe insertion
part, setting it to injector connector (108),
and tighten it temporarily.
a Tighten the sleeve nut on the com-
mon rail side, too, and take care that
the high-pressure pipe will not slant.
6) Tighten holder (98) permanently.
a While pulling the high-pressure pipe
in the opposite direction to the injec-
tor, tighten the bolt.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the holder, remove
the high-pressure pipe.
WA500-6R 15
2 Cylinder head mounting bolt: [*29]

Molybdenum disulfide grease (LM-P) a Check that there is not dirt or foreign matter on
3 Tighten the mounting bolts in the order of 1 – the cylinder head mounting face and in the cyl-
6 shown below. inder, and then set the gasket to the cylinder
1st time: 137 – 157 Nm {14 – 16 kgm} head.
2nd time: 284 – 294 Nm {29.0 – 30.0 kgm} a When fitting the gasket, check that the grom-
3rd time: Using tool A2, tighten the bolts by mets are fitted correctly.
90° (+30°/0).
Add coolant to the specified level. Run the
engine to circulate the coolant through the sys-
tem. Then, check the coolant level again.
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
k Before starting the engine, check that the

wiring harnesses are at least 10 mm apart
from each high-pressure pipe.
a When not using tool A2, make marks (a) and

(b) on each bolt and cylinder head with paint,
and then tighten the bolts by 90° (+30°/0)
a After tightening bolts 1 – 6, tighten bolt 7.
3 Bolt 7: 66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}
16 WA500-6R
Removal and installation of fuel 4. Remove air cleaner bracket (4) and muffler
injector assembly bracket (5).
Removal

2. Remove the muffler fixing band and 4 mount-

ing bolts and lift off muffler assembly (1).
4 Muffler assembly: 46 kg
5. Remove a fuel filter (6) and an oil filter (7).
3. Loosen hose clamps (2) between the air

cleaner and turbocharger and remove the air
cleaner fixing band and air cleaner assembly
(3). [*1] 6. Remove high-pressure pipe clamps (8). [*2]
WA500-6R 17
8. Remove splash prevention cover (10). [*3] 12. Remove the 3 mounting bolts and rocker arm
and shaft assembly (15). [*6]
a Loosen the locknut, and then loosen the
adjustment screw by 2 – 3 turns so that an
excessive force will not be applied to the
push rod when the rocker arm is installed.
9. Remove the wiring harness clamp and discon-

nect connector (11).
a Disconnect the injector connector accord-
1) Apply flat-head screwdriver [1] to the
shoulder (part (a)). 13. Remove 2 nuts (16) from the solenoid valve of
2) While pressing stopper (1a), move flat- the fuel injector. [*7]
head screwdriver [1] in direction X to dis- a Loosen nuts (16) alternately.
connect the connector.
14. Remove wiring harness clamp (17).
15. Remove the mounting bolts of holder (18) and

then remove fuel injector assembly (19) and
holder (18) together. [*8]
a Insert a small L-bar under the connector of
the fuel injector and pry out the fuel injec-
tor assembly slowly.
a Do not grip the solenoid valve at the top of
the injector with pliers etc. to pull off the
injector.
10. Remove the high-pressure pipe clamp and

scatter prevention cover (12) and pull out high-
pressure pipe sleeve (13). [*4]
11. Remove cylinder head cover (14). [*5]
18 WA500-6R
Installation [*6]
q Carry out installation in the reverse order to a Before tightening the mounting bolts, check
removal. that the adjustment screw ball is fitted in the
push rod socket.
[*1] 3 Rocker arm mounting bolt:
3 Air cleaner hose clamp: 93 – 103 Nm {9.5 – 10.5 kgm}
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
q For adjustment of the valve clearance, see
[*2] Testing and adjusting, "Adjusting valve clear-
3 High-pressure pipe clamp mounting bolts: ance".
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*3] [*7]
a Install the cover with the slit facing downward a Take up the slack of the wiring harness and
to the cylinder block side. press it against injector.
a Tighten the nuts alternately.
[*4] 3 Terminal nut:
k Before installing the high-pressure pipe, 2.0 ± 0.2 Nm {0.2 ± 0.02 kgm}
check it for the following defects. If there is
any of these defects, it can cause fuel leak- [*8]
age. Accordingly, replace the high-pres- a Check that there is not dirt in the injector
sure pipe. sleeve.
q Check the taper seal of the connecting part 2 Injector sleeve O-ring: Engine oil (EO30)
(Part (a): Part of 2 mm from the end) for visible 3 Injector holder mounting bolt:
lengthwise slit (b) and dent (c). 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
q Check part (d) (End of the taper seal: Part at 2
mm from the end) for stepped-type wear
(fatigue) which your nail can feel.
2 High-pressure pipe sleeve O-ring:

Engine oil (EO30)
3 High-pressure pipe sleeve nut:
39.2 – 49 Nm {4 – 5 kgm}
3 High-pressure pipe clamp mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
a Install the cover with the slit facing downward.
[*5]
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
WA500-6R 19
Removal and installation of 3. Remove front seal (3) from housing (4) accord-
engine front seal ing to the following procedure.
a Take care in the removal not to damage
Special tools front seal (3) installation position on hous-
ing (4) and the seal contact face on crank-
New/Remodel
shaft (5).
a Before removing, slightly drive the front
Necessity
Sym-
Part No. Part name
Sketch
bol seal in once to free it from fixation.
a When front seal (3) is fixed too hard to the
Q'ty
housing (4), carry out the following proce-
3 795-931-1100 Seal puller t 1
dure.
795T-521-1111 Push tool t 1 N Q 1) Drill through a hole of approx. 3 mm
4 01050-31655 Bolt t 3 dia. on front seal (3).
A 2) Replace the tip of tool A3 with the drill
01050-31635 Bolt t 3
type one.
795T-521-1150 Push tool t 1 N Q
5 3) Insert the top end of tool A3 into the
01050-31635 Bolt t 3 drilled hole, and remove the front seal
by the impact of slide hammer (SH).
Removal (Apply the slide hammer evenly not to
1. Remove right and left partition covers (1) and tilt the front seal.)
cover mounting supports. a Remove the metal powders completely.
a When the sleeve is attached, cut sleeve
(6) using a gad and hammer to remove it.
a Take care not to damage crankshaft (5).
2. Remove damper (2).
20 WA500-6R
1. Procedure for installing standard seal

a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust of the housing.
a When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
a Never remove inside plastic cylinder (7) of
the replacement seal before installing the
seal.
1) Set large inside diameter side (b) of plas-
tic inside cylinder (7) to the end of crank-
shaft (5).
a Take care not to mistake the direction
of the plastic inside cylinder.
Installation
a Check the seal by checking the wear of the
shaft and replace it with the "standard seal" or
"sleeved seal".
If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
"standard seal A". In other cases, install
"sleeved seal B".
a (7): Plastic inside cylinder which is also used
as installation guide.
a (6): Sleeve.
a Do not remove installation guide (7) from front
seal (3) before installing the front seal.
a Handle front seal (3) and sleeve (6) as an
assembly and never separate them from each
other.
Standard spare seal Sleeved seal
WA500-6R 21
2) Hold the metal ring of front seal (3) with 2. Procedure for installing sleeved seal
both hands and push it in evenly as if you a When installing the front seal, do not apply
are passing over the large inside diameter oil or grease to the shaft, inside cylinder
side of plastic inside cylinder (7). surface of sleeve (6) and seal lip.
3) After pushing in the seal, remove plastic 1) Set sleeve (6) and front seal (3) assembly
inside cylinder (7).
to tool A5 (for fitting the sleeved seal).
a When removing the inside cylinder,
2 Sleeve (6) inside cylinder surface:
take care not to damage the seal lip.
4) Using tool A4, tighten the 3 bolts evenly to

press fit seal (3) until the end of tool A4 2) Set the sleeve of the front seal to the end
reaches the end of crankshaft (5). of crankshaft (5) and tighten the 3 bolts
a Tighten tool A4 first until the 55-mm evenly to press fit sleeve and front seal
bolts stop and then replace the 55- assembly (9) until the end of tool A5
mm bolts with the 35-mm bolts and reaches the end of crankshaft (5).
tighten them. a Tighten tool A5 (for press fitting the
a Seal driving distance (a) from crank- sleeved seal) until the 35-mm bolt
shaft: 9.1 – 10.1 mm stops.
a When press fitting the seal, take care
not to damage the lip of the seal with
the tool set etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
22 WA500-6R
3) Remove tool A5 (for press fitting the

sleeved seal) and install tool A4 (for press
fitting the seal).
4) Tighten the 35-mm bolts of tool A4 evenly
to press fit seal and sleeve assembly (9)
until the end of tool A4 reaches the end of
crankshaft (5).
a Seal driving distance (a) from crank-
shaft: 9.1 – 10.1 mm
a When press fitting the seal, take care
not to damage the lip of the seal with
the tool set etc.
3. Install damper (2).
WA500-6R 23
Removal and installation of 3. Install eyebolt [1] to flywheel (2) and sling it.
engine rear seal Remove bolts (3) and flywheel (2).
Special tools 4. While moving flywheel (2) toward this side and
lift it off.
k Since the socket part of the flywheel is
New/Remodel
Necessity
Sym- shallow, it may fall suddenly. Take care
Part No. Part name
Sketch
bol not to catch your fingers in the fly-
Q'ty
wheel.
2 790-331-1110 Wrench t 1 4 Flywheel: 59 kg
3 795-931-1100 Seal puller t 1
795T-421-1260 Push tool t 1 N Q
6 01050-31640 Bolt t 4
01643-31645 Washer t 8
A 795T-421-1240 Push tool t 1 N Q
7 01050-31645 Bolt t 4
01643-31645 Washer t 4
795T-421-1231 Push tool t 1 N Q
8 01050-31645 Bolt t 4
01643-31645 Washer t 8
Removal
1. Remove the engine assembly. For details, see
"Removal and installation of engine assembly". 5. Remove rear seal (4) from flywheel housing (5)
2. Remove ring gear (1). a Take care in the removal not to damage
rear seal (4) installation position on fly-
wheel housing (5) and the seal contact
face on crankshaft (5).
a Before removing, slightly drive the rear
seal in once to free it from fixation.
a When rear seal (4) is fixed too hard to the
flywheel housing (5), carry out the follow-
ing procedure.
1) Drill through a hole of approx. 3 mm
dia. on rear seal (4).
2) Replace the tip of tool A3 with the drill
type one.
3) Insert the top end of tool A3 into the
drilled hole, and remove the front seal
by the impact of slide hammer (SH).
(Apply the slide hammer evenly not to
tilt the rear seal.)
a Remove the metal powders completely.
a When the sleeve is attached, cut sleeve
(7) using a gad and hammer to remove it.
a Take care not to damage crankshaft (6).
24 WA500-6R
Installation
a Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace it
with the "standard seal" or "sleeved seal".
If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
"standard seal A". In other cases, install
"sleeved seal B".
a (8): Plastic inside cylinder which is also
used as installation guide.
a (6): Sleeve.
a Do not remove plastic inside cylinder (8)
from rear seal (4) before installing the rear
q Tool A3 seal.
a Handle rear seal (4) and sleeve (7) as an
assembly and never separate them from
each other.
q Left: Standard seal, Right: Sleeved seal
q Left: Standard seal, Right: Sleeved seal
a Clean, degrease, and dry the contact sur-

face against the flywheel housing.
a Clean, degrease, and dry the seal lip sur-
face (periphery of the crankshaft).
a Check that the end corners and lip sliding
surfaces of the crankshaft are free from
flaw, burr, and rust of the housing.
WA500-6R 25
1. Procedure for installing standard seal 4) Tighten the 4 bolts evenly to press fit rear
a When installing rear seal (4), do not apply seal (4) until the end of tool A6 (for press
oil or grease to the shaft and seal lip. fitting the seal) reaches the end of crank-
1) Set large inside diameter side (b) of guide shaft (6).
(8) of rear seal (4) to the end of crankshaft a Tighten tool A6 (for press fitting the
(6). seal) first until the bolt without washer
a Take care extremely not to mistake stops and then tighten the 25 mm bolt
the direction of the plastic inside cylin- with 2 washers.
der. a When press fitting the seal, take care
not to damage the lip with the tool set
etc.
2) Hold the metal ring of rear seal (4) with

both hands and push it in evenly.
3) After pushing in the seal, remove guide
(8).
a When removing the inside cylinder, 2. Procedure for installing sleeved seal
take care not to damage the seal lip. a When installing the rear seal, do not apply
oil or grease to the shaft, inside cylinder
surface (C) of the sleeve (7) and seal lip.
1) Set sleeve and rear seal assembly (9) to
tool A7 (for fitting the sleeved seal).
2 Sleeve inside cylinder surface (C):
26 WA500-6R
2) Set sleeve (7) of the rear seal to the end of 3. Flywheel

crankshaft (6) and tighten the 4 bolts Using eyebolt [1] (12 mm, P = 1.75), sling fly-
evenly to press fit sleeve and rear seal wheel (2), install it to the crankshaft, and
assembly (9) until the end of tool A7 tighten bolts (3).
reaches the end of crankshaft (6). a If there are 5 punch marks on a bolt, do
a Tighten tool A7 (for press fitting the not use that bolt but replace it.
s leeved seal) until the bolt with 2 Threads and seat of bolt:
washer stops. Engine oil SAE No. 30
3) Remove tool A7 (for press fitting the a Tighten the mounting bolts according to
sleeved seal) and install tool A8 (for press the following procedure.
fitting the seal). 3 Flywheel mounting bolts
4) Tighten the 4 bolts evenly to press fit 1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm}
sleeve and rear seal assembly (9) until the 2nd time:
end of tool A8 reaches the end of crank- 1) When using tool A2 (See the "Spe-
shaft (6). cial tools")
a Tighten tool A8 (for press fitting the Retighten each bolt by 90° (+30°/0)
seal) first until the bolt without washer in the order of [1] – [8].
stops and then tighten the bolt with 2 2) When not using tool A2
washers. Make marks on each bolt and fly-
a After press fitting the seal, remove the wheel with paint, then retighten
red sealant layer from its periphery. each bolt by 90° (+30°/0) in the
a Rear seal driving depth: order of [1] – [8].
13.2 ± 0.2 mm from end
of crankshaft
a When installing, set the dowel pin of

the crankshaft to the dowel hole of
the flywheel.
WA500-6R 27
a After tightening, make 1 punch mark (9)

on each bolt head to indicate the number
of tightening times.
a After installing the flywheel, measure the

facial runout and radial runout with tool [2].
a Radial runout: Max. 0.30 mm
a Facial runout: Max. 0.30 mm
q Carry out the following installation in the

reverse order to removal.
28 WA500-6R
WA500-6R 29
SEN02905-02

© 2009 KOMATSU
All Rights Reserved
30
SEN02906-01
WA500-6R

WA500-6R 60001 and up
Power train, Part 1

Removal and installation of torque converter and transmission assembly ..................................................... 2
Disconnection and connection of power train unit .......................................................................................... 8
Disassembly and assembly of input transfer assembly ................................................................................ 12
Disassembly and assembly of torque converter assembly (Lockup specification) ....................................... 19
Disassembly and assembly of torque converter assembly (Lockup-less specification)................................ 32
WA500-6R 1
Removal and installation of 9. Remove guard (2).

torque converter and
10. Sling center drive shaft (3), remove its mount-
transmission assembly ing bolts (4), and lift it off. [*1]
Removal a Before removing the drive shaft, make a
k Release residual pressure in brake accu- match mark on the coupling.
4
mulator circuit. For detail, see Testing and
Center drive shaft: 50 kg
adjusting "Releasing residual pressure in
brake accumulator circuit".


3. Drain the transmission oil.

6 Transmission oil: Approx. 76 l
11. Support rear drive shaft (5) with transmission

4. Remove the hood. For details, see "Removal jack [1], remove its mounting bolts (6), and lift it
and installation of hood". off. [*2]
a Before removing the drive shaft, make a
5. Remove the operator's cab and floor frame match mark on the coupling.
assembly. For details, see "Removal and
installation of operator's cab and floor frame 4 Rear drive shaft: 45 kg
assembly".
6. Remove the hydraulic tank assembly. For

details, see "Removal and installation of
hydraulic tank assembly".
7. Remove the right and left mudguard seats.
2 WA500-6R
12. Remove bracket (7) and transmission oil feed 19. Lift off transmission filter and bracket assembly
tube (8). (18).
4 Transmission filter and bracket assem-
bly: 43 kg
13. Disconnect hoses (9) and (10).
14. Disconnect hose (11).

20. Loosen hose clamp (19) and remove U-bolt
15. Disconnect parking brake hose (12). (20) and transmission suction tube (21).
16. Disconnect wiring harness connectors RJ1 21. Disconnect wiring harness bracket (22).
(13) and RJ2 (14) and remove the 2 wiring har-
ness clamps.
18. Disconnect tube (17).
WA500-6R 3
22. Disconnect work equipment pump hoses (23), 29. Disconnect hose (37).
(24) and (25).
23. Disconnect hose clamp (26).
24. Disconnect hose (27) and remove brackets

(28) and (29) and work equipment pump outlet
tube (30).
30. Remove pump inlet tube (38).
31. Disconnect pump inlet tube (39).
32. Disconnect pump outlet hoses (40), (41) and

(42).
25. Disconnect wiring harness connector RT1 (31). 33. Disconnect hose (43) and remove bracket
(44).
26. Remove wiring harness clamps (32) and
bracket (33).
28. Disconnect pump outlet hoses (35) and (36).
4 WA500-6R
34. Sling torque converter charging and EPC 38. Remove U-bolt (50) and disconnect oil cooler
pump assembly (45) and remove its mounting tube (51).
bolts. At this time, leave 2 bolts installed.
4 Torque converter charging and EPC
pump assembly: 30 kg
39. Sling the torque converter and transmission

assembly, loosen lock bolts (52), and remove
right and left mounting brackets (53). [*3]
35. Remove tube (46).
40. Remove connecting bolts (54) of the engine

and torque converter and transmission assem-
36. Disconnect hose (47). bly. [*4]
37. Remove U-bolts (48) and bracket (49).
WA500-6R 5
41. Remove torque converter and transmission Installation

assembly (55). q Carry out installation in the reverse order to
a Check that all the wiring harness and pip- removal.
ings are disconnected from the machine
and take care that the assembly will not [*1]
interfere with the machine. 3 Center drive shaft mounting bolt:
4
98 – 123 Nm {10 – 12.5 kgm}
Torque converter and transmission
assembly: 1,930 kg [*2]
3 Rear drive shaft mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a Tighten the drive shaft according to the follow-
ing procedure.
1) Check that the seats of the mating yoke

and drive shaft spider are free from rust,
foreign matter (masking material), bruise,
etc.
2) Set the key way of the yoke vertically,
place the drive shaft on the bottom of the
yoke socket, and fit the key in the key way.
3) Insert the 4 upper and lower bolts and fin-
ger tighten them until the seats of the spi-
der and yoke are fitted.
a At this time, if the key way and socket
of the yoke are tight and the spider is
not fitted easily, drive in the spider
with a plastic hammer (or a copper
hammer). (Do not use a steel ham-
mer which can damage the cross
bearing.)
a If the spider is not fitted perfectly at
this time, it will float and its seat will
be parted from the yoke when the
other parts are tightened. Accord-
ingly, tighten the spider securely.
4) Basically, tighten the bolts in the diagonal
order.
[*3]
3 Bracket (53) mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
3 Transmission mounting bolt:
662 – 829 Nm {67.5 – 84.5 kgm}
a Adjust the clearance between bracket (53) and
lock adjustment bolt (52) to 1.0 – 1.5 mm and
then tighten the locknut.
2 Threaded part of lock adjustment bolt:
Adhesive (LT-2)
[*4]
3 Connecting bolt of engine and torque con-
verter and transmission assembly:
98 – 123 Nm {10 – 12.5 kgm}
6 WA500-6R


again.
q Refilling with oil (Transmission)

again.
q Bleeding air
q Bleed air from the brake circuits. For
details, see Testing and adjusting, "Bleed-
ing air from brake circuit".
q Bleed air from the related circuit. For
details, see Testing and adjusting, "Bleed-
ing air from work equipment circuit".
WA500-6R 7
Disconnection and connection of 6. Remove transmission control valve (12) and

power train unit lubricating oil relief valve (13). [*1]
Preparation work
1. Set torque converter and transmission assem-
bly (1).
4 Torque converter and transmission
assembly:
1,700 kg (Lockup specification)
1,650 kg (Lockup-less specification)
The 3 bolts marked with * are used to clamp other

parts, too.
(Lockup specification)
2. Loosen drain valve (2) to drain the oil.

6 Transmission case: Approx. 76 l
3. Remove right and left transmission mounts (3).
4. Disconnect each ECMV of transmission con-

trol valve and remove wiring harness (4).
(Lockup-less specification)
5. Remove hoses (5) and (6) and pipes (7), (8),
(9), (10) and (11).
8 WA500-6R
7. Remove pipes (14) and (15), block (16) and Disconnection

heater plug (17). 1. Set torque converter and transmission assem-
bly (1).
4 Torque converter and transmission
assembly:
1,700 kg (Lockup specification)
1,650 kg (Lockup-less specification)
8. Remove torque converter regulator valve (19).
2. Torque converter assembly

1) Remove 2 upper mounting bolts (2a) and
15 lower mounting bolts (2b). [*3]
2) Lift off torque converter assembly (3).
4 Torque converter assembly:
460 kg (Lockup specification)
420 kg (Lockup-less specification)
9. Remove pipe (20). [*2]
WA500-6R 9
3. Input transfer Connection

1) Remove 13 mounting bolts (4). [*4] q Carry out connection in the reverse order to
2) Lift off input transfer (5). disconnection.
4
q Before fitting the O-ring, apply grease (G2-LI)
Input transfer: 140 kg
to it.
[*1]
Install the transmission control valve by using guide
bolts [1].
4. Transmission assembly
1) Remove 4 upper mounting bolts (6a) and
8 lower mounting bolts (6b) and discon-
nect the case by using forcing screws. 
[*5] The 3 bolts marked with * are used to clamp other
2) Sling transmission assembly (7) and lift it parts, too.
off from transfer assembly (8). (Lockup specification)
4 Transmission assembly: 550 kg
4 Transfer assembly: 440 kg
(Lockup-less specification)
10 WA500-6R
[*2]
3 Joint bolt A: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Joint bolt B: 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
3 Joint bolt C: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*3]
(Only lockup specification)
2 Input shaft seal ring: Grease (G2-LI)
a Project the seal ring evenly from the shaft.
a If the seal ring is pushed forcibly, it may be bro-
ken. Take care.
3 Torque converter mounting bolts (2a), (2b):
98 – 122.5 Nm {10 – 12.5 kgm}
[*4]
3 Input transfer mounting bolt (4):
98 – 122.5 Nm {10 – 12.5 kgm}
[*5]
3 Transmission mounting bolts (6a), (6b):
98 – 122.5 Nm {10 – 12.5 kgm}
2 Transmission shaft (Spline): Grease (LM-G)
q Refilling with oil

5 Transmission case: 76 l
Power train oil (TO30)
WA500-6R 11
Disassembly and assembly of q Lockup-less specification

input transfer assembly
Disassembly
1. Disconnect the input transfer assembly from

the power train unit. For details, see "Discon-
nect and connection of power train unit".
2. Input shaft
1) Remove input shaft speed sensor (1) and
input shaft (2).
3. Bearing cage assembly (Drive gear side)

1) Remove 6 mounting bolts (4).
2) Using forcing screw [1], remove bearing
cage (5) and shim (6).
a Check the thickness and quantity of
the shims at each position and keep
those shims.
2) Remove seal rings (3) from input shaft (2).

q Lockup specification
3) Remove outer race (7) from bearing cage

(5).
12 WA500-6R
4. Drive gear assembly 6. Bearing cage assembly (Driven gear side)

1) Remove drive gear assembly (8). 1) Reverse input transfer case (11).
3) Using forcing screws [3], remove bearing
cage (13) and shim (14).
those shims.
2) Remove bearings (9) and (10) from drive

gear assembly (8).
4) Remove outer race (15) from bearing

cage (13).
5. Outer race (Drive gear side)

Using puller [2], remove outer race (19) from
the case.
7. Driven gear assembly

1) Remove driven gear assembly (16).
WA500-6R 13
2) Remove bearings (17) and (18) from Assembly

driven gear assembly (16). 1. Outer race (Driven gear side)
Using push tool [1] (Outside diameter: 124
mm), press fit outer race (20) to the case.
8. Outer race
Using puller [4], remove outer race (20) from
the case. 2. Driven gear assembly
1) Using push tool [2], press fit bearings (17)
and (18) to driven gear (21).
2) Install driven gear assembly (16).
14 WA500-6R
3. Bearing cage assembly (Driven gear side) 5] Using clearance gauge [4], measure
1) Using push tool [3] (Outside diameter: 124 the clearance of bearing cage (13) at
mm), press fit outer race (15) to bearing the 3 places marked with *. Then,
cage (13). obtain shim thickness (b) from aver-
age clearance (a).
a Check that the bearing is not
leaning.
a If the dispersion of the above
measured values is larger than
0.15 mm, check if the bearing is
fitted fully or check for another
cause and then set the bearing
normally.
Shim thickness (b): 
a + (0.15 to 0.20) mm
Standard shim thickness: 1.0 mm
Standard clearance: 0.60 – 1.80 mm
2) Adjust the shim of bearing cage (13)

1] Install bearing cage (13) without set-
ting any shim and tighten mounting
bolts (12) to 4.8 ± 0.98 Nm {0.5 ± 0.1
kgm}.
a After installing the bearing, drop
6 cc of transmission oil (TO30)
onto it and rotate it 10 turns.
2] Rotate driven gear (21) 20 turns.
3] Check again that tightening torque of
mounting bolts (12) is 4.8 ± 0.98 Nm
{0.5 ± 0.1 kgm}.
4] If the tightening torque has changed, 6] Install shim (14) of the thickness
repeat steps 1] and 2]. obtained by the above procedure and
tighten mounting bolts (12).
3 Mounting bolt:
98.0 – 122.5 Nm {10 – 12.5 kgm}
WA500-6R 15
7] Install input shaft (2) to driven gear 2) Install drive gear assembly (8).
(21) and measure the rotation torque.
3 Rotation torque:
1.47 – 2.45 Nm {0.15 – 0.25 kgm}
6. Bearing cage assembly (Drive gear side)

1) Using push tool [7] (Outside diameter: 149
mm), press fit outer race (7) to bearing
4. Outer race (Drive gear side) cage (5).
mm), press fit outer race (19) to the case.
2) Adjust the shim of bearing cage (5)

5. Drive gear assembly a Since the shim adjustment and torque
1) Using push tool [6], press fit bearings (9) measurement are carried out on the
and (10) to drive gear (22). drive gear independently, remove the
drive gear.
ting any shim and tighten mounting
bolts (4) to 4.8 ± 0.98 Nm {0.5 ± 0.1
kgm}.
onto it and rotate it 10 turns.
2] Rotate drive gear (22) 20 turns.
3] Check again that tightening torque of
mounting bolts (4) is 4.8 ± 0.98 Nm
{0.5 ± 0.1 kgm}.
4] If the tightening torque has changed,
repeat steps 1] and 2].
16 WA500-6R
6] Install shim (6) of the thickness

obtained by the above procedure and
tighten mounting bolts (4).
3 Mounting bolt:
98.0 – 122.5 Nm {10 – 12.5 kgm}
5] Using clearance gauge [8], measure

the clearance of bearing cage (5) at
the 3 places marked with *. Then,
obtain shim thickness (d) from aver-
age clearance (c).
a Check that the bearing is not
leaning. 7] Install input shaft (2) to drive gear (22)
a If the dispersion of the above and measure the rotation torque.
measured values is larger than 3 Rotation torque:
0.15 mm, check if the bearing is 1.47 – 2.45 Nm {0.15 – 0.25 kgm}
fitted fully or check for another
cause and then set the bearing
normally.
Shim thickness (d): 
c + (0.15 to 0.20) mm
WA500-6R 17
7. Input shaft 8. Connect the input transfer assembly to the

1) Install seal ring (3) to input shaft (2). power train unit. For details, see "Disconnec-
2 Seal ring: Grease (G2-LI) tion and connection of power train unit".
2 Input shaft (Spline): Grease (LM-G)
q Lockup specification
q Lockup-less specification
2) Install input shaft (2).

3) Install input shaft speed sensor (1).
a Finger tighten input shaft speed sen-
sor (1) to the end and then return it by
1/2 turn and lock it with locknut (1a).
2 Locknut: Gasket sealant (LG-5)
3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}
18 WA500-6R
Disassembly and assembly of 4. Pilot

torque converter assembly 1) Remove 8 mounting bolts (4).
2) Using forcing screws [3], remove pilot
(Lockup specification) (65).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Puller 
1 790-101-2102 t 1
F (294 kN {30 ton})
2 793-613-1210 Wrench t 1
Disassembly
1. Disconnect the torque converter assembly

from the power train unit. For details, see "Dis-
connection and connection of power train unit".
1) Remove 16 mounting bolts (5) from the
lower part.
2) Using eyebolts [4], remove torque con-
1) Set torque converter assembly (1) on the
verter assembly (6).
3 Torque converter assembly: 180 kg
block.
3. Housing
1) Using eyebolts [1], sling housing (3).
2) Using forcing screws [2], remove housing
(3).
WA500-6R 19
<Steps 6 – 11 are disassembly procedures for 2) Remove snap ring (12).

torque converter> 3) Remove 20 mounting bolts (13) and tur-
6. Turbine assembly bine (14).
1) Remove 36 lower mounting bolts (7).
(Leave the 2 bolts on the right and left
sides.)
2) Remove the left 2 bolts and turbine
assembly (8), using eyebolts [5].
9. Drive case assembly

2) Using eyebolts [7], remove piston housing
(16).
7. Snap ring and spacer

Remove snap ring (9) and spacer (10).
3) Remove piston (17) and bearing (18) from

piston housing (16).
a Do not remove dowel pin (64) since it
8. Turbine boss assembly is a complete part.
1) Using tool F1 and push tool [6] (Outside 4) Remove piston rings (19a) and (19b).
diameter: 104 mm), remove turbine boss
assembly (11).
20 WA500-6R
5) Remove disc (20). 4) Remove freewheel (24) from race (23).

a When removing the freewheel, take
care of ball (25).
10. Stator assembly

1) Remove stator assembly (21).
11. Pump assembly
1) Install the bolts to the pump case and lock
them with bar [8].
2) Using tool F2, remove nut (26).
2) Remove snap ring (22) from stator assem-

bly (21).
3) Remove race (23) from stator assembly
(21).
3) Remove spacer (27).
a When removing the spacer, take care
of ball (28).
WA500-6R 21
4) Using push tool [9], remove stator shaft 8) Remove inner race (34) and seal ring (35)
(29). from stator shaft (29).
5) Remove inner race (30). 12. PTO gear A assembly

2) Using forcing screws [10], disconnect PTO
gear A assembly (37).
6) Remove 16 mounting bolts (31) and gear

(32).
7) Remove bearing (33).
3) Using eyebolts [11], remove PTO gear A
assembly (37).
22 WA500-6R
4) Remove snap ring (38a) and spacer (39). 3) Using eyebolts [13], remove PTO gear B
5) Remove gear (40) and bearing (41). assembly (45).
6) Remove snap ring (38b) and bearing (57).
4) Remove snap ring (46a) and spacer (47).

7) Remove snap ring (42) and outer race 5) Remove gear (48) and bearing (49).
(43) on the case side. 6) Remove snap ring (46b) and bearing (58).
13. PTO gear B assembly 7) Remove snap ring (50) and outer race
1) Remove 8 mounting bolts (44). (51) on the case side.
gear B assembly.
WA500-6R 23
14. Idler gear Assembly

1) Remove mounting bolt (52). 1. Idler gear
2) Using forcing screw [14], pull out the shaft 1) Install bearings (54a) and (54b) to gear
down and remove gear (53). (53).
3) Remove bearings (54a) and (54b) from 2) Set gear (53) to the case.
gear (53). 3) Fit the O-ring to shaft (55) and press fit
them.
2 O-ring: Grease (G2-LI)
4) Reverse the case and install mounting bolt
(52).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
153 – 190 Nm {15.5 – 19.5 kgm}
24 WA500-6R
2. PTO gear B assembly 8) Fit the O-ring and install PTO gear B
1) Install snap ring (50) to the case. assembly (45), using eyebolts [13].
2) Using push tool [1] (Outside diameter: 99 2 O-ring: Grease (G2-LI)
mm), press fit outer race (51) on the case
side.
3) Using push tool [2] (Inside diameter: 56
mm), press fit bearing (49) to the gear.
3. PTO gear A assembly

1) Install snap ring (42) to the case.
4) Using push tool [4] (Outside diameter: 124 side.
mm), press fit bearing (58) to the cover. 3) Using push tool [7] (Inside diameter: 56
5) Install snap ring (46b). mm), press fit bearing (41) to the gear.
6) Using push tool [5] (Inside diameter: 71 4) Using push tool [8] (Outside diameter: 149
mm), press fit cover assembly (59) to gear mm), press fit bearing (57) to the cover.
(48). 5) Install snap ring (38b).
7) Install spacer (47) and snap ring (46a).
WA500-6R 25
6) Using push tool [9] (Inside diameter: 71 a After press fitting bearing (33), mea-
mm), press fit cover assembly (60) to gear sure dimension (a) at 4 places on the
(40). periphery and check that the error is
7) Install spacer (39) and snap ring (38a). not larger than 0.05 mm.
8) Fit the O-ring and install PTO gear A 2) Install gear (32) to the pump case and
assembly (37), using eyebolts [11]. tighten 16 bolts (31).
2 O-ring: Grease (G2-LI) 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
<Steps 4 – 10 are assembly procedures for

torque converter>
4. Pump assembly 3) Using push tool [11] (Inside diameter: 121
1) Using push tool [10] (Outside diameter: mm), press fit inner race (34) to stator
215 mm), press fit bearing (33) to gear shaft (29).
4) Install seal ring (35).
2 Seal ring: Grease (G2-LI)
(32).
26 WA500-6R
5) Install pump case (61) to stator shaft (29). 7) Install spacer (27).
a When installing, set ball (28) correctly.

mm), press fit inner race (66) to stator 8) Install the bolts to the pump case and lock
shaft (29). them with bar [8].
9) Using tool F2, tighten nut (26).
3 Mounting bolt:
441 – 490 Nm {45 – 50 kgm}
a After tightening nut (26), drop 6 cc of
TO30 or TO10 onto the bearing and
rotate the bearing 10 turns. Then,
check the tightening torque of 441 –
490 Nm {45 – 50 kgm} for nut (26)
again.
a Match the product Nos. (c) and match

symbols "A" (d) of the inner and outer
races of bearing (33) and use those
races as an assembly.
WA500-6R 27
5. Stator assembly 2) Install stator assembly (21).

1) Install freewheel (24) to race (23).
a When inserting freewheel (24), do not
use a hammer etc. but use your
hands.
a When inserting the freewheel, take
care of ball (25).
6. Turbine assembly
1) Install snap ring (12).
2) Install turbine (14) to the turbine boss and
tighten 20 mounting bolts (13).
3 Mounting bolt:
a When installing the one-way clutch, 59 – 74 Nm {6 – 7.5 kgm}
direct arrow (b) of the free rotation
direction on the front face of the cage
toward the input side (turbine side).
Clockwise: Free rotation
Counterclockwise: Locked
a Do not remove the sprag (d).
a When inserting, take care that drag
clip (c) on the periphery of the one-
way clutch will not be hitched in the
ball groove of the outer race.

1) Using eyebolts [13], install drive case (63)
to turbine boss assembly (11).
28 WA500-6R
2) Apply tool [14] (Outside diameter: 150 2) Install seal ring (19b) to piston (17).
mm, Height: 129 mm) to the bottom of tur- a Set pressure receiving side (e) of the
bine boss assembly (11) to hold the latter. seal ring in the arrow direction as
a This work is for securing a space for shown below.
installing the disc to drive case (63). 2 Periphery of seal ring:
Grease (G2-LI)
3) Install disc (20).

3) Using eyebolts [15], install piston housing
(16).
4) Tighten 30 mounting bolts (15).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
8. Piston housing assembly

1) Install seal ring (19a) to piston housing
(16).
a Do not remove dowel pin (64) since it
is a complete part.
2 Periphery of seal ring:
Grease (G2-LI) 5) Using push tool [16] (Outside diameter:
179 mm), press fit bearing (18).
WA500-6R 29
a After press fitting bearing (18), mea- 11. Pilot

sure dimension (e) at 4 places on the Install pilot (65) and tighten 8 mounting bolts
periphery and check that the error is (4).
not larger than 0.05 mm. 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}

Install spacer (10) and snap ring (9).
1) Set torque converter case (66).
10. Turbine assembly

1) Using eyebolts [5], install turbine assem-
bly (8). 2) Install guide bolt [17] to stator shaft (29).
2) Tighten 36 lower mounting bolts (7). 3) Using eyebolts [18] and positioning with
2 Mounting bolt: Adhesive (LT-2) guide bolt [17], install torque converter
3 Mounting bolt: assembly (6).
49 – 58.8 Nm {5 – 6 kgm} 4 Torque converter assembly: 180 kg
3 Drain plug (2 pieces):
9.8 – 12.7 Nm {1 – 1.3 kgm}
30 WA500-6R
4) Tighten 16 mounting bolts (5) from under

side.
13. Housing
1) Fit the O-ring and install housing (3), using
eyebolts [19].
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
14. Connect the torque converter assembly to the

power train unit. For details, see "Disconnec-
tion and connection of power train unit".
WA500-6R 31
Disassembly and assembly of 4. Torque converter assembly

torque converter assembly 1) Remove 16 mounting bolts (6) from the
lower part.
(Lockup-less specification) 2) Remove torque converter assembly (8)
Special tools from case (7).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Puller 
1 790-101-2102 t 1
F (294 kN {30 ton})
2 793-613-1210 Wrench t 1
Disassembly
1. Disconnect the torque converter assembly
from the power train unit. For details, see "Dis-
connection and connection of power train unit".
<Steps 5 – 10 are disassembly procedures for
2. Housing torque converter>
1) Set torque converter assembly (1) on the 5. Turbine assembly
block. 1) Remove 36 lower mounting bolts (9).
2) Remove 12 mounting bolts (2). (Leave the 2 bolts on the right and left
3) Remove housing (3). sides.)
2) Remove the left 2 bolts and lift off turbine
assembly (10).
3. Pilot
2) Remove pilot (5).
32 WA500-6R
6. Snap ring and spacer 8. Drive case assembly

Remove snap ring (11) and spacer (12). Remove bearing (17) from drive case (63).
7. Turbine boss assembly 9. Stator

1) Using tool F1 and push tool [1] (Outside 1) Remove snap ring (18).
diameter: 104 mm), remove turbine boss 2) Remove stator (19).
assembly (13).
10. Pump assembly

2) Remove snap ring (14). 1) Install the bolts to the pump case and lock
3) Remove 20 mounting bolts (15) and tur- them with bar [2].
bine (16). 2) Using tool F2, remove nut (20).
WA500-6R 33
3) Remove spacer (21). 6) Remove 16 mounting bolts (25) and gear

a When removing the spacer, take care (26).
of ball (22). 7) Remove bearing (27).
4) Using push tool [3], remove stator shaft 8) Remove inner race (28) and seal ring (29)
(23). from stator shaft (23).
9) Remove collar (52).
5) Remove inner race (24).

gear A assembly (31).
34 WA500-6R
3) Using eyebolts [5], remove PTO gear A 12. PTO gear B assembly
assembly (31). 1) Remove 8 mounting bolts (39).
gear B assembly.
4) Remove snap ring (32a) and spacer (33).

5) Remove gear (34) and bearing (35).
6) Remove snap ring (32b) and bearing (36). 3) Using eyebolts [7], remove PTO gear B
assembly (40).
7) Remove snap ring (37) and outer race

(38) on the case side. 4) Remove snap ring (41a) and spacer (42).
5) Remove gear (43) and bearing (44).
6) Remove snap ring (41b) and bearing (45).
WA500-6R 35
7) Remove snap ring (46) and outer race Assembly

(47) on the case side. 1. Idler gear
1) Install bearings (50a) and (50b) to gear
(49).
13. Idler gear

1) Remove mounting bolt (48).
2) Using forcing screw [8], pull out the shaft 2) Set gear (49) to the case.
down and remove gear (49). 3) Fit the O-ring to shaft (51) and press fit
them.
4) Reverse the case and install mounting bolt
(48).
3 Mounting bolt:
153 – 190 Nm {15.5 – 19.5 kgm}
3) Remove bearings (50a) and (50b) from

gear (49).
36 WA500-6R
2. PTO gear B assembly 8) Fit the O-ring and install PTO gear B
1) Install snap ring (46) to the case. assembly (40), using eyebolts [7].
2) Using push tool [1] (Outside diameter: 99 2 O-ring: Grease (G2-LI)
side.
mm), press fit bearing (44) to the gear.

1) Install snap ring (37) to the case.
4) Using push tool [3] (Outside diameter: 124 side.
mm), press fit bearing (45) to the cover. 3) Using push tool [6] (Inside diameter: 56
5) Install snap ring (41b). mm), press fit bearing (35) to the gear.
6) Using push tool [4] (Inside diameter: 71 4) Using push tool [8] (Outside diameter: 149
mm), press fit cover assembly (52) to gear mm), press fit bearing (36) to the cover.
(43). 5) Install snap ring (32b).
7) Install spacer (42) and snap ring (41a).
WA500-6R 37
6) Using push tool [9] (Inside diameter: 71 a After press fitting bearing (27), mea-
mm), press fit cover assembly (53) to gear sure dimension (a) at 4 places on the
(34). periphery and check that the error is
7) Install spacer (33) and snap ring (32a). not larger than 0.05 mm.
8) Fit the O-ring and install PTO gear A 2) Install gear (26) to the pump case and
assembly (31), using eyebolts [5]. tighten 16 bolts (25).
2 O-ring: Grease (G2-LI) 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

torque converter>
4. Pump assembly 3) Using push tool [11] (Inside diameter: 121
1) Using push tool [10] (Outside diameter: mm), press fit inner race (28) to stator
215 mm), press fit bearing (27) to gear shaft (23).
4) Install seal ring (29).
(26).
5) Install collar (52).
38 WA500-6R
6) Install pump case (54) to stator shaft (23). 8) Install spacer (21).
a When installing, set ball (22) correctly.

mm), press fit inner race (55) to stator 9) Install the bolts to the pump case and lock
shaft (23). them with bar [2].
10) Using tool F2, tighten nut (20).
3 Mounting bolt:
441 – 490 Nm {45 – 50 kgm}
a After tightening nut (20), drop 6 cc of
TO30 or TO10 onto the bearing and
rotate the bearing 10 turns. Then,
check the tightening torque of 441 –
490 Nm {45 – 50 kgm} for nut (20)
again.
a Match the product Nos. (c) and match

symbols “A” (d) of the inner and outer
races of bearing (27) and use those
races as an assembly.
WA500-6R 39
5. Stator 2) Using push tool [13] (Outside diameter:

1) Install stator (19). 179 mm), press fit bearing (17) to drive
2) Install snap ring (18). case (63).
6. Turbine assembly a After press fitting bearing (17), mea-

1) Install snap ring (14). sure dimension (e) at 4 places on the
2) Install turbine (16) to the turbine boss and periphery and check that the error is
tighten 20 mounting bolts (15). not larger than 0.05 mm.
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

Install spacer (12) and snap ring (11).

1) Install drive case (63) to turbine boss
assembly (13).
40 WA500-6R
9. Turbine assembly 11. Torque converter assembly

1) Sling and install turbine assembly (10). 1) Set torque converter case (56).
2) Tighten 36 lower mounting bolts (9).
3 Mounting bolt:
49 – 58.8 Nm {5 – 6 kgm}
3 Drain plug (2 pieces):
9.8 – 12.7 Nm {1 – 1.3 kgm}
2) Install guide bolt [14] to stator shaft (23).

3) Positioning with guide bolt [14], install
torque converter assembly (8) to case (7).
10. Pilot
Install pilot (5) and tighten 8 mounting bolts (4).
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
4) Tighten 16 mounting bolts (6) from under

side.
WA500-6R 41
12. Housing
1) Fit the O-ring to housing (3).
2) Sling housing (3) and install it to torque
converter assembly (1).
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
13. Connect the torque converter assembly to the

power train unit. For details, see "Disconnec-
tion and connection of power train unit".
42 WA500-6R
WA500-6R 43
SEN02906-01


© 2017 KOMATSU
All Rights Reserved
44
SEN02907-03
WA500-6R

WA500-6R 60001 and up
Power train, Part 2

Disassembly and assembly of transmission assembly ................................................................................... 2
Disassembly and assembly of transfer and parking brake assembly ........................................................... 32
Removal and installation of front axle assembly ........................................................................................... 49
Removal and installation of rear axle assembly............................................................................................ 51
WA500-6R 1
Disassembly and assembly of 3. Transmission assembly

transmission assembly 1) Remove 6 mounting bolts (3) from the
lower output shaft side of transmission
Special tools assembly (2).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 799-301-1500 Oil leak tester t 1
769-514-2000 Remover t 1
2
796-515-2140 Adapter 1
G 790-201-1702 Push tool kit 1
790-201-1741 • Push tool 1
3
790-101-5021 • Grip 1
01010-50816 • Bolt t 1
2) Set transmission assembly (2) on block
[2].
Disassembly 3) Remove 18 mounting bolts (4) from the
upper input shaft side.
1. Disconnect the transmission assembly from
the power train unit. For details, see “Discon-
nection and connection of power train unit”.
2. Sleeves
Using forcing screw [1], remove 5 sleeves (1).
4) Remove 2 tie bolts (6).

5) Install eyebolts [3] to the holes of the
removed tie bolts and remove transmis-
sion assembly (5).
a Do not use an impact wrench to
loosen the tie bolts to prevent dam-
age of the cushion sleeve and seizure
of the tie bolts.
4 Transmission assembly: 410 kg
2 WA500-6R
4. Check of clutch piston operation 3) Disassemble No. 1 carrier housing assem-

Using tool G, check the operating condition of bly according to the following procedure.
the piston before disassembling the transmis- 1] Remove snap ring (9).
sion. 2] Remove No. 2 sun gear (10).
5. Input shaft and No. 1 carrier housing 3] Support housing (11) and push out
assembly input shaft (12) with push tool [5].
1) Remove 13 other tie bolts (6).
a Do not use an impact wrench to
loosen the tie bolts to prevent dam-
age of the cushion sleeve and seizure
of the tie bolts.
2) Using eyebolt [4], remove the input shaft
and No. 1 carrier housing assembly (7).
4] Remove snap ring (13) on the inner

race side.
WA500-6R 3
5] Support housing (11) and push out 3] Using a round rod, drive pin (24) into
No. 1 carrier assembly (14) with push shaft (23).
tool [6] (Inside diameter: 91 mm). 4] Remove shaft (23) from No. 1 carrier
6] Remove spacer (15). (14).
5] Remove pin (24) from shaft (23).
a Take care not to lose pin (24).
6] Remove 2 thrust washers (25), nee-
dle roller bearing (26) and planetary
gear (27).
7] Remove snap ring (16).

8] Remove bearing (17).
9] Remove seal ring (18) from housing
(11).
7] Remove sun gear (28) and spacer

(29).
4) Disassemble No.1 carrier assembly (14)

1] Remove spacer (21) and seal ring
(22).
2] Remove snap ring (19) and No. 1 ring
gear (20).
4 WA500-6R
8] Using push tool [7] (Outside diameter: 7. No. 1 plate, spring and No. 1 disc
64 mm), remove the spacer and bear- Remove 7 No. 1 discs (36), 35 springs (37)
ing assembly (30). and 6 No. 1 plates (38).
10] Using push tool [8], remove bearing
(32).
8. Guide pin and piston

1) Remove 5 guide pins (39) and piston (40).
11] Remove snap ring (33) from No. 1

carrier (14).
12] Using push tool [9], remove bearing
(34).
2) Remove seal ring (41) from piston (40).
6. No. 1 spring
Remove 10 No. 1 springs (35).
WA500-6R 5
9. No. 1 and No. 2 piston housing assembly a When removing cushion sleeve (166)
1) Using eyebolts [10], remove No. 1 and No. from No. 2 piston housing (42), check
2 piston housing assembly (42). slit position (A).
a When disconnecting the dowel pin,
drive it out with a copper hammer.
a When slinging the housing assembly,
take care that the No. 2 piston will not
fall.
10. No. 2 piston

1) Remove No. 2 piston (45).
2) Remove seal rings (43) and (44) from No.

1 and No. 2 piston housing (42).
2) Remove seal ring (46) from No. 2 piston

(45).
3) Remove 15 cushion sleeves (166) from

No. 2 piston housing (42).
6 WA500-6R
11. No. 2 spring 3) Support No. 2 housing assembly (53) and

Remove 10 No. 2 springs (47). push out No. 2 carrier assembly (54) with
push tool [12] and the press
a Push the No. 2 carrier.
12. No. 2 disc, spring and No. 2 plate

Remove 7 No. 2 discs (48), 35 springs (49)
and 6 No. 2 plates (50). 4) Disassemble No. 2 housing assembly (55)
2] Support No. 2 housing assembly (55)
and push out bearing (57) with push
tool [13] (Outside diameter: 179 mm)
and the press.
13. No. 2 carrier and housing assembly

1) Using eyebolts [11], remove the No. 2 car-
rier and housing assembly (51).
2) Remove snap ring (52) on the bearing
inner race side.
3] Remove seal ring (58) from No. 2

housing (55).
WA500-6R 7
5) Disassemble No. 2 carrier assembly (54) 5] Remove pin (65) and shaft (66) from
according to the following procedure. No. 2 carrier (62).
1] Remove spacer (59). a Take care not to lose pin (65).
2] Remove ring gear (61). 6] Remove 2 thrust washers (67), nee-
gear (69).
3] Insert rods in 4 snap ring removing

holes (a) of ring gear (64) and push
out snap ring (63). 14. Guide pin and plate
4] Remove No. 2 carrier assembly (62) Remove 5 guide pins (70) and upper plate
from ring gear (64). (71).
15. No. 3 spring


and 3 No. 3 plates (75).
8 WA500-6R
17. Plate 20. No. 3 piston assembly

Remove lower plate (76). 1) Remove No. 3 piston assembly (79) and
seal rings (80) and (81) from No. 3 and
No. 4 housing (78).
2) Remove No. 4 piston assembly (82) and
seal rings (83) and (84) from No. 3 and
No. 4 housing (78).
18. No. 3 ring gear

Remove No. 3 ring gear (77).
19. No. 3 and No. 4 housing and piston assem-

bly
1) Using eyebolts [13], remove No. 3 and No. 21. Plate
4 housing and piston assembly (78). Remove upper plate (85).
22. No. 4 spring


WA500-6R 9
24. Plate 3) Disassemble No. 3 and No. 4 carrier

Remove lower plate (90). assembly (91) according to the following
procedure.
1] Using tool G2, pull out No. 3 shaft
(92).
a Take care not to lose ball (93).
gear (96).
25. No. 3 and No. 4 carrier assembly

1) Using eyebolts [14], sling No. 3 and No. 4
carrier assembly (91) temporarily.
2) Using bar [15], push up No. 3 and No. 4
carrier assembly (91) to remove.
a When No. 3 and No. 4 carrier assem-

bly (91) is disassembled, bearing
(104) comes out to the end of plane-
tary gear (96). Take care that bearing
(104) will not contact the thrust
washer.
10 WA500-6R
3] Using a round rod, drive pin (97) into 7] Remove seal ring (106) from No. 3
No. 4 shaft (98). and No. 4 carrier (105).
4] Using round rod [16], drive out No. 4 8] Remove bushing (107).
shaft (98) from the No. 3 shaft carrier
side.
dle roller bearing (102) and No. 4
planetary gear (103).
26. No. 4 sun gear

1) Remove snap ring (108) and spacer (109).
2) Remove No. 4 sun gear (110).
3) Remove seal ring (111) from spacer (109).
6] Using push tool [17], push out bearing

(104) with the press.
WA500-6R 11
27. No. 4 ring gear 29. No. 5 plate

1) Remove 4 mounting bolts (112) and cover Remove No. 5 upper plate (119).
(113).
2) Remove No. 4 ring gear (114).
30. No. 5 spring

28. No. 5 housing and No. 5 piston assembly
1) Using eyebolts [17], remove No. 5 housing 31. Remove 3 No. 5 discs (121), 15 springs (122)
assembly (115). and 2 No. 5 plates (123).
a When slinging the housing, take care
that the No. 5 piston will not fall. 32. Remove 5 guide pins (124).
2) Using eyebolts (17a), remove No. 5 piston
(116) from No. 5 housing assembly (115).
3) Remove seal ring (117) from No. 5 piston

(116).
4) Remove seal ring (118) from No. 5 hous-
ing (115).
12 WA500-6R
33. Remove No. 5 ring gear (125).
34. Remove No. 5 plate (126).
35. Remove bearing (127).
3) Disassemble No. 5 carrier assembly (129)

36. No. 5 sun gear

1) Remove spacer (160) and No. 5 sun gear
(161).
2) Remove bearing (127) and seal ring (162)
from spacer (160).
2] Remove shaft (131), ball (132) and

plug (133) from No. 5 carrier assem-
bly (129).
gear (136).
37. No. 5 carrier assembly

2) Using eyebolts [18], remove No. 5 carrier
assembly (129).
WA500-6R 13
38. No. 6 plate 2) Remove seal ring (144) from No. 6 piston
Remove No. 6 upper plate (137). (143).
3) Remove seal ring (146) from No. 6 hous-
ing (145).
39. No. 6 spring

43. No. 6 hub
40. Remove 4 No. 6 discs (139), 20 springs (140) Remove No. 6 hub (147).
41. Remove 5 guide pins (142).
44. Output shaft

1) Remove snap ring (148).
42. No. 6 piston 2) Support the cage and drive out output
1) Remove No. 6 piston (143). shaft (149) with push tool [19] and a ham-
mer.
a Place a receiver to receive the shaft
which will fall down.
14 WA500-6R
3) Remove bearing (150) from output shaft 3) Remove seal ring (154) from cage assem-
(149). bly (153).
45. Cage assembly 46. No. 6 housing assembly

1) Remove snap ring (151). 1) Remove snap ring (155) from No. 6 hous-
ing assembly (152).
2) Support No. 6 housing assembly (152)

and push out cage assembly (153) with 2) Using push tool [21], remove bearing
push tool [20] (Outside diameter: 139 mm) (157), bushing (158) and ball (159) from
and the press. housing (156).
WA500-6R 15
Assembly 2) Using push tool [3] (Inside diameter: 141

mm), press fit No. 6 housing assembly
1. No. 6 housing assembly
(152) to cage assembly (153).
a Press the inner race of bearing (157).
mm), press fit bearing (157) to No. 6 hous-
ing (156).
mm), press fit bushing (158) and ball (159)
to No. 6 housing (156).
3) Install snap ring (155) to No. 6 housing

(152).
3. Output shaft
mm), press fit bearing (150) to output
shaft (149).
2) Set No. 6 housing assembly (152) to tool
[5].
2. Cage assembly
1) Install 2 seal rings (154) to cage (153).
mm), press fit output shaft and bearing
assembly (149).
a Press bearing (150) of the output
shaft.
16 WA500-6R
5. Guide pin
Install 5 guide pins (142).
6. No. 6 pin
Install No. 6 piston (143).
7. No. 6 hub
Install No. 6 hub (147).
4. Seal ring
1) Install seal ring (146) to No. 6 housing
assembly (145).
2) Install seal ring (144) to No. 6 piston
assembly (143).
8. No. 6 plate, spring and No. 6 disc

Install 3 No. 6 plates (141), 20 springs (140)
and 4 No. 6 discs (139).
9. No. 6 spring
Install 10 No. 6 springs (138).
a Set groove (a) of the seal ring in pres-

sure receiving direction (b).
10. No. 6 plate

Install No. 6 upper plate (137).
WA500-6R 17
11. No. 5 carrier assembly 2) Using eyebolts [18] and setting the dowel
1) Assemble No. 5 carrier assembly (129) pin, install No. 5 carrier assembly (129).
according to the following procedure. 3) Install 11 mounting bolts (128).
1] Install needle roller bearing (135) to a Drive in the dowel pin with a copper
planetary gear (136). hammer.
2] Fit 2 thrust washers (134) each to 2 Mounting bolt: Adhesive (LT-2)
both sides of planetary gear (136) 3 Mounting bolt:
and set them to the No. 5 carrier. 157 – 177 Nm {16 – 18 kgm}
a Align each part with the shaft
hole.
3] Fit plug (133) and ball (132) to shaft
(131) and install them.
a Check that the planetary gear
rotates smoothly.
12. No. 5 sun gear

1) Install No. 5 sun gear (161).
2) Install bearing (127) and seal ring (162) to
spacer (160).
4] Install snap ring (130) to No. 5 carrier

assembly (129).
18 WA500-6R
13. Install the bearing and spacer assembly (127). 20. Install No. 5 housing and No. 5 piston
assembly
14. Install No. 5 plate (126). 1) Install seal ring (117) to No. 5 piston (116).
2) Install seal ring (118) to No. 5 housing
15. Install No. 5 ring gear (125). (115).
16. Install 5 guide pins (124).

a Set groove (c) of the seal ring in pres-
17. Install 2 No. 5 plates (123), 3 No. 5 discs (121) sure receiving direction (d).
and 15 springs (122) alternately.
18. Install 10 No. 5 springs (120).
3) Using eyebolt [7], install No. 5 housing

(115) and No. 5 piston (116).
a While installing, support No. 5 piston
19. No. 5 plate (116) with the hand to prevent it from
Install No. 5 upper plate (119). falling.
WA500-6R 19
21. No. 4 ring gear 2) Install No. 4 sun gear (110).

1) Install snap ring (163). 3) Install spacer (109).
2) Install No. 4 ring gear (114). 4) Install snap ring (108).
3) Install cover (113). 23. Plate

4) Install 4 mounting bolts (112). Install lower plate (90).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
24. No. 4 plate, spring and No. 4 disc

Install 2 No. 4 plates (89), 15 springs (87) and
3 No. 4 discs (88).
22. No. 4 sun gear and spacer
1) Install seal ring (111) to spacer (109). 25. No. 4 spring
2 Seal ring: Grease (G2-LI) Install 10 No. 4 springs (86).
20 WA500-6R
26. Plate 28. No. 3 and No. 4 housing assembly

Install upper plate (85). Using eyebolts [8], install No. 3 and No. 4
housing assembly (78).
a While installing, support No. 4 piston (80)
with the hand to prevent it from falling.
a Drive in the dowel pin with a copper ham-
mer.
27. No. 3 piston and No. 4 piston assembly

1) Install seal rings (81) and (84) to No. 3
and No. 4 housing (78).
2) Install seal ring (80) to No. 3 piston (79)
and then install them to No. 3 and No. 4
housing (78). 29. No. 3 and No. 4 carrier assembly
3) Install seal ring (83) to No. 4 piston (82) 1) Assemble the No. 3 and No. 4 carrier
and then install them to No. 3 and No. 4 assembly according to the following pro-
housing (78). cedure.
2 Seal ring: Grease (G2-LI) 1] Install seal ring (106) to No. 3 and
No. 4 carrier (164).
a Set groove (e) of the seal ring in pres-

sure receiving direction (f).
2] Using push tool G3, press fit bushing
(107) to No. 3 and No. 4 carrier (164).
WA500-6R 21
3] Using push tool [9], press fit bearing a If pin (97) was removed from car-
(104) to No. 3 and No. 4 carrier (164). rier (164), remove the burrs from
edge (g) with sandpaper.
a Do not apply sandpaper to inside
surface (h), however.
4] Install needle roller bearing (102) to

5] Fit 2 thrust washers (101) to both
sides of planetary gear (103) and set 8] Install needle roller bearing (95) to
them to the No. 3 and No. 4 carrier. planetary gear (96).
a Align each part with the shaft 9] Put 2 thrust washers (94) to both
hole. sides of the planetary gear and set
6] While setting the pin holes, install them to the No. 3 and No. 4 carrier.
shaft (98). 10] Install shaft (92) and ball (93).
7] Install pin (97). a Check that the planetary gear
rotates smoothly.
22 WA500-6R
11] Install No. 3 and No. 4 carrier assem- 33. No. 3 plate, spring and No. 3 disc
bly (129). Install 3 No. 3 plates (75), 20 springs (73) and
a Apply push tool [10] to No. 3 and 4 No. 3 discs (74).
No. 4 carrier assembly (129) and
press fit the bearing inner race to 34. No. 3 spring
the output shaft. Install 10 No. 3 springs (72).
30. Guide pin 35. Plate

Install 5 guide pins (70). Install upper plate (71).
31. No. 3 ring gear

Install No. 3 ring gear (77).
32. Plate
Install lower plate (76).
WA500-6R 23
36. No. 2 carrier and housing assembly

1) Assemble the No. 2 carrier assembly
1] Set snap ring (63) to No. 2 carrier
assembly (62) and install ring gear
(64).
2] Install snap ring (63) to the groove of
ring gear (64) securely.
a If pin (65) was removed from car-

rier (62), remove the burrs from
edge (m) with sandpaper.
surface (n), however.

4] Fit 2 thrust washers (67) to both sides
of planetary gear (69) and set them to
the No. 2 and No. 4 carrier (62).
hole.
5] While setting the pin holes, install
shaft (66).
6] Install pin (65).
rotates smoothly. 7] Install spacer (59) and ring gear (61)
to the No. 2 carrier assembly.
24 WA500-6R
2) Assemble the No. 2 housing assembly 4] Support No. 2 carrier assembly (165)
according to the following procedure. and press fit No. 2 housing (54) with
1] Install seal ring (58) to No. 2 housing push tool [13].
(55). a Press fit the bearing inner race.
2 Seal ring: Grease (G2-LI) 5] Install snap ring (52).
2] Support No. 2 housing assembly (55) 3) Using eyebolts [14], install No. 2 carrier
and press fit bearing (57) with push and housing assembly (51).
tool [12].
3] Install snap ring (56).

1) Install 6 No. 2 plates (50), 7 No. 2 discs
(48) and 35 springs (49) alternately.
2) Install 10 springs (47).
WA500-6R 25
38. No. 1 and No. 2 piston housing assembly 5] Install 15 cushion sleeves (166) to
1) Assemble No. 1 and No. 2 piston housing No. 2 piston housing (42).
assembly according to the following pro-
cedure.
1] Install seal rings (43) and (44) to No.
1 and No. 2 piston housing (42).
2] Install seal ring (41) to No. 1 piston
(40).
3] Install seal ring (46) to No. 2 piston
(45).
4] Install No. 1 piston (40) and No. 2 pis-
ton (45) to No. 1 and No. 2 piston
housing (42).
a When installing cushion sleeve (166) to
No. 2 piston housing (42), set slit (A) to
the position which you checked when you
removed it.
a Set groove (j) of the seal ring in

pressure receiving direction (k).
39. Using eyebolts [15], install No. 1 and No. 2 pis-

ton housing assembly (42).
a While installing, support No. 2 piston (45)
with the hand to prevent it from falling.
a Drive in the dowel pin with a copper ham-
mer.
26 WA500-6R
40. No. 1 carrier assembly

1) Assemble the No. 1 carrier assembly
1] Using push tool [16], press fit bearing
(34) to No. 1 carrier (14).
2] Install snap ring (33) to No. 1 carrier
(14).
a If pin (24) was removed from car-

rier (14), remove the burrs from
edge (r) with sandpaper.
surface (s), however.

4] Fit 2 thrust washers (25) to both sides
of planetary gear (27) and set them to
the No. 1 carrier (14).
hole.
5] While setting the pin holes, install
shaft (23).
6] Install pin (24).
rotates smoothly.
7] Set No. 1 ring gear (20) to No. 1 car-
rier assembly (14) and install snap
ring (19).
WA500-6R 27
41. Input shaft 44. No. 2 sun gear

Support No. 1 carrier (14) and press fit input 1) Install No. 2 sun gear (10).
shaft (12) with push tool [22]. 2) Install snap ring (9).
45. Input shaft and No. 1 carrier assembly

Using eyebolts [20], install the input shaft and
No. 1 carrier assembly (167).
42. Spacer and sun gear

Install spacer (29) and sun gear (28).
43. Bearing and spacer

1) Using push tool [18] (Inside diameter: 66 46. Guide pin
mm), press fit bearing (32) to spacer (30). Install 5 guide pins (39).

mm), press fit spacer (30).
3) Install snap ring (31) to spacer (30).
a After assembling, check that the
bearing rotates lightly.
28 WA500-6R
47. No. 1 plate, spring and No. 1 disc 3) Install snap ring (16) to fix bearing (17).
Install 6 No. 1 plates (38), 35 springs (37) and
7 No. 1 discs (36) alternately.
48. No. 1 spring

Install 10 No. 1 springs (35).
4) Using eyebolts [24], install No. 1 housing

(11).
49. No. 1 housing

1) Install seal ring (18) to No. 1 housing (11).
2) Using push tool [23] (Outside diameter:
149 mm), press fit bearing (17).
5) Install eyebolt [25] to the input shaft, sling

the input shaft, and install snap ring (13).
WA500-6R 29
6) Install 13 tie bolts (6). 51. Transmission assembly

a Do not install 2 tie bolts (6a) to install 1) Install dowel pin (168) from the output
the eyebolts. shaft side.
a Finger tighten the tie bolts so that 2) Install the eyebolts to the bolt holes
they will not damage the cushion marked with *.
sleeves until they reach the tap hole.
a Use an impact wrench after the
threads are engaged perfectly.
a Do not degrease the threads of the tie
bolts.
3 Mounting bolt:
157 – 177 Nm {16 – 18 kgm}
3) Set transmission case (169) on block [26].

4) Using eyebolts [27], install transmission
assembly (5).
50. Check of operation and stroke of clutch

piston
Using tool G, check the operation and stroke of
the clutch piston.
a Air pressure:
0.29 – 0.49 MPa {3 – 5 kg/cm2}
Piston Stroke (mm)
No. 1 7
No. 2 7
No. 3 4.2 5) Set dowel pin (168) and install the trans-
mission assembly.
No. 4 3
6) Install 6 lower mounting bolts (3) and 18
No. 5 3 upper mounting bolts (4).
No. 6 4 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2 Shaft (Spline): Grease (LM-G)
30 WA500-6R
7) Install 2 tie bolts (170) which were

removed to install the eyebolts.
a Finger tighten the tie bolts so that
they will not damage the cushion
sleeves until they reach the tap hole.
a Use an impact wrench after the
threads are engaged perfectly.
a Do not degrease the threads of the tie
bolts.
3 Mounting bolt:
157 – 177 Nm {16 – 18 kgm}
52. Sleeve
Using forcing screw [1], install 5 sleeves (1).
53. Couple the transmission assembly with the

power train unit. For details, see “Disconnec-
tion and connection of power train unit”.
WA500-6R 31
Disassembly and assembly of Disassembly

transfer and parking brake 1. Disconnect the transfer and parking brake
assembly from the power train unit. For
assembly details, see "Disconnection and connection of
Special tools power train unit".
New/Remodel
2. Remove strainer (1) and drain valve (2).
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-101-2501 Push puller t 1
790-101-2610 • Leg 1
790-101-2660 • Adapter 1
790-101-2510 • Block 1
4 790-101-2560 • Nut 1
01643-32060 Washer t 2
Puller 
790-101-2102 t 2
(294 kN {30 ton})
790-101-1102 Pump t 6
790-101-2501 Push puller t 1 3. Remove speed sensor (3).
790-101-2540 • Washer 1
790-101-2620 • Leg 2
G 790-101-2510 • Block 1
790-101-2660 • Adapter 2
790-101-2560 • Nut 2
791-112-1180 • Nut 1
5
791-520-4140 Screw t 1
793T-615-1630 Adapter t 1 N Q
793T-615-1640 Push tool t 1 N Q
01643-32060 Washer t 2
Puller 
790-101-2102 t 1
(294 kN {30 ton}) 4. Input shaft bearing cage assembly
790-101-1102 Pump t 1 1) Remove 6 mounting bolts (4).
6 793-615-1140 Spline wrench t 1 2) Using forcing screws [1], remove bearing
cage assembly (5).
7 796-720-3800 Wrench assembly t 1
32 WA500-6R
3) Remove shim (6). 6. Outer race (Input shaft side)

a Check the thickness and quantity of Remove outer race (12) from the case.
those shims.
7. Cover (Input shaft side)

1) Reverse the transfer case.
4) Using push tool [2], remove outer race (7) 2) Remove 3 mounting bolts (13) and cover
from bearing cage assembly (5). (14).
5. Input shaft gear assembly 8. Intermediate shaft bearing cage assembly

1) Remove input shaft gear assembly (8). 1) Remove 8 mounting bolts (15).
2) Remove bearings (10) and (11) from input 2) Using forcing screws [3], remove bearing
shaft gear assembly (8). cage assembly (16).
WA500-6R 33
3) Remove shim (17). 10. Outer race (Intermediate shaft side)

a Check the thickness and quantity of Remove outer race (22) from the case.
those shims.
<Steps 11 – 22 are disassembly procedures for

parking brake>
4) Remove outer race (18) and O-ring (86) 11. Parking brake emergency release valve
from bearing cage assembly (16). 1) Reverse the case.
2) Remove mounting bolts (32) and parking
brake emergency release valve (33).
3) Remove O-ring (87) from the mating face.
4) Using forcing screw [4], remove sleeve
(34).
5) Remove O-rings (88) from sleeve (34).
9. Intermediate shaft gear assembly

1) Remove intermediate shaft gear assembly
(19).
2) Remove bearings (20) and (21) from inter-
mediate shaft gear assembly (19).
34 WA500-6R
12. Coupling (Rear side) 14. Cover assembly

Remove bolt (35), holder (36) and coupling 1) Remove mounting bolts (41) and remove
(37). oil seal (43), dust seal (44) and O-ring (45)
from cage (42).
13. Parking brake assembly

1) Remove 12 mounting bolts (38). 2) Install stopper bolts [7] and remove 4
a Do not remove 4 hexagon socket hexagon socket head bolts (39).
head bolts (39). 3) Loosen stopper bolts [7] gradually to dis-
2) Using forcing screws [5], disconnect park- connect cover assembly (46) from the
ing brake assembly (40). case. (The cover assembly is lifted up
from the case about 21 mm by the spring.)
3) Remove the forcing screws used in the

above step from parking brake assembly 4) Lift off cover assembly (46).
(40) and lift off the parking brake assem-
bly, using eyebolts [6].
4) Remove O-ring (89).
WA500-6R 35
5) Remove bearing (47), dowel pin (48) and 17. Piston

O-ring (90) from cover assembly (46). 1) Using eyebolts [9], lift off piston (54).
2) Remove seal rings (55) and (56).
15. Spring
Remove 18 outer springs (49) and 18 inner 18. Gear
springs (50). Remove gear (77).
16. Spacer assembly 19. Plate

1) Remove spacer assembly (51). 1) Reverse the housing.
2) Using push tool [8], remove inner race 2) Remove 4 mounting bolts (57) and plate
(53) from spacer (52). (58).
36 WA500-6R
20. Snap ring and end plate 2) Remove snap ring (91).
Remove snap ring (59) and end plate (60).
23. Coupling (Front side)

21. Plate, disc and wave spring Remove bolt (23), holder (24) and coupling
Remove 5 plates (61), 5 discs (62) and 5 wave (25).
springs (63) alternately.
24. Seal cage

22. End plate 1) Remove 4 bolts (80) and seal cage (81).
1) Remove end plate (64). 2) Remove shim (82).
the shims and keep those shims.
WA500-6R 37
3) Remove O-ring (29), oil seal (83) and dust 26. Output shaft bearing cage assembly
seal (84) from seal cage (81). 1) Remove 6 mounting bolts (66).
2) Using forcing screws [10], remove bearing
cage assembly (67).
3) Using push tool [11], remove outer races
(68a) and (68b), collar (68c) and bearings
(68d) and (68e) from bearing cage (69).
a Since the 2 bearings are not change-
able with each other, keep them and
their respective cages as sets.
25. Output shaft

Using tool G4, remove output shaft (65).
27. Output shaft gear

1) Remove output shaft gear (70) and spacer
(71).
2) Remove 3 mounting bolts (72) and oil
plate (73).
38 WA500-6R
Assembly 3. Bearing cage assembly (Intermediate shaft

gear side)
1. Outer race (Intermediate shaft side) 1) Using push tool [2] (Outside diameter: 179
Using push tool [1] (Outside diameter: 179 mm), press fit outer race (18) to bearing
mm), press fit outer race (22) to the case. cage (16).
2) Fit O-ring (86).
2. Intermediate shaft gear assembly

1) Press fit bearings (20) and (21) to interme-
diate shaft gear assembly (19). 3) Install intermediate shaft bearing cage
assembly (16) without setting any shim.
2) Install intermediate shaft gear assembly

(19).
2 Bearing: Grease (LM-G)
WA500-6R 39
4) Adjusting preload on intermediate shaft 4. Cover (Input shaft side)

bearing Fit the O-ring, install cover (14), and tighten the
Adjust the shim of bearing cage (16) mounting bolts (13).
according to the following procedure. 2 O-ring: Grease (G2-LI)
ting shim (17) and tighten the mount-
ing bolts to 4.9 Nm {0.5 kgm}.
onto it and rotate it about 10
turns.
2] Rotate intermediate shaft gear (19)
20 turns and check the tightening
torque of 4.9 Nm {0.5 kgm} for the
mounting bolts again.
repeat 1] and 2] above.
4] If the tightening torque has not
changed, set shim (17) (Standard 5. Outer race (Input shaft side)
thickness: 1 mm) and tighten the 1) Reverse the case.
m o u n t i n g b o l ts t o t h e s p e c i f i e d 2) Using push tool [3] (Outside diameter: 159
torque. mm), press fit outer race (12) to the case.
5] Using tool G6 and the torque wrench,
measure the rotation torque of inter-
mediate shaft gear (19).
3 Rotation torque:
0.49 – 0.98 Nm {0.05 – 0.1 kgm}
Standard shim thickness: 1 mm
a Check that the gear has no play.
6] After adjusting the preload, remove
intermediate shaft gear (19) and
bearing cage (16) (since the preload
on each gear must be adjusted inde-
pendently).
6. Input shaft gear assembly

1) Press fit bearings (10) and (11) to input
shaft gear (8).
40 WA500-6R
2) Install input shaft gear (8). 3) Adjusting preload on input shaft bearing
2 Bearing: Grease (LM-G) Adjust the shim of bearing cage (5)
ting shim (6) and tighten the mounting
bolts to 4.9 Nm {0.5 kgm}.
onto it and rotate it about 10
turns.
2] Rotate input shaft gear (8) 20 turns
and check the tightening torque of 4.9
Nm {0.5 kgm} for mounting bolts
again.
repeat 1] and 2] above.
7. Bearing cage assembly (Input shaft gear 4] If the tightening torque has not
side) changed, set shim (6) (Standard
1) Using push tool [4] (Outside diameter: 159 thickness: 2 mm) and tighten the
mm), press fit outer race (7) to bearing m o u n t i n g b o l ts t o t h e s p e c i f i e d
cage (5). torque.
5] Using tool G7 and the torque wrench,
measure the rotation torque of input
shaft gear (8).
3 Rotation torque:
0.49 – 0.98 Nm {0.05 – 0.1 kgm}
Standard shim thickness: 2 mm
a Check that the gear has no play.
2) Install input shaft bearing cage assembly

(5) without setting the shim.
WA500-6R 41
8. Output shaft gear assembly 11. Output shaft bearing

1) Put spacer (71), output shaft gear (70) and 1) Using tool G5, press fit bearing (68d).
oil plate (73) in the case. 2) Install collar (68c).
2) Tighten 3 mounting bolts (72). 3) Press fit bearing (68e) similarly.
9. Outer race and output shaft

1) Using push tool [5], press fit outer race
(68a) to bearing cage (69).
2) Install output shaft (65) and support it on
block [6].
12. Outer race

Using push tool [6], press fit outer race (68b).
a After installing the bearing, drop 6 cc of
transmission oil (TO30) onto it and rotate it
about 10 turns.
10. Output shaft bearing cage assembly

Fit the O-ring and install bearing cage assem-
bly (69).
42 WA500-6R
13. Seal cage Portion “c”: Grease may be forced out

1) Using the push tool, press fit oil seal (83) into the space between oil seal
to seal cage (81). and dust seal.
2 Oil seal fitting surface:
a Apply the gasket sealant thinly over
the inside surface of the seal cage
(81) and wipe off the projected part.
a Dimension "a" is 17.7 to 17.8 mm.
4) Adjust the shim according to the following

procedure.
1] Fit the O-ring and install seal cage
(81) without setting the shim.
a Do not tighten the mounting
bolts.
2) Press fit dust seal (84) to seal cage (81) 2] Rotate the shaft about 20 turns.
by using the push tool. 3] Using clearance gauges, measure
a When installing dust seal (84), direct clearance (a) between the seal cage
its lip out. (81) and fitting surface.
a Dimension "b" is 9.3 to 9.4 mm. Shim thickness (b):
a – (0.05 to 0.10) mm
4] Set shim (82) of thickness (b)
obtained by the above procedure and
tighten bolts (80).
3) Apply or fill grease to/into the oil seal and

dust seal lip as shown in the following figure.
Portion "a":Apply grease (G2-S or G2-LI)
to the lip ends (4 places).
Portion "b":Fill grease (G2-S or G2-LI) into
the spaces "between the main
lip and dust lip of oil seal",
"between the dust seal and oil
seal", and "between the double
lips of dust seal" up to 40 to
60%.
Excessively applied grease
can be mistaken for oozing oil.
Take care.
Wipe off the grease forced in or
out.
WA500-6R 43
14. Coupling (Front side) 17. Spacer assembly

1) Fit the O-ring and install coupling (25), 1) Using push tool [2] (Inside diameter: 106
holder (24) and bolt (23). mm), press fit inner race (53) to spacer
2 O-ring: Grease (G2-LI) (52).
2 Mounting bolt: Adhesive (LT-2) 2) Install spacer assembly (51) to cover
3 Mounting bolt: assembly (46).
824 – 1,030 Nm {84.0 – 105 kgm}
18. Spring
15. Intermediate shaft gear assembly 1) Install 18 outer springs (49) and 18 inner
Referring to step 2, install the intermediate springs (50).
shaft gear assembly which has been removed. 2) Install O-ring (90).
parking brake>
16. Cover
Assemble the cover assembly according to the
mm), press fit bearing (47) to cover (46).
2) Install 2 dowel pins (48).
44 WA500-6R
19. Piston 2) Install 4 hexagon socket head bolts (76).

1) Install seal rings (55) and (56) to piston (54).
a Set groove (c) of the seal ring as
shown in the figure.
2) Install piston (54) to cover assembly (46).
22. Gear
Install gear (77).
20. Plug
1) Remove 2 plugs (74).
2) Install the washers to 2 parking brake
assembly mounting bolts and tighten them
into the plug holes.
a Tighten the bolts gradually and alter-
nately.
a Pull the piston by tightening the bolts.
23. Plate, disc and wave spring

2) Install end plate (64).
21. Housing
1) Install housing (75) to cover (46).
WA500-6R 45
3) Install 5 discs (62), 5 wave springs (63)

and 5 plates (61) alternately.
26. Seal cage

1) Press fit oil seal (43) to seal cage (42) by
24. Snap ring and end plate using push tool.
Install end plate (60) and fix it with snap ring 2 Oil seal press fitting surface: Liq-
(59). uid gasket (LG-5) (Thinly apply
to inside of seal cage (42), and
wipe off excess.)
a Dimension "a" is 17.7 to 17.8 mm.
25. Plate
1) Install plate (58) and tighten 4 mounting
bolts (57).
2 Mounting bolt: Adhesive (LT-2) 2) Press fit dust seal (44) to seal cage (42)
by using the push tool.
a When installing the dust seal, direct
its lip out.
a Dimension "b" is 9.3 to 9.4 mm.
2) Reverse the parking brake assembly.

3) Remove the 2 bolts used to install the
spring and install plugs (74).
2 Plug: Gasket sealant (LG-5)
46 WA500-6R
3) Apply or fill grease to/into the oil seal and

dust seal lip as shown in the following fig-
ure.
Portion "a":Apply grease (G2-S or G2-LI)
to the lip ends (4 places).
Portion "b":Fill grease (G2-S or G2-LI) into
the spaces "between the main
lip and dust lip of oil seal",
"between the dust seal and oil
seal", and "between the double
lips of dust seal" up to 40 to
60%. Excessively applied
grease can be mistaken for
oozing oil. Take care.
Wipe off the grease forced in or 3) Install 12 mounting bolts (38).
3 Mounting bolt:
out.
Portion “c”: Grease may be forced out 98 – 123 Nm {10 – 12.5 kgm}
into the space between oil seal
and dust seal.
4) Install seal cage (42) and tighten 4 mount- 28. Sleeve

ing bolts (41). 1) Fit O-ring (88) to sleeve (34).
2) Using forcing screw [4], install sleeve (34).
3) Fit O-ring (87) and install parking brake
emergency release valve (33).
27. Parking brake assembly

1) Fit O-ring (89).
2) Using eyebolts [6], install parking brake
assembly (40).
WA500-6R 47
29. Coupling (Rear side) 31. Install strainer (1) and drain valve (2).
1) Fit the O-ring and install coupling (37),
holder (36) and bolt (35).
a Set coupling (37) to the position of the
coupling on the opposite side.
3 Mounting bolt:
824 – 1,030 Nm {84.0 – 105 kgm}
32. Connect the transfer and parking brake

assembly to the power train unit. For details,
see "Disconnection and connection of power
train unit".
30. Speed sensor

1) Tighten speed sensor (3) until it touches
the gear lightly and then return it by 1/2 - 1
turn to make clearance (d).
Clearance (d): 0.75 – 1.5 mm
2) Tighten locknut (85).
3 Locknut:
49.0 – 68. 6 Nm {5 – 7 kgm}
48 WA500-6R
Removal and installation of front 4. Remove front frame cover (2).

axle assembly
Removal
k Stop the machine on a level ground and
lower the bucket to the ground.
1. Start the engine, dump the bucket gradually to

raise the machine body, and set stands [1]
securely under the front frame.
k Apply the parking brake and lock the
rear tires with chocks.
5. Disconnect brake hose (3).
2. See "Releasing residual pressure in brake

accumulator circuit" in "Testing and adjusting",
and release residual pressure in accumulator
circuit.
6. Remove the mounting bolts and disconnect
3. Install a nylon sling around front tire and wheel
front drive shaft (4). [*2]
assembly (1), sling it, remove its mounting
a When disconnecting the drive shaft, make
bolts, and lift it off. Remove both of the right
a match mark between it and coupling.
and left tires. [*1]
4 Front tire and wheel assembly: 830 kg
WA500-6R 49
7. Sling front axle assembly (5), remove its 8 Installation

mounting bolts (6), and lift it off. [*3] q Carry out installation in the reverse order to
4
removal.
Front axle assembly: 2,300 kg
[*1]
3 Front tire mounting bolt:
824 – 1,030 Nm {84.0 – 105 kgm}
[*2]
3 Drive shaft mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
3 Front axle mounting bolt:
2,450 – 3,038 Nm {250 – 310 kgm}
q Bleeding air
Bleed air from the brake circuit. For details,
see Testing and adjusting, "Bleeding air from
brake circuit".
50 WA500-6R
Removal and installation of rear 5. Install a nylon sling around rear tire and wheel
axle assembly assembly (1), sling it, remove its mounting
bolts, and lift it off. Remove both of the right
Removal and left tires. [*1]
k
4
Stop the machine on a level ground and
lower the bucket to the ground. Rear tire and wheel assembly: 830 kg
1. Start the engine, dump the bucket gradually to

raise the machine body, and set stands [1]
securely under the front end of the rear frame.
2. Tilt the bucket slowly until the front tires are

fully lowered to the ground and the rear tires
are floated.
3. Set jack [2] under the counterweight to support

the rear end of the rear frame.
k Apply the parking brake and lock the
front tires with chocks.
6. Disconnect brake hoses (2) and (3).
7. Disconnect wiring harness connector R17 (4)

and remove the 2 wiring harness connectors.
8. Disconnect grease tubes (5) and (6).
4. See "Releasing residual pressure in brake

accumulator circuit" in "Testing and adjusting",
and release residual pressure in accumulator
circuit.
WA500-6R 51
9. Disconnect rear drive shaft (7). [*2] Installation

removal.
[*1]
3 Rear tire mounting bolt:
824 – 1,030 Nm {84.0 – 105 kgm}
[*2]
3 Drive shaft mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
3 Axle (Support) mounting bolt:
1,519 – 1,911 Nm {155 – 195 kgm}
10. Sling rear axle assembly (8) and support rear
support (9) with jack [3]. q Bleeding air
11. Remove support mounting bolts (10), discon- see Testing and adjusting, "Bleeding air from
nect the support and rear axle assembly from brake circuit".
the machine, and lower the jack and crane
slowly to remove the assembly. [*3]
12. Sling the left (right) side of the axle housing,

support the other side with a jack or a forklift,
and pull out the rear axle and support assem-
bly to the side of the machine.
4 Rear axle and support assembly: 
2,400 kg
52 WA500-6R
WA500-6R 53
SEN02907-03

© 2018 KOMATSU
All Rights Reserved
54
SEN02908-01
WA500-6R

WA500-6R 60001 and up
Power train, Part 3

Removal and installation of front differential assembly ................................................................................... 2
Disassembly and assembly of differential assembly (LSD specification)........................................................ 4
Disassembly and assembly of differential assembly (LSD-less specification) .............................................. 18
Disassembly and assembly of final drive assembly (Front and rear)............................................................ 29
WA500-6R 1
Removal and installation of front 5. Using forcing screw [1], pull out drive shaft (4).
differential assembly a Pull out the drive shaft by about 200 mm.
a Pull out the drive shaft on the opposite
a This section describes the removal and instal- side similarly.
lation procedures for the front differential
assembly. Remove and install the rear differ-
ential assembly similarly.
Removal
k Stop the machine on a level ground, set the
lock bar to the frame, and lock the tires with
chocks.
1. Remove the front axle assembly. For details,

see "Removal and installation of front axle
assembly".
2. Remove plug (1) and drain the axle oil. [*1]

a Set the drain plug at the bottom.
6 Axle oil 6. Remove 18 mounting bolts (5). [*3]
Front: Approx. 98 l
Rear: Approx. 85 l 7. Using eyebolts [2], remove front differential
assembly (6). [*4]
3. Remove 7 bolts (2). [*2] 4 Front differential assembly:

LSD-less specification: 370 kg
4. Remove cover (3). LSD specification: 400 kg
(LSD: Limited Slip Differential)
a Remove the O-ring from the mating face
of the housing.
2 WA500-6R
Installation q Refilling with oil

5
Axle oil
removal.
Front: 98 l
Rear: 85 l
[*1]
3 Plug (1): 58.8 – 78.4 Nm {6 – 8 kgm}
[*2]
Mounting bolt (2): 98 – 123 Nm {10 – 12.5 kgm}
[*3]
Mounting bolt (5): 490 – 608 Nm {50 – 62 kgm}
[*4]
Adjusting clearance adjustment bolt
1) Tighten clearance adjustment bolt (7) to
cap (9) and then return it by 20 – 30° to
make clearance (a).
Clearance (a): 0.08 – 0.13 mm
2) Tighten nut (8).
3 Nut (8): 343 – 441 Nm {35 – 45 kgm}
WA500-6R 3
Disassembly and assembly of 2) Loosen nut (4) with a bar until you can
differential assembly rotate it with your fingers.
3) Sling the differential gear and case
(LSD specification) assembly.
LSD: Limited Slip Differential 4) Remove mounting bolts (5) and cap (6).
a Make marks on the right and left
caps.
Special tools 5) Remove nut (4).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
790-501-5000 Repair stand Q'ty

t 1
H 1 790-901-4110 Bracket t 1
793T-622-2120 Plate t 1 N Q
Disassembly
1. Set differential assembly (1) to tool H1.
4 Differential assembly: 430 kg
6) Using sling [1], remove differential gear
and case assembly (7).
a Take care not to drop bearing outer
race (8).
4 Differential gear and case assem-
bly: 210 kg
2. Differential gear and case assembly

a Perform the following work on the right
and left sides similarly.
1) Remove mounting bolts (2) and remove
lock (3).
4 WA500-6R
3. Gear case cover A 5. Pressure ring A

1) Remove 24 mounting bolts (9). Remove pressure ring A (16).
2) Remove gear case cover A (10).
6. Side gear A
Remove side gear A (17).
4) Remove thrust plate (12) and dowel pin
(13) from gear case cover A (10).
7. Cross shaft and pinion gear

Remove cross shaft (18) and pinion gear (19)
4. Disc and plate together.
Remove 3 discs (14) and 4 plates (15).
WA500-6R 5
8. Side gear B 11. Gear case cover B

Remove side gear B (20). 1) Remove thrust plate (25) and dowel pin
(26) from gear case cover B (24).
9. Pressure ring B
Remove pressure ring B (21). 2) Reverse the gear case and remove bear-
ing (27).
4) Remove gear case cover B (29) from
bevel gear (30).
10. Disc and plate

Remove 4 plates (22) and 3 discs (23).
12. Coupling
1) Remove mounting bolt (31) and holder
(32).
2) Remove shim (33), O-ring (34) and cou-
pling (35).
6 WA500-6R
13. Pinion assembly 6) Disassemble the pinion assembly accord-

1) Remove 18 mounting bolts (36). ing to the following procedure.
2) Using forcing screws [2], disconnect pin- 1] Using tool [4] (Inside diameter: 321
ion assembly (37). mm), support pinion case (39).
2] Using push tool [5], pull out pinion
shaft (40).
3) Using eyebolts [3], remove pinion assem-

bly (37).
4 Pinion assembly: 95 kg 3] Using puller [6] (294 kN {30 ton}), pull
4) Remove shim (38). out bearing (41).
the shim.
4] Remove dust seal (42), oil seal (43)

and bearing (44).
5) Remove differential carrier (47) from tool 5] Remove bearing outer race (45).
H1.
4 Differential carrier assembly: 85 kg
WA500-6R 7
Assembly 2. Gear case cover B

1. Bevel gear assembly 1) Install dowel pin (26) to gear case cover B
1) Using push tool [10] (Inside diameter: 131 (24).
mm), press fit bearing (27) to gear case 2) Install thrust plate (25).
cover B (29).
a Press fit the inner race of the bearing.
3. Disc and plate

Install 3 discs (23) and 4 plates (22) alter-
2) Install gear case cover B (29) to bevel nately.
gear (30). 2 Both sides of plate and disc: AXO80
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
4. Pressure ring B
Install pressure ring B (21).
8 WA500-6R
5. Side gear B 8. Pressure ring A

Install side gear B (20). Install pressure ring A (16).
a When installing, mesh the internal teeth of
the disc with the gear spaces.
9. Disc and plate

Install 4 plates (15) and 3 discs (14) alter-
6. Cross shaft and pinion gear nately.
Install cross shaft (18) and pinion gear (19) a When installing, mesh the internal teeth of
together. the disc with the gear spaces.
2 Both sides of plate and disc: AXO80
7. Side gear A
Install side gear A (17).
WA500-6R 9
Adjusting internal clearance of LSD

Standard (Before After adjustment After adjustment
1) Adjusting clearance between plate and Combination of adjustment) (Sample 1) (Sample 2)
disc plates Flange Cover Flange Cover Flange Cover
1] Using depth gauge [1], measure level side side side side side side
difference (A2) between the case and 425–22–37450

2 2 1 1 4 4
(3.4 mm)
washer.
425–22–37460
2] Using depth gauge [1], measure level (3.5 mm)
2 2 3 3 0 0
difference (A1) of the cover.
q Clearance
(A): A2 – A1 = 0.2 to 0.8 mm 2) Adjusting clearance between thrust
a Measure the clearance at 4 washer and cover
places equally spaced on the 1] Install thrust washer (12) to cover (10)
periphery and obtain the aver- temporarily.
age.
2] Using depth gauge [1], measure level

difference (B1) between the cover
and washer.
3] Using depth gauge [1], measure level
difference (B2) between the case and
washer.
q Clearance (B): (B2 – B1) + (A/2)
a Measure the bottom side simi-
larly.
a Measure the clearance at 4
places equally spaced on the
periphery and obtain the aver-
age.
3] If the clearance is out of the standard

range, adjust it by using plates of dif-
ferent thickness.
q Part No. 425-22-37450: 3.4 mm
q Part No. 425-22-37460: 3.5 mm
a Be sure to use plates of the
same thickness for the lower
side. (See the table.)
a When assembling the plates and
discs, minimize the clearance.
10 WA500-6R
2) Install dowel pin (13) and thrust plate (12)

to gear case cover A (10).
a When installing, apply grease (G2-LI)
thinly to the thrust plate to prevent it
from falling.
4] If the clearance is out of the standard

range, adjust it by using plates of dif-
ferent thickness.
q Part No. 425-22-37390: 3.75 mm
q Part No. 425-22-37380: 4.0 mm
q Part No. 425-22-37370: 4.25 mm 3) Install gear case cover A (10).
10. Gear case cover A 3 Mounting bolt:
1) Using push tool [11] (Inside diameter: 131 98 – 123 Nm {10 – 12.5 kgm}
mm), press fit bearing (11) to gear case
cover (A) (10).
WA500-6R 11
Measuring differential rotation torque 2) Using sling [1], install differential gear and
1) Using the bearing, cap and nut, install the case assembly (7).
differential gear and case assembly tem- a Take care not to drop bearing outer
porarily to the differential carrier. race (8).
2) Fix either side gear of the differential gear 4 Differential gear and case assem-
case assembly with shaft [1] (Stop the bly: 210 kg
rotation of the side gear).
3) Measure the rotation torque of the side
gear on the opposite side with torque
wrench [2].
a Set the case so that it can rotate freely.
a A measuring instrument which satisfies
the measurement condition and can be
fixed to the side gear is usable.
3 Differential rotation torque:
Max. 34 Nm {3.5 kgm}
3) Install nut (4) to the threaded part on the

differential carrier side.
4) Install cap (6) and tighten mounting bolts
(5).
3 Mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}
a Set the match mark on cap (6).
a Drop 6 cc of axle oil (AXO80) onto
the bearing and rotate it about 10
11. Differential gear and carrier assembly turns.
a Perform the following work on the right a Before tightening mounting bolts (5),
and left sides similarly. rotate the bevel gear 20 – 30 turns to
1) Set differential carrier (47) to tool H1. run in the bearing.
12 WA500-6R
5) Adjust the preload on the differential bear-

ing according to the following procedure.
1] Using tool [12], tighten nut (4).
12. Pinion assembly

1) Assemble the pinion assembly according
to the following procedure.
2] Apply push-pull scale [13] to the tip of 1] Using push tool [6] (Inside diameter:
bevel gear (30) and measure starting 101 mm), press fit bearing (41) to pin-
torque (b). ion shaft (40).
Starting torque (b):
53.9 – 83.4 N {5.5 – 8.5 kg}
a If the measured value is out of
the above range, adjust it by
rotating nut (4).
2] Press fit bearing (44) and bearing

outer race (45) to pinion case (46).
a Drop 6 cc of axle oil (AXO80)
onto the bearing and rotate it
about 10 turns.
a Precautions for adjusting start-
ing torque
q If the nut is tightened too much
for starting torque adjustment or
the starting torque is adjusted
defectively, return the nut to the
condition before the adjustment
work.
q At this time, hit the bevel gear
lightly with a plastic hammer
while rotating it.
q At this time, check that there is
not clearance in part (c) and
adjust the preload again.
WA500-6R 13
3] Using push tool [7] (Inside diameter: 2) Coupling

76 mm), press fit pinion case (46) to 1] Install coupling (35).
pinion shaft (40). 2] Install O-ring (34) and shim (33)
a Press fit the inner race of bearing removed for disassembly.
(44). 3] Install holder (32) and tighten mount-
ing bolts (31).
a While rotating the pinion shaft 20
– 30 turns, tighten mounting bolts
(31) gradually.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
824 – 1,030 Nm {84.0 – 105 kgm}
4] Install dust seal (42) and oil seal (43).

a Using the jig, press fit the oil seal
so that its height (a) will be
14 ± 0.5 mm.
a Install the dust seal so that its
height (b) will be the same with
the oil seal.
2 Oil seal: Grease (G2-LI)
Gasket sealant 3) Adjust the preload on the pinion shaft
(THREEBOND 1110B) according to the following procedure.
2 Dust seal: Grease (G2-LI) 1] Install measuring bolt [8] to pinion
a Apply the gasket sealant thinly assembly (37).
over the inside surface of the oil 2] Using push-pull scale [9], measure
seal fitting part of the pinion case starting torque (a).
and wipe off the projected part. Starting torque (a):
49.0 – 127.4 N {5 – 13 kg}
increasing or decreasing the
shims.
14 WA500-6R
4) Install shim (38) removed for disassembly. 2] Apply dial gauge [14] perpendicularly
Shim adjustment allowance: to the tooth surface on the reverse
0.71 – 2.21 mm side at the outer end of the bevel
5) Fit the O-ring and install pinion assembly gear.
(37). 3] Adjust adjustment nut (4) so that dial
2 O-ring: Grease (G2-LI) gauge [14] will indicate the following
4 Pinion assembly: 103 kg range (backlash).
6) Tighten 18 mounting bolts (36). Standard backlash: 0.36 – 0.51 mm
3 Mounting bolt: a Adjust the backlash at 3 – 4
245 – 309 Nm {25 – 31.5 kgm} places and measure it with the
pinion gear fixed.
13. Adjusting tooth contact and backlash
Adjust the backlash and tooth contact simulta-
neously.
1) Adjust the backlash according to the fol-
lowing procedure.
1] Move the bevel gear with adjustment
nuts (4a) and (4b).
a Rotate adjustment nuts (4a) and (4b)
by the same quantity in the same
direction so that the adjusted preload
on the bearing will not change.
q When backlash is less than standard

range
Loosen the adjustment nut on the bevel
gear side and tighten the adjustment nut
on the opposite side by the same angle (to
move the bevel gear in direction (A)).
q When the backlash is above standard
range
Loosen the adjustment nut on the oppo-
site side and tighten the adjustment nut on
the bevel gear side by the same angle (to
move the bevel gear in direction (B)).
WA500-6R 15
2) Checking tooth contact

1] Apply red lead thinly to the surface of
the pinion gear and turn the bevel
gear in the forward and reverse direc-
tions, and then check the tooth con-
tact pattern on the bevel gear.
2] The center of the tooth contact must
be at the middle of the tooth height
and at a point about 33% of the tooth
length (x) from small end (C), and the
tooth contact width must be 30 – 60%
of the tooth length (y).
Check that there is not a strong con-
tact at tip (A), bottom (B), small end
(C) or large end (D). If bevel pinion is too close to bevel gear
a If the tooth contact is adjusted in a The tooth contact pattern is as follows.
this way, the teeth come in con- q Increase the shims of the bevel pinion to
tact with each other correctly move the bevel pinion in direction (E).
when they are loaded. q Move the bevel gear in direction (F).
3) Adjusting tooth contact If bevel gear is too close to bevel pinion

If the tooth contact pattern is not proper, a The tooth contact pattern is as follows.
adjust it according to the following proce- q Decrease the shims of the bevel pinion to
dure. move the bevel pinion in direction (C).
a After adjusting the tooth contact, q Move the bevel gear in direction (D).
check the backlash again.
If bevel pinion is too far from bevel gear

a The tooth contact pattern is as follows.
q Decrease the shims of the bevel pinion to
move the bevel pinion in direction (C).
q Move the bevel gear in direction (D).
16 WA500-6R
If bevel gear is too far from bevel pinion 15. Differential assembly
a The tooth contact pattern is as follows. Remove differential assembly (1) from tool H1.
4
q Increase the shims of the bevel pinion to
Differential assembly: 430 kg
move the bevel pinion in direction (E).
q Move the bevel gear in direction (F).
14. Lock
After finishing all adjustments, install lock (3)
and tighten mounting bolts (2).
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
WA500-6R 17
Disassembly and assembly of 2) Loosen nut (4) with a bar until you can
differential assembly rotate it with your fingers.
3) Sling the differential gear and case
(LSD-less specification) assembly.
4) Remove mounting bolts (5) and cap (6).
a Make distinction marks on the right
Special tools
and left caps.
New/Remodel
5) Remove nut (4).
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-501-5000 Repair stand t 1
H 1 790-901-4110 Bracket t 1
793T-622-2120 Plate t 1 N Q
Disassembly
1. Set differential assembly (1) to tool H1.

4 Differential assembly: 390 kg
6) Using sling [1], remove differential gear
and case assembly (7).
a Take care not to drop bearing outer
race (8).
bly: 180 kg
2. Differential gear and case assembly

and left sides similarly.
1) Remove mounting bolts (2) and remove
lock (3).
18 WA500-6R
3. Gear case cover A 4. Side gear A

1) Remove 8 mounting bolts (9). Remove side gear A (14).
2) Remove gear case cover A (10).

Remove cross shaft (15), pinion gear (16) and
4) Remove dowel pin (13) from gear case washer (17) together.
cover A (10).
6. Side gear B
5) Remove thrust plate (12). Remove side gear B (18).
WA500-6R 19
7. Gear case cover B 9. Pinion assembly

1) Remove thrust plate (20) and dowel pin 1) Remove 18 mounting bolts (36).
(21) from gear case cover B (19). 2) Using forcing screws [2], disconnect pin-
ion assembly (37).

3) Remove 20 mounting bolts (23). 3) Using eyebolts [3], remove pinion assem-
4) Remove gear case cover B (24) from bly (37).
bevel gear (25). 4 Pinion assembly: 95 kg
4) Remove shim (38).
the shim.
8. Coupling
1) Remove mounting bolt (31) and holder
(32).
2) Remove shim (33), O-ring (34) and cou- 5) Remove differential carrier (47) from tool
pling (35). H1.
20 WA500-6R
6) Disassemble the pinion assembly accord- Assembly

ing to the following procedure. 1. Bevel gear assembly
1] Using tool [4] (Inside diameter: 321 1) Using push tool [10] (Inside diameter: 131
mm), support pinion case (39). mm), press fit bearing (22) to gear case
2] Using push tool [5], pull out pinion cover B (24).
shaft (40). a Press fit the inner race of the bearing.
3] Using puller [6] (294 kN {30 ton}), 2) Install gear case cover B (24) to bevel
pull out bearing (41). gear (25).
3 Mounting bolt:
(Front) 550 –608 Nm {56 – 62 kgm}
(Rear) 490 – 608 Nm {50 – 62 kgm}
4] Remove dust seal (42), oil seal (43)

and bearing (44).
5] Remove bearing outer race (45).
WA500-6R 21
2. Gear case cover B 5. Side gear A

1) Install dowel pin (21) to gear case cover B Install side gear A (14).
(19).
2) Install thrust plate (20).
6. Gear case cover A

3. Side gear B mm), press fit bearing (11) to gear case
Install side gear B (18). cover (A) (10).

Install cross shaft (15), pinion gear (16) and 2) Install dowel pin (13) and thrust plate (12)
washer (17) together. to gear case cover A (10).
a When installing, apply grease (G2-LI)
thinly to the thrust plate to prevent it
from falling.
22 WA500-6R
3) Install gear case cover A (10). 2) Using sling [1], install differential gear and
4) Tighten 8 mounting bolts (9). case assembly (7).
3 Mounting bolt: a Take care not to drop bearing outer
490 – 608 Nm {50 – 62 kgm} race (8).
bly: 180 kg
7. Differential gear and carrier assembly

and left sides similarly. 3) Install nut (4) to the threaded part on the
1) Set differential carrier (47) to tool H1. differential carrier side.
4 Differential carrier assembly: 85 kg 4) Install cap (6) and tighten mounting bolts
(5).
3 Mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}
a Set the match mark on cap (6).
turns.
a Before tightening mounting bolts (5),
rotate the bevel gear 20 – 30 turns to
run in the bearing.
WA500-6R 23
5) Adjust the preload on the differential bear-

ing according to the following procedure.
1] Using tool [12], tighten nut (4).
8. Pinion assembly
1) Assemble the pinion assembly according
to the following procedure.
2] Apply push-pull scale [13] to the tip of 1] Using push tool [6] (Inside diameter:
bevel gear (30) and measure starting 101 mm), press fit bearing (41) to pin-
torque (b). ion shaft (40).
Starting torque (b):
53.9 – 83.4 N {5.5 – 8.5 kg}
rotating nut (4).
2] Press fit bearing (44) and bearing

outer race (45) to pinion case (46).
a Drop 6 cc of axle oil (AXO80)
onto the bearing and rotate it
about 10 turns.
a Precautions for adjusting starting torque
q If the nut is tightened too much for starting
torque adjustment or the starting torque is
adjusted defectively, return the nut to the
condition before the adjustment work.
q At this time, hit the bevel gear lightly with a
plastic hammer while rotating it.
q At this time, check that there is not clear-
ance in part (c) and adjust the preload
again.
24 WA500-6R
3] Using push tool [7] (Inside diameter: 2) Coupling

76 mm), press fit pinion case (46) to 1] Install coupling (35).
pinion shaft (40). 2] Install O-ring (34) and shim (33)
a Press fit the inner race of bearing removed for disassembly.
(44). 3] Install holder (32) and tighten mount-
ing bolts (31).
a While rotating the pinion shaft 20
– 30 turns, tighten mounting bolts
(31) gradually.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
824 – 1,030 Nm {84.0 – 105 kgm}
4] Install dust seal (42) and oil seal (43).

2 Oil seal: Grease (G2-LI)
Gasket sealant
(THREEBOND 1110B)
2 Dust seal: Grease (G2-LI)
a Apply the gasket sealant thinly
over the inside surface of the oil
seal fitting part of the pinion case
and wipe off the projected part. 3) Adjust the preload on the pinion shaft
1] Install measuring bolt [8] to pinion
assembly (37).
2] Using push-pull scale [9], measure
starting torque (a).
Starting torque (a):
49.0 – 127.4 N {5 – 13 kg}
increasing or decreasing the
shims.
WA500-6R 25
4) Install shim (38) removed for disassembly. 2] Apply dial gauge [14] perpendicularly
Shim adjustment allowance: to the tooth surface on the reverse
0.71 – 2.21 mm side at the outer end of the bevel
5) Fit the O-ring and install pinion assembly gear.
(37). 3] Adjust adjustment nut (4) so that dial
2 O-ring: Grease (G2-LI) gauge [14] will indicate the following
4 Pinion assembly: 110 kg range (backlash).
6) Tighten 18 mounting bolts (36). Standard backlash: 0.36 – 0.51 mm
3 Mounting bolt: a Adjust the backlash at 3 – 4
245 – 309 Nm {25 – 31.5 kgm} places and measure it with the
pinion gear fixed.
9. Adjusting tooth contact and backlash

Adjust the backlash and tooth contact simulta- q When backlash is less than standard
neously. range
1) Adjust the backlash according to the fol- Loosen the adjustment nut on the bevel
lowing procedure. gear side and tighten the adjustment nut
1] Move the bevel gear with adjustment on the opposite side by the same angle (to
nuts (4a) and (4b). move the bevel gear in direction (A)).
a Rotate adjustment nuts (4a) and q When the backlash is above standard
(4b) by the same quantity in the range
same direction so that the Loosen the adjustment nut on the oppo-
adjusted preload on the bearing site side and tighten the adjustment nut on
will not change. the bevel gear side by the same angle (to
move the bevel gear in direction (B)).
26 WA500-6R
2) Checking tooth contact If bevel pinion is too far from bevel gear
1] Apply red lead thinly to the surface of a The tooth contact pattern is as follows.
the pinion gear and turn the bevel q Decrease the shims of the bevel pinion to
gear in the forward and reverse direc- move the bevel pinion in direction (C).
tions, and then check the tooth con- q Move the bevel gear in direction (D).
tact pattern on the bevel gear.
2] The center of the tooth contact must
be at the middle of the tooth height
and at a point about 33% of the tooth
length (x) from small end (C), and the
tooth contact width must be 30 – 60%
of the tooth length (y).
Check that there is not a strong con-
tact at tip (A), bottom (B), small end
(C) or large end (D).
a If the tooth contact is adjusted in
this way, the teeth come in con-
tact with each other correctly
when they are loaded.
If bevel pinion is too close to bevel gear
3) Adjusting tooth contact

If the tooth contact pattern is not proper,
adjust it according to the following proce-
dure.
a After adjusting the tooth contact,
check the backlash again. If bevel gear is too close to bevel pinion
q Decrease the shims of the bevel pinion to
move the bevel pinion in direction (C).
q Move the bevel gear in direction (D).
WA500-6R 27
If bevel gear is too far from bevel pinion 11. Differential assembly
a The tooth contact pattern is as follows. Remove differential assembly (1) from tool H1.
4
Differential assembly: 390 kg
10. Lock
After finishing all adjustments, install lock (3)
and tighten mounting bolts (2).
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
28 WA500-6R
Disassembly and assembly of 2. Draining oil

final drive assembly Remove drain plug (2) and drain the oil.
a Set the drain plug at the bottom.
(Front and rear)
6 Axle oil
Front: Approx. 98 l
Special tools Rear: Approx. 85 l
New/Remodel
3. Cover
Necessity
Sym-
Part No. Part name Remove 7 bolts (3) and cover (4).
Sketch
bol
Q'ty
H 3 793T-622-2210 Fixture t 3 N Q
Disassembly
chocks.
1. Tire wheel assembly

1) Raise the machine body with the work
equipment or a jack and set a stand under
the axle.
2) Using a sling, sling tire wheel assembly 4. Drive shaft
(1), remove the hub mounting bolts, and 1) Using forcing screw [2], pull out drive shaft
lift off the tire wheel assembly. (5).
4 Tire wheel assembly: 850 kg 2) Using sling [3], remove drive shaft (5).
3) Remove spacer (6), sun gear (7) and snap
ring (8) from drive shaft (5).
WA500-6R 29
5. Planetary carrier assembly a Since the bearing has been fitted

1) Remove 3 hexagonal head bolts (9). to the mating part, make a dis-
2) Using forcing screws [4], disconnect plan- tinction mark on it.
etary carrier assembly (10) from the wheel
hub.
3) Using sling [5], remove planetary carrier
assembly (10).
4 Planetary carrier assembly: 110 kg
6. Ring gear
1) Using tools H3, fix wheel hub (15) and
brake housing (16).
a Install tools H3 to 3 places at regular
intervals.
4) Disassemble the planetary carrier assem- a Keep tools H3 installed until step 6 is
bly according to the following procedure. finished.
1] Using a press, pull out shaft (11) and
remove planetary gear (12), ball (13)
and bearing (14).
a Enter a No. on the case and
arrange and keep the removed
parts to prevent them from mix-
ing with other parts.

3) Remove retainer (18) and shim (19).
the shim.
30 WA500-6R
4) Using sling [9], remove ring gear assem- Assembly

bly (20). 1. Ring gear
1) Assemble the ring gear assembly accord-
1] Using push tool [7] (Inside diameter:
221 mm), press fit bearing (24) to ring
gear hub (23).
a After press fitting the bearing,
check that there is not clearance
between it and hub.
5) Disassemble the ring gear assembly

1] Remove 12 mounting bolts (21) and 6
lock plates (22).
2] Using sling [6], remove ring gear hub
(23).
2] Before installing, measure thickness

(a) of retainer (18).
a Measure the thickness at 2
places and obtain the average.
3] Remove bearing (24) from ring gear

hub (23).
WA500-6R 31
3] Using sling [6], install ring gear hub 3) Adjustment procedure for wheel bearing
(23). 1] Install retainer (18) and tighten 3
4] Install 6 lock plates (22) and tighten mounting bolts (17) temporarily with-
12 mounting bolts (21). out setting the shim.
a Install each lock plate (22) with
the wider end in.
a Degrease the bolt holes thor-
oughly.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
2] Remove tool H3 which has been fix-

ing wheel hub (15) and brake housing
(16).
2) Using sling [9], install ring gear assembly

(20).
turns.
32 WA500-6R
3] While rotating wheel hub (15) 20 – 30

turns, tighten mounting bolts (17)
alternately and evenly to the following
torque.
3 Mounting bolt:
62.7 ± 4.9 Nm {6.4 ± 0.5 kgm}
4] Insert depth micrometer [10] or a dial
gauge in the measurement hole of
retainer (18) and measure distance
(b) between retainer (18) and tube
(26) and obtain shim thickness (C).
a Measure the distance at 2 places
and obtain the average.
Shim thickness (C): (b – a) + 0.3 mm
(Dimension (a) was measured in step 1) 6] Remove retainer (18) and install shim
(19) of the thickness obtained in the
above step.
a Assemble the shims so that the
number of them will be mini-
mized.
7] Install retainer (18) again and tighten
8 mounting bolts (17) alternately and
evenly to the following torque.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
8] Remove tool H3 which has been fix-

ing wheel hub (15) and brake housing
5] Install tool H3 and fix wheel hub (15) (16).
and brake housing (16) again.
WA500-6R 33
2. Planetary carrier 3. Drive shaft

1) Assemble the planetary carrier assembly 1) Install snap ring (8), sun gear (7) and
according to the following procedure. spacer (6) to drive shaft (5).
1] Set planetary gear (12) and bearing 2) Using sling [1], install drive shaft (5).
(14) to the carrier case. 3) Using guide bolt [2], set the spline at the
2] Fit ball (13) to shaft (11) and press fit end of drive shaft (5) and push it in.
them to the carrier case. a If the sun gear does not mesh with
a Press fit shaft (11) with the ball hole the planetary gear, rotate the wheel
out. Stop before the hole and adjust hub with the hand to mesh those
the hole. gears.
a After press fitting the shaft, check that
the planetary gear rotates lightly.
4. Cover
1) Fit the O-ring, install cover (4), and tighten
2) Using sling [5], install planetary carrier 7 bolts (3).
assembly (10). 2 O-ring: Grease (G2-LI)
a Using guide bolt [4], set the bolt 3 Mounting bolt:
holes. 98 – 123 Nm {10 – 12.5 kgm}
4 Planetary carrier assembly: 110 kg 2) Install drain plug (2).
3) Tighten 3 hexagon head bolts (9). a Set the drain plug at the bottom.
3 Mounting bolt: 3 Drain plug (2):
59 – 74 Nm {6 – 7.5 kgm} 58.8 – 78.4 Nm {6 – 8 kgm}
34 WA500-6R
5. Refilling with oil

1) Remove level plug (27).
2) Remove oil filler plug (28) and add oil to
the specified level.
5 Axle oil
Front: 98 l
Rear: 85 l
3) Install level plug (27) and oil filler plug
(28).
3 Level plug (27):
127.4 – 176.4 Nm {13 – 18 kgm}
3 Oil filler plug (28):
127.4 – 176.4 Nm {13 – 18 kgm}
6. Tire wheel assembly

1) Using the sling, set tire wheel assembly
(1) to the wheel hub and tighten the hub
mounting bolts temporarily.
4 Tire wheel assembly: 850 kg
2) Raise the machine body with the work
equipment or the jack, remove the stand
under the axle, and lower the tire to the
ground.
3) Tighten the hub mounting bolt to the spec-
ified torque.
3 Hub mounting bolt:
824 – 1,034 Nm {84 – 105 kgm}
WA500-6R 35
SEN02908-01

© 2011 KOMATSU
All Rights Reserved
36
SEN02909-01
WA500-6R

WA500-6R 60001 and up
Brake system
Removal and installation of brake assembly (Front and rear) ........................................................................ 2
Disassembly and assembly of brake assembly (Front and rear) .................................................................... 6
Disassembly and assembly of slack adjuster assembly ............................................................................... 12
Disassembly and assembly of brake accumulator charge valve assembly .................................................. 13
WA500-6R 1
Removal and installation of brake 3. Disconnect brake tube (1). [*1]

assembly (Front and rear) 1
Special tools
New/Remodel
Necessity
Sketch
Q'ty
- 793-605-1001 Brake tester t 1
1 793-605-1200 Stop valve t 1
2 793-605-1120 Nipple t 1
8 3 793-605-1130 Tee t 1
4 790-301-1361 Gauge t 1
5 793-605-1140 Nipple t 1
6 790-101-1430 Coupler t 1 5. Remove brake disc wear indicator (3). [*2]
9 790-101-1102 Pump t 1
H
10 790-301-1720 Adapter t 1
11 07002-12034 O-ring t 1
12 799-101-5160 Nipple t 1
13 799-401-2220 Hose t 1
14 790-261-1130 Coupling t 1
15 793T-622-2410 Fixture t 3 Q
Commercially
16 Sling q 2
available
Removal
chocks. 6. Remove 15 mounting bolts (6). [*3]
1. Remove the final drive assembly. For details, 7. Using sling H16, remove brake and wheel hub
see "Disassembly and assembly of final drive assembly (7).
assembly (Front and rear)". 4 Brake and wheel hub assembly: 350 kg
2. Leave tool H15 (used to fix the wheel hub and

brake housing) installed for the above work as
it is.
2 WA500-6R
8. Remove 8 O-rings (16) from brake piston Installation

assembly (15). 1. Install retainer (10) and bearing (9) to axle (8).
a Drip 6 cc of axle oil (AXO80) on the bear-
ing, and turn the bearing approximately 10
turns.
9. Remove bearing (9) and retainer (10) from axle

(8). [*4]
2. Install O-rings (16) (8 pieces) to brake piston

assembly (15).
3. Set brake and wheel hub assembly (7) by

using sling H16.
4 Brake and wheel hub assembly (7):
350 kg
4. Install with bolts (6) (15 pieces).

3 Bolt (6): 490 to 608 Nm {50 to 62 kgm}
WA500-6R 3
5. Install brake disc wear indicator (3). 9. Install coupling H14, brake tester H8, and
pump H9.
6. Install cover (2).
10. Install hose H13 and coupling H14.
11. Adjust the brake disc wear indicator according

Adjustment of brake disc wear indicator to the following procedure.
7. Remove union (20). 1) Operate pump H9, and apply oil pressure
of 5.39 to 5.88 MPa {55 to 60 kg/cm2} to
brake oil port (d).
2) Remove cap (11), and loosen nut (13).
3) With shaft (12) fully pushed in, turn guide
(14) and flush guide end face (a) with
shaft groove end (b) at (c).
4) Tighten nut (13).
3 Nut (13):
58.8 to 78.4 Nm {6.0 to 8.0 kgm}
5) Install the cap (11).
3 Cap (11):
29.4 to 39.2 Nm {3.0 to 4.0 kgm}
8. Install O-ring H11, adapter H10, nipple H12,

and hose H13.
4 WA500-6R
12. Install brake tube (1).

3 Brake tube (1):
84 to 132 Nm {8.5 to 13.5 kgm}
Final drive assembly

13. Leave installed fixture H15 (fixing the wheel
hub and brake housing) as it is.
14. Install the final drive assembly. For details see

"Disassembly and assembly of final drive
assembly (Front and rear)".
WA500-6R 5
Disassembly and assembly of

brake assembly (Front and rear) 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792T-422-1220 Plate t 1 N Q
2 790-101-5421 Grip t 1
01010-81240 Bolt t 1
3 793T-622-2210 Fixture t 3 N Q
792-520-2110 Installer t 1 3. Cylinder assembly
791-580-1600 Push tool t 1
2) Using forcing screws [1], disconnect cylin-
791-580-1610 • Plate 1 der assembly (2).
791-580-1620 • Arm 4 3) Using eyebolts [2], remove cylinder
791-580-1640 • Plate 1 assembly (2).
4
791-580-1650 • Plate 4
01010-51425 • Bolt 8
H
01541-21670 • Nut 4
01640-21426 • Washer 4
792-530-1630 Stud t 4
792-520-2110 Installer t 1
793T-622-2310 Plate t 1 N Q
793T-622-2320 Arm t 4 N Q
791-580-1640 Plate t 1
5
792-530-1630 Stud t 4
01010-61425 Bolt t 4
01640-21426 Washer t 4 4) Disassemble the cylinder assembly
01580-01613 Nut t 4 according to the following procedure.
1] Install eyebolt [3], push in the head of
Disassembly shaft (3) with bar [4], and remove pin
1. Remove the brake assembly. For details, see (5) from underside.
"Removal and installation of brake assembly 2] Remove shaft (3) and spring (4).
(Front and rear)".
2. Remove tool H3 (used to fix the wheel hub and

brake housing) installed for the above work.
6 WA500-6R
3] Reverse cylinder assembly (2) and 4. Plate and disc

remove piston (6). Remove 8 discs (13), 9 plates (14) and bottom
plate (15).
a Before removing, make match marks
between the inner gear and discs and
between the outer gear and plates.
a Since the discs are made of soft material,
take care not to scratch them.
a Remove the discs and plates alternately.
4] Remove 9 mounting bolts (7) and

inner cylinder (8).
5. Outer gear
1) Using eyebolts [5], remove outer gear
(16).
5] Remove seal ring (9) from piston (6).

6] Remove seal ring (10) from inner cyl-
inder (8).
2) Remove oil seal (17) and floating seal (18)

from outer gear (16).
WA500-6R 7
6. Wheel hub Assembly

1) Remove bearing outer races (19) and 1. Wheel hub
(20). 1) 1) Using push tool [6] (Outside diameter:
313 mm), press fit outer race (20) to wheel
hub (21).
mm), press fit outer race (19) to wheel hub
(21).
2) Remove 6 mounting bolts (22) and

remove seal cage (23) and O-ring (25)
from wheel hub (21).
3) Remove floating seal (24) from seal cage
(23).
3) Install O-ring (25) and seal cage (23) to
wheel hub (21).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
8 WA500-6R
5) Using tool H5, install floating seal (24) to 2. Outer gear

wheel hub (21). 1) Using tool H2, install oil seal (17) to outer
a Fit the O-ring to the floating seal. gear (16).
a Take care not to twist the O-ring of the 2 Seal lip surface: Grease (G2-LI)
floating seal and tighten tool H5
evenly.
2) Using tool H4, install floating seal (18) to

outer gear (16).
a Remove all of the white powder pro- a Fit the O-ring to the floating seal.
tecting the surface of O-ring (24a) a Take care not to twist the O-ring of the
with alcohol etc. floating seal and tighten tool H4
a Thoroughly degrease the floating seal evenly.
and O-ring contact surface of the
wheel hub.
a After press fitting O-ring (24a) of the
floating seal, measure height (t) at 4
places on the periphery and check that
its dispersion is not larger than 1 mm.
a Apply axle oil to the seal surface of
floating seal (24b) to prevent dirt from
sticking.
WA500-6R 9
a Remove all of the white powder pro- 3. Plate and disc

tecting the surface of O-ring (18a) 1) Install bottom plate (15).
with alcohol etc. 2) Install 9 plates (14) and 8 discs (13) alter-
a Thoroughly degrease the floating seal nately.
and O-ring contact surface of the a Match the match marks made
wheel hub. between the inner gear and discs and
a After press fitting O-ring (18a) of the between the outer gear and plates.
floating seal, measure height (t) at 4 a Since the discs are made of soft
places on the periphery and check that material, take care not to scratch
its dispersion is not larger than 1 mm. them.
a Apply axle oil to the seal surface of
floating seal (18b) to prevent dirt from
sticking.
4. Cylinder assembly
1) Assemble the cylinder assembly accord-
3) Using eyebolts [5], install outer gear (16). 1] Install seal rings (10) and (11) to inner
cylinder (8).
2] Install seal ring (9) to piston (6).
10 WA500-6R
3] Install inner cylinder (8).

4] Tighten 9 mounting bolts (7).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
6] Reverse cylinder assembly (2).

7] Install shaft (3) and spring (4).
8] Install eyebolt [3], push in the head of
shaft (3) with bar [4], and install pin
5] Match groove (G) in piston (6) to (5) from underside.
bleeder cover mounting hole (H) in
cylinder (2), and install piston (6).
4 Piston (6): 25 kg
a Top and bottom of groove (G) are
the same.
2) Fit the O-ring and install cylinder assembly

(2), using eyebolts [2].
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
WA500-6R 11
5. Install tool H3 (to fix the wheel hub and brake Disassembly and assembly of
housing). slack adjuster assembly 1
a Only the precautions for assembling the slack

adjuster assembly are described in this sec-
tion.
Assembly of slack adjuster assembly

2 Valve and outside of spring (a):
Grease (G2-LI)
2 Threaded part of plug (b):
CEMEDINE 366 or equivalent
2 Threaded part of plug (c):
6. Install the brake assembly. For details, see

"Removal and installation of brake assembly
(Front and rear)".
12 WA500-6R
Disassembly and assembly of 2 Plug (3): Adhesive (LT-2)

2 Plug (4): THREEBOND 1305 or equivalent
brake accumulator charge valve
assembly 1
a Only the precautions for assembling the brake

accumulator charge valve assembly are
described in this section.
Assembly of brake accumulator charge

valve assembly
2 Plug (1): THREEBOND 1305 or equivalent
2 Plug (2): Adhesive (LT-2)
WA500-6R 13
SEN02909-01

© 2019 KOMATSU
All Rights Reserved
14
SEN02910-01
WA500-6R

WA500-6R 60001 and up
Undercarriage and frame

Removal and installation of center hinge pin .................................................................................................. 2
Removal and installation of large counterweight assembly ............................................................................ 9
Removal and installation of small counterweight assembly .......................................................................... 10
WA500-6R 1
Removal and installation of center 4. Set jacks [1] under the right and left of the rear
hinge pin 1
frame.
5. Set jack [2] under the front frame.

Special tools
New/Remodel
Necessity
Sketch
Q'ty
1 793-520-2630 Bar t 2
2 793-520-2640 Push tool t 1
3 793-520-2650 Guide t 1
4 790-101-2300 Push puller t 1
1 5 790-101-2102 • Block 1
6 02215-11622 • Nut 2
Puller 294 kN 6. Set jack [3] under the rear counterweight.
7 790-101-2102 t 1
{30 ton}
K
8 790-101-1102 Pump t 1
1 793-520-2530 Guide t 1
2 01010-31480 Bolt t 2
3 01643-31445 Washer t 2
2 4 793-520-2640 Push puller t 1
Puller 294 kN
5 790-101-2102 t 1
{30 ton}
6 790-101-1102 Pump t 1
Removal
k Stop the machine on a level ground and 7. Remove guard (1).
lower the bucket.
k Release residual pressure in brake accu- 8. Sling center drive shaft (2), remove its mount-
mulator circuit. For detail, see Testing and ing bolts, and lift it off. [*1]
adjusting "Releasing residual pressure in a Before removing the drive shaft, make a
brake accumulator circuit". match mark between it and the coupling.
k
4
Disconnect the cable from the negative (–)
terminal of the battery. Center drive shaft: 49 kg


3. Remove the operator's cab and floor frame

installation of operator's cab and floor frame
assembly".
2 WA500-6R
9. Disconnect wiring harness connectors JF1 (3),

JF2 (4) and JF3 (5) and remove wiring harness
clamps (6) and (7).
14. Remove bolts (21) and (22) and retainer (22)

and pull out lower hinge pin. [*3]
a After removing the bolts, pull out the pin
10. Disconnect hoses (8), (9), (10), (11) and (12). while adjusting the height of the front
frame and rear frame with the jacks.
11. Disconnect hoses (13), (14), (15), (16) and

(17). 15. Remove 4 bolts (24) and plate (25). [*4]
16. Remove 6 bolts (26), 4 bolts (27) and retainer

(28), and pull out the hinge pin. [*5]
a After removing the bolts, pull out the pin
while adjusting the height of the front
frame and rear frame with the jacks.
a Check the quantity and thickness of the
shims between retainer (28) and frame.
12. Disconnect right and left steering hoses (18).
13. Remove right and left bolts (19) and pull out
right and left cylinder bottom pins (20). [*2]
a After removing the pins, retract the piston
rods of the cylinders.
shims on the frame.
WA500-6R 3
17. Remove bushing (29) from the frame. 20. Remove bolts (33) and remove retainer (34)
from the front frame. [*6]
shims between the retainer and frame.
21. Remove dust seal (35) from the retainer. [*7]
22. Remove dust seal (36) from the frame. [*8]
23. Remove bearing (37) from the frame. [*9]
18. Pull out front frame (30) forward slowly to dis-

connect it from rear frame (31).
a When disconnecting the front frame, bal-
ance it carefully.
a Check that all the pipings and wiring har-
nesses are disconnected.
a Move the front frame about 100 mm each
time.
24. Remove bolts (38) and remove retainer (39)

from the front frame. [*10]
shims between the retainer and frame.
25. Remove dust seal (40) from the retainer. [*11]
26. Remove bushing (41) and dust seal (42) from

the front frame. [*12]
27. Remove bearing (43) from the frame. [*13]
19. Remove bushing (32) and collar from the rear

frame.
4 WA500-6R
Installation [*3]
q Carry out installation in the reverse order to q Install the lower hinge pin according to the fol-
removal. lowing procedure.
5) Install bushing (32) and collar (44) to the
[*1] frame.
3 Drive shaft mounting bolt: 6) Align the front frame and rear frame.
98 – 123 Nm {10 – 12.5 kgm} k When aligning the pin holes, use a
a Tighten the drive shaft according to the follow- bar. Never insert your fingers in
ing procedure. the pin holes.
1) Check that the seats of the mating yoke 7) Fit retainer (23) to hinge pin (45), insert
and drive shaft spider are free from rust, them in the pin hole, and tighten bolts
foreign matter (masking material), bruise, (22).
etc. 2 Periphery of hinge pin:
2) Set the key way of the yoke vertically, Grease (G2-LI)
place the drive shaft on the bottom of the 2 Threaded part of retainer mounting
yoke socket, and fit the key in the key way. bolt: Adhesive (LOCTITE 262)
3) Insert the 4 upper and lower bolts and fin- 3 Retainer mounting bolt:
ger tighten them until the seats of the spi- 245 – 309 Nm {25 – 31.5 kgm}
der and yoke are fitted. 2 Threaded part of pin mounting bolt:
a At this time, if the key way and socket of Adhesive (LOCTITE 262)
the yoke are tight and the spider is not fit- 3 Retainer mounting bolt:
ted easily, drive in the spider with a plastic 343 – 426 Nm {35 – 43.5 kgm}
hammer (or a copper hammer). (Do not
use a steel hammer which can damage
the cross bearing.)
a If the spider is not fitted perfectly at this
time, it will float and its seat will be parted
from the yoke when the other parts are
tightened. Accordingly, tighten the spider
securely.
4) Basically, tighten the bolts in the diagonal
order.
[*2]
a Adjust the shim so that clearances (a) and (b)
between the cylinder and mounting face of the
frame will be 0.5 mm or less respectively.
WA500-6R 5
[*4], [*5] [*6], [*7], [*8], [*9]

q Install the upper hinge pin according to the fol- q Assemble the lower hinge according to the fol-
lowing procedure. lowing procedure.
1) Measure the thickness of retainer (28) in 1) Using push tool K2, press fit bearing (37)
advance at 3 places of Ø 6.5 hole of the to the frame.
retainer. a Take care that the bearing will not
2) Install bushing (29) to the upper hinge. lean.
3) Temporarily install retainer (28) to hinge a Since the clearance of the bearing is
pin (46) with bolts (27) and insert hinge pin adjusted properly, do not change the
(46) in the pin hole. combination of it and spacer. When
2 Periphery of hinge pin: the bearing needs to be replaced,
Grease (G2-LI) replace it and spacer as a set.
4) Tighten bolts (27) to the specified torque. a Fill the inside of the bearing with
a While tightening the bolts, check the grease.
behavior of each of them. 2) Press fit dust seal (35) to retainer (34).
5) After tightening the bolts to the specified a Press fit the dust seal with the lip side
torque, measure the clearance between out.
the retainer and rear frame at 3 places of 2 Lip of dust seal: Grease (G2-LI)
Ø 6.5 hole. 3) Evenly tighten the 6 mounting bolts of
6) Select shims so that their total thickness retainer (34) at intervals of 60°.
will be 0.08 – 0.18 mm less than the mea- 3 Mounting bolt (When adjusting
sured clearance. shim):
7) Remove the retainer, install shim (47), and 34.3 Nm {3.5 kgm} ± 10%
tighten the retainer mounting bolts to the 4) Select shims so that their total thickness
specified torque. will be 0.08 – 0.18 mm less than clear-
2 Threaded part of retainer (26) ance (a) between the retainer and hinge
mounting bolt: measured at 4 places on the periphery.
Adhesive (LOCTITE 262) 5) Tighten the mounting bolts to the specified
3 Retainer (26) mounting bolt: torque.
245 – 309 Nm {25 – 31.5 kgm} 2 Threaded part of retainer mounting
2 Threaded part of pin mounting bolt bolt: Adhesive (LT-2)
(27): Adhesive (LOCTITE 262) 3 Retainer mounting bolt:
3 Pin mounting bolt (27): 245 – 309 Nm {25 – 31.5 kgm}
343 – 426 Nm {35 – 43.5 kgm} 6) Press fit dust seal (36).
2 Threaded part of pin mounting bolt a Press fit the dust seal with the lip side
(24): Adhesive (LOCTITE 262) out.
3 Pin mounting bolt (24): 2 Lip of dust seal: Grease (G2-LI)
343 – 426 Nm {35 – 43.5 kgm}
6 WA500-6R
5) Tighten the mounting bolts to the specified

torque.
2 Threaded part of retainer mounting
bolt: Adhesive (LT-2)
3 Retainer mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
6) Press fit dust seal (42).
a Press fit the dust seal with the lip side
out.
2 Lip of dust seal: Grease (G2-LI)
7) Install bushing (41).
[*10], [*11], [*12], [*13]

q Assemble the upper hinge pin according to the
1) Using push tool K1, press fit bearing (43)
to the frame.
a Take care that the bearing will not
lean.
a Since the clearance of the bearing is
adjusted properly, do not change the
combination of it and spacer. When
the bearing needs to be replaced,
replace it and spacer as a set.
a Fill the inside of the bearing with
grease.
2) Press fit dust seal (40) to retainer (39).
a Press fit the dust seal with the lip side
out.
2 Lip of dust seal: Grease (G2-LI)
3) Evenly tighten the 6 mounting bolts of
retainer (38) at intervals of 60°.
3 Mounting bolt (When adjusting
shim): 34.3 Nm {3.5 kgm} ± 10%
4) Select shims so that their total thickness
will be 0.08 – 0.18 mm less than clear-
ance (a) between the retainer and hinge
measured at 4 places on the periphery.
WA500-6R 7


again.
q Bleeding air
each part".
8 WA500-6R
Removal and installation of large 6. Remove right and left battery box covers (6)
counterweight assembly 1
and (7).
Removal
1. Remove the radiator guard assembly. For

details, see "Removal and installation of radia-
tor guard assembly".
2. Disconnect wiring harness connector R18 (1)

(when removing only the left-hand battery).
3. Disconnect right and left battery cables (2) and

(3). 7. Sling counterweight assembly (8), remove its 4
mounting bolts, and lift it off. [*1]
4. Remove right and left battery holders (4). 4 Counterweight: 2,520 kg
5. Lift off right and left batteries (5).

4 Battery: 64 kg
Installation
removal.
[*1]
3 Counterweight mounting bolt:
1,372 – 1,764 Nm {140 – 180 kgm}
WA500-6R 9
Removal and installation of small Installation

counterweight assembly 1
removal.
Removal [*1]
k Disconnect the cable from the negative (–) 3 Counterweight mounting bolt:
terminal of the battery. 785 – 980 Nm {80 – 100 kgm}
1. Remove the right and left batteries and right

and left battery covers. For details, see
"Removal and installation of large counter-
weight assembly".
2. Sling counterweight assembly (2), remove its 4

mounting bolts (1), and lift it off. [*1]
4 Counterweight: 870 kg
10 WA500-6R
WA500-6R 11
SEN02910-01


© 2017 KOMATSU
All Rights Reserved
12
SEN02911-01
WA500-6R

WA500-6R 60001 and up
Hydraulic system
Removal and installation of hydraulic tank assembly...................................................................................... 2
Removal and installation of cooling pump assembly ...................................................................................... 5
Removal and installation of fan pump assembly............................................................................................. 6
Removal and installation of work equipment pump assembly ........................................................................ 7
Removal and installation of steering, torque converter charge and EPC pump assembly ............................. 9
Removal and installation of work equipment valve assembly ....................................................................... 10
Disassembly and assembly of work equipment control valve assembly....................................................... 13
Disassembly and assembly of steering cylinder assembly ........................................................................... 16
Disassembly and assembly of lift arm and bucket cylinder assembly .......................................................... 20
Removal and installation of steering valve assembly ................................................................................... 26
WA500-6R 1
Removal and installation of 7. Disconnect heater hose (5).

hydraulic tank assembly 1
8. Remove partition rubber plates (6) and (7).
Removal a Disconnect and move partition rubber
k Loosen the oil filler cap of the hydraulic plate (7) to the right.
tank gradually to release the pressure in
the hydraulic tank.



9. Remove clamps (9) of transmission breather
(8) and move the breather aside. [*2]
assembly".
5. Loosen hose clamps (1) between the air

cleaner and turbocharger and remove air
cleaner fixing bands (2) and air cleaner assem-
bly (3). [*1]
6. Remove air cleaner bracket (4).
2 WA500-6R
10. Disconnect hose clamps (10) and (11) fixed 13. Disconnect flange (19).
together with the hydraulic tank.
14. Disconnect hoses (20), (21) and (22).
a Disconnect the hoses on the opposite side
of the block from the pump and motor.
11. Disconnect all of air conditioner and reservoir

tank hose clamps (12) fixed together with the
hydraulic tank.
15. Loosen hose clamps (23).
17. Remove tube (26).
18. Disconnect heater hose clamps (27).

a Disconnect all of the heater hose clamps
fixed together with the hydraulic tank.
12. Disconnect hoses (13), (14), (15), (16), (17)

and (18) and all of the hose clamps fixed
together with the hydraulic tank.
WA500-6R 3
19. Remove 8 hydraulic tank mounting bolts (29).  Installation

[*3] q Carry out installation in the reverse order to
removal.
[*1]
[*2]
2 Threaded part of hose clamp mounting bolt:
Adhesive (LT-2)
3 Hose clamp mounting bolt:
101 Nm {10.3 kgm}
[*3]
a Adjust the clearance between the hydraulic
tank and rear frame to 0.5 mm or less with the
20. Lift off hydraulic tank (30). shim.
a Before lifting off, check that all the pipings
are disconnected. q Refilling with coolant
4 Hydraulic tank assembly: 480 kg specified level. Run the engine to circulate the

again.
q Charging air conditioner with refrigerant

Fill the air conditioner circuit with refrigerant
(R134a).
q Bleeding air
Bleed air from the related part. For details, see
Testing and adjusting, "Bleeding air from work
equipment circuit".
4 WA500-6R
Removal and installation of Installation

cooling pump assembly 1
removal.
Removal
k Loosen the oil filler cap of the hydraulic [*1]
tank gradually to release the pressure in 3 Pump mounting bolt:
the hydraulic tank. 235 – 285 Nm {23.5 – 29.5 kgm}
terminal of the battery. q Refilling with coolant
1. Drain the coolant. specified level. Run the engine to circulate the
6 Coolant: Approx. 90 l coolant through the system. Then, check the
2. Drain the hydraulic oil. q Refilling with oil (Hydraulic tank)

6 Hydraulic oil: Approx. 337 l Add oil through the oil filler to the specified
3. Remove the hood. For details, see "Removal again.
q Bleeding air
4. Remove the operator's cab and floor frame Bleed air from the related circuit. For details,
assembly. For details, see "Removal and see Testing and adjusting, "Bleeding air from
installation of operator's cab and floor frame work equipment circuit".
assembly".
5. Removal and installation of hydraulic tank

installation of hydraulic tank assembly".
6. Disconnect pump inlet tube (1) and outlet hose

(2).
7. Remove the 2 mounting bolts and cooling

pump assembly (3). [*1]
WA500-6R 5
Removal and installation of fan Installation

pump assembly 1
removal.
Removal
k Loosen the oil filler cap of the hydraulic [*1]
tank gradually to release the pressure in 3 Pump mounting bolt:
the hydraulic tank. 98 – 123 Nm {10 – 12.5 kgm}
terminal of the battery. a Check that the clearance between the shroud
and fan (Standard clearance: 6 mm) is even. If
1. Drain the coolant. it is uneven, loosen the mounting bolts of the
6 Coolant: Approx. 90 l fan motor mounting bracket and adjust it.

2. Drain the hydraulic oil. Add coolant through the coolant filler to the
6 Hydraulic oil: Approx. 337 l specified level. Run the engine to circulate the
and installation of hood". q Refilling with oil (Hydraulic tank)
4. Remove the operator's cab and floor frame level. Run the engine to circulate the oil
assembly. For details, see "Removal and through the system. Then, check the oil level
installation of operator's cab and floor frame again.
assembly".
q Bleeding air
5. Remove the hydraulic tank. For details, see Bleed air from the related circuit. For details,
"Removal and installation of hydraulic tank see Testing and adjusting, "Bleeding air from
assembly". hydraulic drive fan circuit".
6. Disconnect wiring harness connector T02 (1)

and remove the wiring harness clamp.
8. Disconnect pump outlet hose (3).
10. Remove 3 pump mounting bolts and lift off fan

4 Fan pump assembly: 25 kg
6 WA500-6R
Removal and installation of work 7. Disconnect hoses (2), (3), (4) and (5).
equipment pump assembly 1
8. Disconnect pump inlet tube (6).
Removal
k Loosen the oil filler cap of the hydraulic 9. Remove the tube fixing U-bolt and pump outlet
tank gradually to release the pressure in tube (7).
the hydraulic tank.



10. Remove the 2 pump mounting bolts and lift off
work equipment pump assembly (8). [*1]
installation of operator's cab and floor frame 4 Work equipment pump assembly: 
assembly". 106 kg
5. Remove the hydraulic tank. For details, see

"Removal and installation of hydraulic tank
assembly".
6. Remove side cover (1) on the right of the

transmission.
WA500-6R 7
Installation
removal.
[*1]
3 Work equipment pump mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}


again.
q Bleeding air
Bleed air from the related circuit. For details,
work equipment circuit".
8 WA500-6R
Removal and installation of 9. Remove the 2 pump mounting bolts and lift off
steering, torque converter charge steering, torque converter charge and EPC
and EPC pump assembly 1
4 Steering, torque converter charge and
Removal
k
EPC pump assembly: 60 kg
Loosen the oil filler cap of the hydraulic
the hydraulic tank.



Installation
4. Remove the operator's cab and floor frame q Carry out installation in the reverse order to
assembly. For details, see "Removal and removal.
assembly". [*1]
3 Steering, torque converter charge and EPC
5. Remove the hydraulic tank. For details, see pump assembly mounting bolt:
"Removal and installation of hydraulic tank 235 – 285 Nm {23.5 – 29.5 kgm}
assembly".
6. Disconnect pump inlet tubes (1), (2) and (3). Add coolant through the coolant filler to the
7. Disconnect pump outlet hoses (4), (5) and (6). coolant through the system. Then, check the
8. Disconnect hoses (7), (8), (9) and (10).
again.
q Bleeding air
steering cylinder circuit".
WA500-6R 9
Removal and installation of work 4. Remove bracket (3).

equipment valve assembly 1
Removal
k Loosen the oil filler cap of the hydraulic 6. Remove accumulator fixing clamps (5) and (6).
the hydraulic tank.
k See "Releasing residual pressure in work
equipment circuit" in "Testing and adjust-
ing", and release residual pressure from
work equipment circuit and ECSS (travel
damper) circuit.


7. Remove the 2 accumulator mounting bolts and
lift off accumulator assembly (7).
4 Accumulator assembly: 121 kg
3. Remove right and left round covers (2).
9. Disconnect brake hose (9).
10 WA500-6R
10. Disconnect hoses (10), (11), (12) and (13). 15. Remove tubes (25) and (26).
16. Disconnect tubes (27) and (28).
17. Disconnect hoses (29), (30), (31), (32) and

(33).
11. Disconnect wiring harness connectors F24

(14), F07 (15) and F10 (16).
13. Disconnect wiring harness connectors F08 18. Remove 4 work equipment valve assembly
(18), F09 (19) and F16 (20). mounting bolts (34).
14. Remove hoses (21) and (22) and brackets (23) 19. Set a wooden block and steel plate [1] to the
and (24). frame. Sling work equipment valve assembly
(35) and pull it out to this side to remove.
4 Work equipment valve assembly: 
153 kg
WA500-6R 11
Installation
removal.

again.
q Bleeding air
work equipment circuit".
12 WA500-6R
Disassembly and assembly of q Valve mating face

2 Valve mating face (b):
work equipment control valve
SEALEND 242 or equivalent
assembly 1
a Only the precautions for assembling the work

equipment control valve assembly are
described in this section.
Assembly of work equipment control valve

assembly
q When assembling, apply engine oil to the
spool sliding surfaces.
q When slinging the work equipment control
valve assembly, use tap holes (a).
WA500-6R 13
q Plate mounting bolt (1) and cover mounting q Plugs

bolts (2) a Thoroughly degrease and dry the plugs and
3 Plate mounting bolt (1): threaded parts of the valve mounting holes
156.8 – 196 Nm {16 – 20 kgm} with denatured alcohol etc.
3 Cover mounting bolt (2): a Do not apply oil pressure for 2 hours after
156.8 – 176.5 Nm {16 – 18 kgm} installing the plugs.
a Tighten the mounting bolts in the following 2 Lift arm spool plug (3): LOCTITE No. 638
order. 2 Bucket spool plug (4): LOCTITE No. 638
14 WA500-6R
qECSS valve
Loosen locknut (6) and tighten plug (5) to the
specified torque. Then, tighten locknut (6) to
the specified torque. At this time, check that
no clearance is made at parts (c) on the seat
surface (to prevent oil from flowing in through
the seat of plug (5)).
3 Plug (5): 19.6 – 27.5 Nm {2.0 – 2.8 kgm}
3 Locknut (6): 19.6 – 27.5 Nm {2.0 – 2.8 kgm}
qMain relief valve assembly

After installing main relief valve assembly (8) to
the work equipment control valve, adjust the
main relief valve. For details, see Testing and
adjusting, "Testing and adjusting work equip-
ment hydraulic circuit".
3 Locknut (9): 49 – 58.5 Nm {5 – 6 kgm}
q O-ring on valve mounting face

a Before assembling the whole work equipment
control valve assembly, check that the O-ring
of each valve is fitted to the groove securely.
a Check O-ring (7) particularly since it is not cir-
cular.
WA500-6R 15
Disassembly and assembly of 3. Pull cylinder head and piston rod assembly (3)
steering cylinder assembly 1
out of cylinder (4) and lift it off.
a Since oil flows out when the piston rod
Special tools assembly is pulled out of the cylinder, pre-
pare an oil receiver.
New/Remodel
Necessity
Sym- 4. Remove cylinder (4) from tool U1.
Part No. Part name
Sketch
bol
Q'ty
790-502-1003
1 or Repair stand t 1
1 790-502-2000
2 790-101-1102 Pump 1
Wrench assem-
2 790-330-1100 t 1
bly
Socket 
3 790-302-1290 (Width across t 1
flats: 60 mm)
1 790-201-1500 Push tool kit t 1
U 2 790-201-1590 • Plate t 1
4
4 790-101-5021 • Grip 1 5. Set the cylinder head and piston rod assembly
to tool U1 and loosen nut (5) with torque multi-
5 01010-50816 • Bolt 1
plier [1] and socket U3.
1 790-201-1702 Push tool kit t 1 a Torque multiplier [1]: 16 : 1
2 790-201-1781 • Push tool t 1 a Width across flats of socket U3: 60 mm
5
4 790-101-5021 • Grip 1
5 01010-50816 • Bolt 1
1 790-720-1000 Expander t 1
6 2 796-720-1660 Ring t 1
3 07281-01159 Clamp t 1
Disassembly
1. Set cylinder assembly (1) to tool U1.
2. Using tool U2, remove cylinder head (2) from

the cylinder.
16 WA500-6R
6. Remove nut (5) and then remove piston 2) Remove rod packing (18).
assembly (6) and cylinder head assembly (7)
from rod (8). 3) Remove buffer ring (19).
4) Remove O-ring (20) and backup ring (21).
5) Remove O-ring (22).
6) Remove bushing (23) from cylinder head

(24).
7. Disassembly of piston assembly

1) Remove wear ring (9).
2) Remove piston ring (10) from piston (11).
8. Disassembly of cylinder head assembly

1) Remove snap ring (16) and dust seal (17).
WA500-6R 17
Assembly 2. Assembly of piston assembly

a When assembling, coat the sliding surfaces of 1) Using tool U6-1, expand piston ring (10).
each part with engine oil and take care not to a Set the piston ring to the tool and
damage the rod packings, dust seals, and O- rotate the handle of the tool by 8 – 10
rings. turns to expand the piston ring.
2) Remove piston ring (10) from tool U6-1
1. Assembly of cylinder head assembly and install it to piston (11).
1) Using U5, press fit bushing (23) to cylinder

head (24).
a When press fitting, take extreme care
not to deform the bushing.
2) Install buffer ring (19).
3) Install rod packing (18).
a Take care of the installed directions of
rod packing (18) and buffer ring (19).
4) Using the push tool, install dust seal (17)
to cylinder head (24).
6) Install O-ring (22).
7) Install backup ring (21) and O-ring (20).
a Do not insert the backup ring forcibly, 3) Install tool U6-2 to the piston ring and
but warm it in water at 50 – 60°C and shrink the piston ring with clamp U6-3.
then insert it. 4) Install wear ring (9).
18 WA500-6R
3. Set piston rod (8) to tool U1. 6. Remove piston rod and head assembly (3)
from tool U1.
4. Install cylinder head assembly (7) and piston
assembly (6) to the rod and install nut (5). 7. Set cylinder (4) to tool U1.
8. Sling piston rod and head assembly (3) and

install it to cylinder (4).
5. Using torque multiplier [1] and socket U3,

tighten nut (5).
3 Piston nut:
9. Using tool U2, tighten cylinder head nut (2).
3 Cylinder head nut:
Power of torque multiplier [1] 16 times
Width across flats of nut (5) 60 mm 785 ± 78.5 Nm {80 ± 8.0 kgm}
1,764.0 ± 176.4 Nm
Tightening torque for nut
{180.0 ± 18.0 kgm} 10. Remove the cylinder assembly from tool U1.
WA500-6R 19
Disassembly and assembly of lift 3. Set the cylinder to tool U1 and pull cylinder
arm and bucket cylinder assembly1 head and piston rod assembly (3) out of cylin-
der (4) and lift it off.
Special tools a Since oil flows out when the piston rod
assembly is pulled out of the cylinder, pre-
New/Remodel
pare an oil receiver.
Necessity
Sketch
Q'ty
1 790-502-1003 Repair stand t 1
1
2 790-101-1102 Pump 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
1 790-201-1500 Push tool kit t 1
3 790-201-1680 • Plate 1
4
4 790-101-5021 • Grip 1
5 01010-50816 • Bolt 1
U 1 790-201-1702 Push tool kit t 1
3 790-201-1871 • Push tool 1 4. Disassemble the piston rod assembly accord-
5 ing to the following procedure.
4 790-101-5021 • Grip 1
1) Set piston rod assembly (3) to tool U1.
5 01010-50816 • Bolt 1
1 790-720-1000 Expander t 1
4 796-720-1680 Ring t 1
6 5 07281-01589 Clamp t 1
6 796-720-1690 Ring t 1
7 07281-01919 Clamp t 1
Disassembly
1. Set cylinder assembly (1) to tool U1.
2. Remove mounting bolt (2) of the cylinder head.
5. Remove piston assembly lock screw (5).

Screw size: M12 × Pitch 1.75
20 WA500-6R
a If screw (5) is so caulked that you cannot 8. Disassembly of piston assembly

remove it, tighten it temporarily and cut 1) Remove guard rings (11).
the threads on it with tap [1], and then 2) Remove wear rings (12).
remove it. 3) Remove piston ring (13).
4) Remove the O-ring and backup ring (14).
6. Using tool U2, remove piston assembly (6).

q When not using tool U2, loosen the piston 9. Disassembly of cylinder assembly
assembly by using the drilled holes (DH) 1) Remove O-ring (15) and backup ring (16).
(Ø10: 2 places). 2) Remove the snap ring and dust seal (17).
7. Remove cylinder head assembly (7) from pis-

ton rod assembly (9).
WA500-6R 21
3) Remove rod packing (18). Assembly

4) Remove buffer ring (21). a When assembling, coat the sliding surfaces of
5) Remove bushing (19). each part with engine oil and take care not to
damage the U-packings, dust seals, and O-
rings.
1. Assemble the cylinder head assembly accord-

1) Using push tool U4, press fit bushing (19)
to cylinder head (20).
a When press fitting, take extreme care
not to deform the bushing.
2) Install rod packing (18).

the rod packing.
3) Install buffer ring (21).
the buffer ring.
4) Install backup ring (16) and O-ring (15) in
order.
a Do not insert the backup ring forcibly,
but warm it in water at 50 – 60°C and
then insert it.
22 WA500-6R
2. Assemble the piston assembly according to

the following procedure.
1) Using tool U6-1, expand piston ring (13).
a Set the piston ring to the tool and
rotate the handle of the tool by 8 – 10
turns to expand the piston ring.
2) Remove the piston ring from tool U6-1 and
install it to piston (10).
3) Install tool U6-4 and shrink the piston ring
with clamp U6-5.
4) Install wear ring (12) to the piston.
5) Install guard ring (11) to the piston.
6) Install the O-ring and backup ring (14) to
the piston.
5) Using push tool U5, install dust seal (17)
to the cylinder head and fix it with snap
ring (22).
WA500-6R 23
3. Install cylinder head assembly (7) to piston rod

(9).
q When either or both of the rod and

piston are new
1] Screw in piston assembly (6) until it
4. Piston rod assembly touches rod end [part B]. Then, using
1) Set piston rod assembly (3) to tool U1. tool U2, tighten the piston assembly
to the specified torque.
2) Assemble piston assembly (6) according 2] Make a screw hole to install screw (5).
to the following procedure. a Make a hole horizontally with a
q When reusing piston rod assembly d r i l l a t t h e V- g r o o v e o f t h e
(3) and piston assembly (6) threaded part of piston (6) and
a Clean the piston rod and piston thor- rod (3).
oughly and remove chips, dirt, etc. q Threading dimensions (mm)
1] Screw in piston assembly (6). Then,
using tool U2, tighten piston assem- Diameter of Depth of tap Tap to be Tapping
bly (6) until the screw holes (H) are tap drill hole drill hole used depth
aligned. 10.3 27 12 × 7.5 20
a Remove burrs from the threaded 3] After making the hole, remove the all
parts with a file etc. chips and dirt and clean thoroughly.
24 WA500-6R
4] Tighten screw (5). 5. Set cylinder (4) to tool U1 and sling cylinder
2 Threaded part (b) of screw:  head and piston rod assembly (3) and install it
Adhesive (LT-2) to the cylinder.
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
5] Caulk 4 points (a) of the threaded part
with a punch.
1) Tighten cylinder head mounting bolt (2).

3 Cylinder head mounting bolt (2):
Lift arm: 
529.7 ± 78.5 Nm {54.0 ± 8.0 kgm}
Bucket: 
892 ± 137 Nm {91.0 ± 14 kgm}
2) Remove cylinder assembly (1) from tool
U1.
3) Remove piston rod assembly (3) from tool

U1.
WA500-6R 25
Removal and installation of 8. Sling steering valve assembly (15), remove its
steering valve assembly 1
4 mounting bolts, and lift it off.
4 Steering valve assembly: 31 kg
Removal

2. Remove guard and seat (1).
3. Remove plate (2).
4. Remove toolbox (3).
5. Remove covers (4), (5) and (6).
Installation
removal.

again.
q Bleeding air
See Testing and adjusting, "Bleeding air from
steering cylinder circuit".
6. Disconnect hoses (7), (8), (9), (10), (11), (12)
and (13).
7. Disconnect tube (14).
26 WA500-6R
WA500-6R 27
SEN02911-01


© 2017 KOMATSU
All Rights Reserved
28
SEN02912-00
WA500-6R

WA500-6R 60001 and up
Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
WA500-6R 1
Removal and installation of work 5. Sling bucket cylinder (5), pull out pin (6), and
equipment assembly 1
disconnect the bucket cylinder from the bell
crank.
Removal a After disconnecting the bucket cylinder,
k Stop the machine on a level ground and start the engine and retract the piston rod.
lower the bucket to the ground.
k Set the lock bar to the frame, apply the
parking brake, and lock the tires with
chocks.
1. Sling the bucket link and remove pin (1). [*1]

a Using a lever block, fix the bucket link to
the bell crank.
a If any shim is inserted, check its quantity
and thickness.
2. Remove right and left bucket hinge pins (2). 

[*2]
and thickness. 6. Fix bucket cylinder (5) to the frame with a
nylon sling etc.
3. Disconnect the bucket from the lift arm by mov-
ing the machine in reverse or sling the bucket
with a crane.
4 Bucket: 3,110 kg
7. Set stand [1] under the lift arm end and release
the residual pressure in the hydraulic piping.
4. Disconnect grease hose (4).
2 WA500-6R
8. Sling lift arm cylinder (7) and remove pin (8). 12. Disconnect right and left grease tubes (13).
a Remove the other lift arm cylinder pin
according to the above procedure.
a After disconnecting the lift arm cylinder,
start the engine and retract the piston rod.
13. Sling lift arm, bell crank and bucket link assem-
bly (14), pull out right and left pins (15), and lift
off the assembly. [*4]
a When slinging above assembly, insert
9. Remove coves (9) and (10). block [2] in the bell crank.
10. Disconnect wiring harness connector F13 (11) and thickness.
4
and remove the 3 wiring harness clamps.
Lift arm, bell crank and bucket link
assembly: 3,240 kg
11. Remove lift arm angle sensor assembly (12). 
[*3]
14. Sling bucket link assembly (16), pull out pin

(17), and remove the assembly from the bell
crank.
4 Bucket link: 157 kg
WA500-6R 3
15. Sling bell crank (18), pull out pin (19), and 18. Remove dust seal (25) and bushing (26) from
remove the bell crank from the lift arm. bucket link (16).
4 Bell crank: 754 kg
16. Remove dust seal (21) and bushing (22) from

lift arm (20). [*5]
17. Remove dust seal (23) and bushing (24) from

bell crank (18).
4 WA500-6R
Installation [*3]
q Carry out installation in the reverse order to Adjust the lift arm angle sensor assembly. For
removal. details, see Testing and adjusting, "Testing and
adjusting lift arm position sensor lever".
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes. [*4]
k When starting the engine, check that the Sling the assembly of the lift arm, bell crank and
directional lever is in neutral and the park- bucket link and set it to the lift arm mounting hole of
ing brake is applied. the front frame. Insert a shim so that clearances (c)
on the right and left sides will be the same, and
[*1] then install pin (15) and lock it with the bolt.
Sling bucket link (16) and install cord rings (27) a Take care that the cord ring will not be caught.
while aligning the holes for pin (1). Insert a shim so a Clearance (c): Max. 1.0 mm
that clearances (a) on the right and left sides will be k After installing the pin, set a stand under
the same, and then install pin (1) and lock it with the lift arm end.
the bolt.
a Take care that the cord ring will not be caught.
a Clearance (a): Max. 1.5 mm
[*5]
Press fit the respective bushings to the bucket link,
bell crank and lift arm with puller [3] and install the
[*2] dust seals.
Operate the control lever to align the holes for 2 Bushing: Grease (G2-LI)
bucket mounting pin (2) and install cord rings (28). a The following figure shows the lift arm.
Insert a shim so that clearances (b) on the right and
left sides will be the same, and then install mount-
ing pin (2) and lock it with the bolt.
a Take care that the cord ring will not be caught.
a Clearance (b): Max. 1.5 mm
q Supply grease to each pin.
WA500-6R 5
SEN02912-00


© 2007 KOMATSU
All Rights Reserved
6
SEN02913-03
WA500-6R

WA500-6R 60001 and up
Cab and its attachments

Removal and installation of operator's cab assembly (Separate cab and floor specification) ........................ 2
Removal and installation of operator's cab and floor frame assembly (Cab-floor unit specification) .............. 7
Removal and installation of operator's cab glass (Stuck glass) .....................................................................11
Disassembly and assembly of operator's seat assembly.............................................................................. 20
WA500-6R 1
Removal and installation of operator's 3. Remove brake combination box front cover (5).
cab assembly 
(Separate cab and floor specification)1
Removal
chocks.
1. Remove floor skirt cover (1) and right and left

covers (2).
4. Remove upper cover (6) of the steering valve

cover.
2. Open the external air filter cover and remove

filter (3) and filter box (4).
5. Remove right and left covers (7) under the

hydraulic tank.
2 WA500-6R
6. Disconnect tipping protection wire (8). 9. Remove front step (11).
7. Disconnect heater hose clamp (9). 10. Remove air conditioner pipe and heater hose
fixing plate (12).
8. Disconnect reservoir tank and sub tank hose

clamps (10). 11. Remove the floor mat.
12. Remove rear wiper motor cover (13).
13. Remove rear cover (14).
14. Remove lunchbox (15).
WA500-6R 3
15. Disconnect rear windshield wiper wiring har- 21. Disconnect internal temperature sensor con-
ness connector C15 (16). nector (23).
16. Disconnect rear window washer hose (17). 22. Disconnect parking brake switch (24).
17. Disconnect KOMTRAX wiring harnesses (18). 23. Disconnect switch connectors (25) L59, (26)
L65, L66, L69, L70, (27) L67, L68, L72 (if
18. Remove the 5 mounting bolts and disconnect equipped) and (28) C10.
rear controller box (19) from the rear side of
the cab. 24. Remove the 10 mounting bolts and monitor
dashboard cover (29).
19. Remove the 4 mounting bolts and disconnect

right console (20). 25. Remove right and left covers (30) and (31) on
the front side of the cab.
20. Remove right and left pillar covers (21) and

(22). 26. Disconnect 6 wiring harness clamps (32).
27. Remove wiring harness protection cover (33).
4 WA500-6R
28. Disconnect wiring harness connectors (34) 33. Disconnect hose (42) of the cooler and heater
AL1, (35) CL1, (36) CL2 and (37) CL15. hoses from the air conditioner unit.
29. Remove 4 bolts (38) marked with a. 34. Remove the 4 mounting bolts and disconnect
air conditioner unit assembly (43) from the cab.
30. Remove 2 screws (39) marked with q.
31. Disconnect wiper motor wiring harness con-

nector (40) C12.
35. Disconnect internal air filter (44) from the floor.
32. Disconnect window washer hose (41).
WA500-6R 5
36. Remove the operator's cab mounting bolts.  Installation

[*1] q Carry out installation in the reverse order to
q Remove the bolts marked with a and q removal.
from the underside of the floor.
q Remove the bolts marked with e from the [*1]
top of the floor. 3 Cab mounting bolt:
(M20): 490 – 608 Nm {52 – 62 kgm}
(M12): 98 – 123 Nm {10 – 12.5 kgm}
[*2]
Replace seal (46) between the operator's cab and
floor frame.
1) Stick the seal along the periphery of the
floor frame top.
2) Remove oil, grease, dust, etc. from the
sticking surface.
3) Do not cut the bent parts of the seal but
stick them as they are. Bend each part by
10 – 20 mm.
a If the operator's cab is not sealed per-
fectly, the pressurizing performance
of the cab lowers and the noise in the
operator's cab increases.
37. Lift off operator's cab assembly (45).

a When removing the operator's cab, check
that all the wiring harnesses and pipings
are disconnected and take extreme care
that the cab will not interfere with another
part. [*2]
4 Operator's cab assembly: 720 kg
6 WA500-6R
Removal and installation of operator's 2. Remove right and left side panels (1).
cab and floor frame assembly 
(Cab-floor unit specification) 1
Removal
chocks.
k Loosen the hydraulic tank cap gradually to
release the internal pressure of the hydrau-
lic tank.
k Operate the work equipment control lever 2
- 3 times to release the pressure in the PPC
accumulator circuit.
k Release residual pressure in brake accu-
mulator circuit. For detail, see Testing and 3. Remove cover (2).
adjusting "Releasing residual pressure in
brake accumulator circuit".
k
4. Remove box (3).
Disconnect the cable from the negative (–)
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In the case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
5. Remove the bolts from the rear part of cover
k If refrigerant gas (R134a) gets in your eyes, (4).
you may lose your sight.
Accodingly, put on protective goggles
while you are collecting the refrigerant
(R134a) or filling the air conditioner circuit
with the refrigerant (R134a). Collecting and
filling work must be conducted by a quali-
fied person.

WA500-6R 7
6. Remove the bolts from the front part of cover 13. Disconnect wiring harness connectors LR1
(5). (14), LR4 (15), LS2 (16), LR3 (17), LR2 (18),
LR6 (19) and LR5 (20).
8. Remove toolbox (7).
14. Disconnect wiring harness connector bracket

(21) from the frame.
9. Disconnect air conditioner hoses (8) and (9).  15. Disconnect wiring harness clamps (22) and
[*1] (23).
10. Disconnect hose bracket (10).
16. Disconnect wiring harness connectors FL1

(24) and RT1 (25).
11. Disconnect brake hoses (11) and (12).
17. Disconnect wiring harness clamps (26) and
12. Disconnect steering hose (13). (27) from the bracket.
8 WA500-6R
18. Disconnect heater hoses (28) and (29). 21. Disconnect steering hoses (33) and (34).
22. Disconnect brake booster hoses (35), (36),

(37) and (38).
23. Remove rear windshield wiper motor cover

(39).
25. Remove lunchbox (41).
20. Disconnect window washer hoses (32).
26. Disconnect ground wire (42) from the floor

frame.
WA500-6R 9
27. Remove 4 front and rear rubber caps (43). Installation

28. Remove 4 front and rear nuts (44). [*2] removal.
[*1]
a When installing the air conditioner circuit
hoses, take care that dirt, dust, water, etc. will
not enter them.
a Before connecting each air conditioner hose,
check that the O-rings are fitted to its joints.
a Check that each O-ring is not damaged or
deteriorated.
2 Threaded part of refrigerant piping: ND-OIL8
3 Threaded part of hose (M16 x 1.5): 
12 – 15 Nm {1.2 – 1.5 kgm}
Threaded part of hose (M24 x 1.5): 
30 – 35 Nm {3.0 – 3.5 kgm}
29. Lift off operator's cab and floor frame assembly a Tighten each nut with 2 spanners.
(45). q Charge the air conditioner circuit with refriger-
a Before removing the assembly, check that ant (R134a).
all the wiring harnesses and pipings are
[*2]
3
disconnected.
Floor frame mounting nut: 
4 Operator's cab and floor frame assem- 1,177 – 1,471 Nm {120 – 150 kgm}
bly: 1,200 kg

again.
q Bleeding air
Bleed air from the each part. For details, see
Testing and adjusting, "Bleeding air from brake
circuit" and "Bleeding air from steering cylinder
circuit".
10 WA500-6R
Removal and installation of operator's cab glass (Stuck glass) 1
a In this section, the procedure for replacing the (1): Front glass
stuck glass is explained. (2): Right door glass
(3): Right window glass
(4): Rear window glass
(5): Left window glass
WA500-6R 11
Special tools a If the window glass is broken finely, it may

be removed with knife [4] and a screw-
New/Remodel
driver. (If the screwdriver is applied
Necessity
directly to the normal window glass, the
Sketch
glass will be probably broken.)
a
Q'ty
When using knife [4], insert a screwdriver
in the cut to widen it and move the knife
1 793-498-1120 Clear plate t 2
forward.
2 2 793-498-1130 Plate t 2
X
3 793-498-1110 Magnet t 2
3 793-498-1210 Lifter (Suction cup) t 2
Removal
a The operator's cab glasses of this machine are
fully stuck with adhesive.
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between

broken window glass (1) and operator's cab
(2).
2. Remove the window glass.
a If the glass is narrow, you may cut the

adhesive by the following method; Insert a
fine wire (piano wire, etc.) [2] in the adhe-
sive and grip its both ends with pliers [3],
etc. (or hold them by winding them onto
something) and cut the adhesive with the
wire.
12 WA500-6R
Installation
1. Using scraper [5], remove the remaining adhe-
sive from the sticking surfaces.
a Do not scratch the paint.
4. Stick both-sided adhesive tape (4) along the

inside edge of the glass sticking section.
q Size of both-sided adhesive tape: 
7 × 4.8 mm
2. Remove oil, dust, dirt, etc. from the sticking a When sticking the both-sided adhesive
surfaces of cab (2) and window glass (3) with tape, do not touch the cleaned surface as
white gasoline. long as possible.
a If the sticking surfaces are not cleaned a Do not remove the release tape of the
well, the glass may not be stuck perfectly. both-sided adhesive tape on the glass
a Clean all the black part on the back side of sticking side before sticking the glass.
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
a Take care that the corner (part "b") of

both-sided adhesive tape (4) will not float.
3. When the adhesive was removed with the

scraper, if any paint was flaked off, coat the
bare part with paint.
a If the glass is installed without repairing
the bare part, that part will be rusted.
a Do not apply paint to a part which will be
coated with primer.
WA500-6R 13
a When sticking the both-sided adhesive 3) Using tool X3 (suction cup), place window
tape around a side or a rear window glass, glass (3) on tool X2-1 (5-mm spacer) and
start at center of the top and make a clear- set it to the operator's cab.
ance of about 5 mm at end joint (c).
4) Check the clearance between window

5. Position the replacement glass. glass (3) and operator's cab (2) on the
1) Stick X2-2 (thin steel sheet) to tool X2-1 right and left sides and adjust it evenly.
(spacer) with adhesive. 5) Stick tape [6] between window glass (3)
q Spacer thickness (t): 5 mm and operator's cab (2) and draw position-
2) Set tool X2-3 (magnet) to tools X2-1 and ing line (a) on the tape.
X2-2 and set them to the 2 lower places of 6) Cut the tape between window glass (3)
the window glass sticking section of oper- and operator's cab (2) with a knife, and
ator's cab (2). then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab
before installing the window glass.
14 WA500-6R
6. Apply primer. 3) Evenly apply paint primer (7) to the parts

a The using limit of primer (5) is 4 months on the outside of both-sided adhesive tape
after the date of manufacture. Do not use (4) on operator's cab (2) which will be
the primer after this limit. coated with the adhesive.
a Use the primer within 2 hours after 2 Paint primer:
unpacking it. SUNSTAR PAINT PRIMER 580 SUPER
a Even if the primer is packed again just a Do not apply the primer more than 2
after it is unpacked, use it within 24 hours times. (If it is applied more than 2
after it is unpacked for the first time. (Dis- times, its performance will be lowered.)
c a r d t h e pr im e r 2 4 h ou r s a fte r i t i s a Parts to be coated with primer: Apply
packed.) the primer all over dimension (d) on
1) Stir the primers for paint and glass suffi- the outside of the both-sided adhe-
ciently before using them. sive tape.
a If the primer has been stored in a q Dimension to apply primer (d): 23 mm
refrigerator, leave it at the room tem- a After applying the primer, leave it in
perature for at least half a day before air for at least 5 minutes (within 8
stirring it. (If the primer is unpacked hours) to dry.
just after taken out of the refrigerator, a If the glass primer is applied by mis-
water will be condensed. Accord- take, wipe it off with white gasoline.
ingly, leave the primer at the room (If wrong primer is applied, the glass
temperature for a sufficient time.) will not be stuck.)
2) When reusing primer brush (6), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
WA500-6R 15
4) Evenly apply glass primer (8) to the black 7. Apply adhesive.

part of window glass (3) to be stuck. a Use either of the 2 types of the adhesive,
2 Glass primer: depending on the season.
SUNSTAR GLASS PRIMER 580 SUPER 2 Adhesive (April – October): 
a Do not apply the primer more than 2 SUNSTAR PENGUINE SEAL 
times. (If it is applied more than 2 580 SUPER "S"
times, its performance will be low- 2 Adhesive (October – April): 
ered.) SUNSTAR PENGUINE SEAL 
a Parts to be coated with primer: Apply 580 SUPER "W"
the primer to the sticking surface of a The using limit of the adhesive is 4 months
window glass (3) and all over dimen- after the date of manufacture. Do not use
sion (d) on both-sided adhesive tape the adhesive after this limit.
(4) and operator's cab (2). a Keep the adhesive in a dark place where
q Dimension to apply primer (d): 23 mm the temperature is below 25°C.
a Do not apply the primer to the a Never heat the adhesive higher than
boarder about 5 mm wide between 30°C.
the black part and transparent part of a When reusing the adhesive, remove the
the glass. all hardened part from the nozzle tip.
a After applying the primer, leave it in 1) Break aluminum seal (10) of the outlet of
air for at least 5 minutes (within 8 adhesive cartridge (9) and install the noz-
hours) to dry. zle.
a If the paint primer is applied by mis-
take, wipe it off with white gasoline.
(If wrong primer is applied, the glass
will not be stuck.)
2) Cut the tip of the adhesive nozzle (11) so

that dimensions (f) and (g) will be as fol-
lows.
q Dimension (f): 10 mm
q Dimension (g): 12 mm
16 WA500-6R
3) Set adhesive cartridge (9) to caulking gun a Apply adhesive (12) to dimensions
[7]. (h) and (j) of both-sided adhesive
a An electric caulking gun is more effi- tape (4) of operator's cab (2).
cient. q Dimension (h): 10 mm
a Apply adhesive (12) higher than both-
sided adhesive tape (4).
a Apply the adhesive evenly in height.
4) Remove release tape (13) of the both-

sided adhesive tape on the glass side.
8. Install window glass (3).

a If the glass is positioned wrongly, the
adhesive must be removed and cleaned,
and then the primer and adhesive must be
applied again. Accordingly, position the
glass very carefully when sticking it.
1) Similarly to step 1, match tools X2-1, X2-2
and X2-3 and set them to the 2 lower
places of the window glass sticking part of
operator's cab (2).
5) Apply adhesive (12) to the outside of both-

sided adhesive tape (4) of the operator's
cab.
a Before applying the adhesive, check
that the primer is applied to the sur-
face to which the adhesive will be
applied.
WA500-6R 17
2) Using tool X3, raise and place window 3) After sticking window glass (3), press it
glass (3) on tool X2-1 (5-mm spacer) and evenly.
stick it to the operator's cab. a Press all over the window glass to the
a Match the lines of the match tapes degree that the window glass will be
stuck in step 5. stuck to the both-sided adhesive
a Stick the glass within 10 minutes after tape.
applying the adhesive. a Do not press the window glass too
a Before sticking the glass, check again strongly.
that the primer is applied to the glass
sticking surface.
9. Cure the stuck window glass for a certain time.

a Curing time before removing tool X2-1
a Check that clearance (k) between the (5-mm spacer) (at temperature of 20°C
front side of the front glass and right and humidity of 60%): 10 hours
and left side glasses is even. a Curing time before operating machine
q Clearance (k): 5 mm after application of adhesive: 24 hours 
(1 day)
18 WA500-6R
10. If the front glass and the right and left front 2) Fill the joint of the glasses with caulking
glasses are replaced, seal them. material (15).
1) Stick masking tapes (14) along the parts to a The using limit of the following caulk-
be sealed shown in the figure. ing material is 4 months after the date
a Stick the masking tapes to both inside of manufacture. Do not use the
and outside of the operator's cab. caulking material after this limit.
2 Caulking material:
SUNSTAR PENGUINE SEAL
No. 2505
3) Remove the caulking material projected

from the joint with cardboard [8] etc.
4) Remove the masking tapes from the win-

dow glass.
11. Remove the primer and adhesive from the

operator's cab and window glass.
a Using white gasoline, wipe off the adhe-
sive before it dries.
a When cleaning the glass, do not give an
impact to it.
WA500-6R 19
Disassembly and assembly of 2. Removal and installation of seat pad and

operator's seat assembly 1
backrest upholstery
[ Manufactured by GRAMMER ]
a Although the machine of the joystick steering

specification is not equipped with the left arm-
rest, its operator's seat assembly are also dis-
assembled and assembled according to the
I. Upper seat
1. Removal and installation of storage box
Removal
1) Remove the storage box by referring to "1.
Removal and installation of storage box".
2) Undo the 4 screws (1), and remove the
backrest upholstery (2).
3) Undo the 5 screws (4), and remove the
seat pad (5).
4) Disconnect the connectors (3) and (6).
Installation
1) Connect the connectors (3) and (6).
2) Install the seat pad (5), and fix it with the 5
Removal screws (4).
1) Open the storage box (1). 3) Install the backrest upholstery (2), and fix
2) Remove the hook (3). it with the 4 screws (1).
3) Undo the screws (2) and remove the stor- 4) Install the storage box by referring to "1.
age box (1). Removal and installation of storage box".
Installation
1) Set the storage box (1) and fix it with the
screws (2).
2) Install the hook (3).
20 WA500-6R
3. Removal and installation of mechanical 4. Removal and installation of armrests

lumbar support (If equipped)
Removal Removal
1) Remove the storage box by referring to "1. 1) Remove the cover (1).
Removal and installation of storage box". 2) Unscrew the hexagon nuts (2) and
2) Remove the backrest upholstery by refer- remove the nuts and washers (3).
ring to "2. Removal and installation of seat 3) Remove the armrests (4).
pad and backrest upholstery".
3) Drill off the rivets (1), loosen the spring
steel sheets (2) from the L-bar (3) and Installation
remove them. 1) Set the armrests (4).
4) Unhook the L-bars (3) from the catch ele- 2) Put the washers (3) and tighten hexagon
ment (4). nuts (2).
5) Undo the hexagon socket screw (5) and 3 Hexagon nuts: 25 Nm {2.6 kgm}
remove the adjusting knob (6) with the 3) Install the cover (1).
toothed wheel (7).
6) Drill off the rivet (8), remove the wrap
spring brake element (9) and the catch
element (4).
Installation
1) Install the wrap spring brake element (9)
and the catch element (4), and fix them
with the rivets (8).
2) Install the adjusting knob (6) and the
toothed wheel (7), and tighten the hexa-
gon socket screw (5).
3) Install the catch element (4) to the L-bars
(3) and fix with the rivets (1).
4) Install the 2 spring steel sheets (2) to the
L-bar (3), and fix with the rivets (1).
5) Install the backrest upholstery by referring
to "2. Removal and installation of seat pad
and backrest upholstery".
6) Install the storage box by referring to "1.
WA500-6R 21
5. Disassembly and assembly of backrest
Removal a Insert the bearing (B/8) into the upper

1) Detach the storage box by referring to "1. hole on the backrest support on the
Removal and installation of storage box". right side (figure B/4).
2) Remove the backrest upholstery by refer- 2) Press the backrest (1) slightly to the left
ring to "2. Removal and installation of seat and install it.
pad and backrest upholstery". a The big cylindrical stamping on the
3) Remove the armrests by referring to "4. backrest adjustment (figure C/2) must
Removal and installation of armrests". (If engage into the big positional bore
equipped) hole on the backrest support on the
4) Disassemble the backrest adjustment by left side (figure C/3).
referring to "6. Disassembly and assembly a The integral catch on the backrest
of backrest adjustment". (figure A/1) must engage into the tor-
5) Unscrew the hexagon nut (5) and remove sion spring (figure A/9).
the washers (6) and (7). 3) Put the washer (10) and tighten the hexa-
6) Remove the hexagon bolt (11) and the gon bolt (11).
washer (10). 4) Put the washers (6) and (7), and tighten
7) Press the backrest (1) slightly to the left the hexagon nut.
and take it off upwards. 3 Hexagon nuts: 25 Nm {2.6 kgm}
8) Remove the bearing (8) and the torsion 5) Assemble the backrest adjustment by
spring (9) from the backrest (1). referring to "6. Disassembly and assembly
of backrest adjustment".
Installation 6) Install the armrests by referring to "4.
1) Install the bearing (8) and the torsion Removal and installation of armrests". (If
spring (9) to the backrest (1). equipped)
a Oil the bearing point (Q) on the back-
rest (1) for the bearing (8) with acid-
free multiple-purpose lubricant.
22 WA500-6R
7) Install the backrest upholstery by referring 7. Disassembly and assembly of seat angle
to "2. Removal and installation of seat pad and seat depth adjuster
6. Disassembly and assembly of backrest

adjustment
Disassembly
1) Remove the storage box by referring to "1.
2) Remove the backrest upholstery by refer-
ring to "2. Removal and installation of seat
pad and backrest upholstery".
3) Remove the armrests by referring to "4.
Removal and installation of armrests". (If
equipped)
Disassembly
4) Fold the backrest (1) forwards.
1) Remove the seat pad by referring to "2.
5) Unscrew 3 flat-headed screws (2), remove
Removal and installation of seat pad and
the adaptor plate (3) and the flat-headed
backrest upholstery".
screw (4).
2) Remove the switch by the following proce-
6) Remove the lever (5) and handle (6).
dure. (If equipped)
1] Disconnect the spring (1).
2] Tilt the switch-plate (2) forwards and
Assembly
remove it.
1) Fold the backrest(1) forwards.
3] Drill off the rivet (3) and remove the
2) Install the handle (6) and the lever (5).
seat switch (4).
3) Tighten the 3 flat-headed screws (4),
install the adaptor plate (3) and then
tighten the flat-headed screw (2).
a The lifter of the flat-headed screw (4)
must engage into the nut of the adap-
tor plate (3).
3 Flat-headed screw:
12 Nm {1.2 kgm}
4) Install the armrests by referring to "4.
Removal and installation of armrests". (If
equipped)
5) Install the backrest upholstery by referring
to "2. Removal and installation of seat pad
WA500-6R 23
3) Remove the flexible support plate (7) by 1] Turn the lever (14) clockwise until it
the following procedure. snaps-in, install the plate (15).
1] Press the spring plate (5) ("P" posi- 2] Install the spring (13) to hook (a) of
tion) inwards (arrow), operate the the lever (14) and hook (b) of the
lever for seat angle adjustment (6). plate (15).
2] Pull the flexible support plate (7) to 3] Install the cover (9), the levers for
backwards and remove it. seat angle and seat depth adjustment
4) Remove the plate (15) by the following (6), (10), the linkage rod (11) and the
procedure. locking lever (12), then tighten the
1] Drill off the rivet and remove the hexagon socket screws (8).
spring steel sheet (5). 4] Install the spring steel sheet (5) and
2] Unscrew the hexagon socket screws fix it with the rivet.
(8), remove the cover (9), the levers 6) Install the flexible support plate by the fol-
for seat angle and seat depth adjust- lowing procedure.
ment (6), (10), the linkage rod (11) 1] Press the spring plate (5) ("P" posi-
and the locking lever (12). tion) inwards (arrow), operate the
3] Remove the spring (13). lever for seat angle adjustment (6).
4] Turn the lever (14) clockwise until it 2] Swivel the flexible support plate (7)
snaps-in, pull the plate (15) to the upwards and install it.
very front and remove it. 3] Install the end hook of the linkage rod
5) Remove the covers on the right and left (11) to the position (c) of the lever
side by referring to "8. Removal and instal- (10), and the other side of hook of the
lation of covers". linkage rod (11) to the port (d) of the
6) Unscrew the nut (16), remove the lever lever (14).
(14) and the screw (17).
7) Drill off the rivet (18) and remove the
spring steel sheets (19).
8) Drill off the rivet (20) and remove the
locating element (21).
Assembly
1) Install the locating element (21) and fix it
with the rivet (20).
2) Install the spring steel sheets (19) and fix
it with the rivet (18).
3) Set the lever (14) and the screw (17), and
fix with nut (16).
4) Install the covers on the right and left side
by referring to "8. Removal and installation
of covers".
5) Assemble the plate (15) by the following
procedure.
24 WA500-6R
Removal
2) Remove spring(1) and switch-plate (2). (If
equipped)
3) Remove the flexible support plate by fol-
lowing procedure.
1] Press the spring sheet inwards
(arrow), operate the lever for seat
angle adjustment (3).
2] Pull the flexible support plate (4) to
backwards and remove it.
4) Remove the spring (5).
7) Install the switch (4) by the following pro- 5) Turn the lever (6) clockwise until it snaps-
cedure. (If equipped) in, pull the plate (7) to the very front and
1] Install the seat switch (4) and fix it remove it.
with the rivet (3). 6) Drill off the rivet (8) and remove the wash-
2] Tilt the switch-plate (2) forwards and ers (9).
install it. 7) Unhook the covers (10) by pulling them
3] Install the spring (1). forwards and remove them in an upward
8) Install the seat pad by referring to "2. direction.
Installation
8. Removal and installation of covers 1) Install the covers (10) of right and left.
2) Install the washers (9) and fix it with the
rivet (8).
3) Turn the lever (6) clockwise until it snaps-
in, then install the plate (7).
4) Remove the spring (5) (see 7. Disassem-
bly and assembly of seat angle and seat
depth adjuster).
5) Install the flexible support plate (4) (see 7.
Disassembly and assembly of seat angle
and seat depth adjuster).
6) Install spring (1) and switch-plate (2) (see
7. Disassembly and assembly of seat
angle and seat depth adjuster). (If
equipped)
7) Install the seat pad by referring to "2.
WA500-6R 25
9. Removal and installation of slide rails Installation

1) Install the slide rails (10).
2) Put the nuts (9) and tighten the hexagon
socket screws (8).
a Replace the hexagon socket screws
(8) with new ones.
3 Hexagon socket screws:
25 Nm {2.6 kgm}
3) Install the bellows to the upper part of the
suspension system.
4) Put the washers (7) and install the seat
top assembly (1).
5) Put the washers (5) and nuts (6), then
tighten the hexagon socket screws (4).
(4) with new ones.
25 Nm {2.6 kgm}
6) Push the seat top assembly (1) as far for-
ward as possible.
7) Put the nuts (3) and tighten the hexagon
socket screws (2).
(2) with new ones.
25 Nm {2.6 kgm}
8) Push the seat top assembly (1) as far
back as possible.
9) Install the seat pad by referring to "2.
Removal
2) Push the seat top assembly (1) as far
back as possible.
3) Unscrew the hexagon socket screws (2)
and remove the nuts (3).
4) Push the seat top assembly (1) as far for-
ward as possible.
5) Unscrew the hexagon socket screws (4),
remove the washers (5) and nuts (6).
6) Remove the seat top assembly (1) and
remove the washers (7).
7) Disconnect the bellows from the upper
part of the suspension system and lay it
down.
8) Unscrew the hexagon socket screws (8)
and remove the nuts (9).
9) Remove the slide rails (10).
26 WA500-6R
II. Suspension 2. Removal and installation of front cover
1. Removal and installation of top cover
Removal
1) Remove the upper part of the seat by
Removal referring to "I. Upper seat".
1) Remove the upper part of the seat by 2) Remove the top cover by referring to "1.
referring to "I. Upper seat". Removal and installation of top cover".
2) Pull the connecting cable (3) inwards 3) Bore out 2 rivet heads and drive out blind
through the upper cover (2). rivets (1), remove the front cover (2).
3) Remove the 2 bellows pins (1) and take
the upper cover (2) off.
Installation
1) Install the front cover (2) and fix it with the
Installation 2 rivets (1).
1) Install the connecting cable (3) inwards 2) Install the top cover by referring to "1.
through the upper cover (2). Removal and installation of top cover".
2) Install the upper cover (2) and fix it with 3) Install the upper part of the seat by refer-
the 2 bellows pins (1). ring to "I. Upper seat".
3) Install the upper part of the seat by refer-
ring to "I. Upper seat".
WA500-6R 27
3. Removal and installation of bellows
Installation
Removal 1) Install the wire insert (5) to the bellows (2).
1) Remove the upper part of the seat by 2) Install the bellows (2).
referring to "I. Upper seat". 3) Fix the bellows (2) with pins (3) to the
2) Remove the bellows (2) from the upper lower part of the suspension (6) in the
part of the suspension (1) by following reverse order of their removal.
procedure. 4) Fix the connecting cable with the cable tie
1] Take bellows pins (4) off on the front. (10). (If equipped)
2] Take bellows pins (3) off on the left 5) Fix the bellows (2) with pins (3) to the
side of the top. upper part of the suspension (1) in the
3] Remove 2 bellows pins (4) on the reverse order of their removal.
back and take 2 bellows pins (3) off 6) Install the upper part of the seat by refer-
the upper part of the suspension sys- ring to "I. Upper seat".
tem (1).
4] Take 3 bellows pins (3) on the right
side off the upper part of the suspen-
sion (1) and pull the bellows (2) over
the handle for vertical shock absorber
adjustment (9).
3) Remove the bellows (2) from the lower
part of the suspension (6) by the following
procedure.
1] Take 3 bellows pins (3) on the front
side off the lower part of the suspen-
sion (6).
2] Release 2 bellows pins (3) on the left
side from the lower part of the sus-
pension (6).
3] Release 4 bellows pins (3) on the
back side from the lower part of the
suspension (6).
4] Remove a cable tie (10) on the right
side from the connecting cable, and
take 2 bellows pins (3) off the lower
part of the suspension (6). (If
equipped)
4) Lift the bellows (2) over the lower part of
the suspension (6) and remove the bel-
lows (2) in a downward direction.
5) Remove the wire insert (5) from the bel-
lows (2).
28 WA500-6R
4. Removal and installation of Bowden pull

wire and handle for vertical shock absorber
adjustment
Removal 10) Mark the points where the Bowden pull

1) Remove the upper part of the seat by wire (5) is fastened with the swinging
referring to "I. Upper seat". structure (14) with the cable tie (8) and
2) Remove the top cover by referring to "1. take the cable tie (8) off.
Removal and installation of top cover". 11) Pull the fixation (12) off the vertical shock
3) Take the bellows off by referring to "3. absorber (13).
Removal and installation of bellows". 12) Take the Bowden pull wire (5) off the bear-
4) Move the suspension system to the high- ing (9).
est position. 13) Remove the fixation (12) from the fork
k Risk of crushing! Secure the sus- (11).
pension between the swinging 14) Take the Bowden pull wire (5) off the fork
structure and lower part of the (11), remove the fork (11) and compres-
suspension system with suitable sion spring (10).
spacers. 15) Mark the location of the mounting hole for
5) Screw out Torx screw (2). the Bowden pull wire (5) in the upper part
6) Pull the handle for vertical shock absorber of the suspension (4), pull the Bowden pull
adjustment (1) off the upper part of the wire (5) out of the upper part of the sus-
suspension (4). pension (4) and then remove it.
7) Remove the Bowden pull wire (5) from the
handle for vertical shock absorber adjust-
ment (1).
8) Push the Bowden pull wire (5) off the
bearing for Bowden pull wire (6).
9) Bore out the rivet head and drive out the
blind rivet (7), and remove the bearing for
Bowden pull wire (6).
WA500-6R 29
Installation
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Put the Bowden pull wire (5) to the upper
part of the suspension (4) through the
location of the mounting hole marked
before removing the Bowden pull wire (5).
3) Install the fork (11) and compression
spring (10), and take the Bowden pull wire
(5) to the fork (11).
4) Install the fixation (12) to the fork (11).
5) Take the Bowden pull wire (5) to the bear-
ing (9).
6) Put the fixation (12) to the vertical shock
absorber (13).
7) Install the Bowden pull wire (5) and fix it
with the cable tie (8) at the marked points.
a Install the Bowden pull wire according
to the marking.
8) Install the bearing for Bowden pull wire (6)
and fix it with the rivet (7).
9) Install the Bowden pull wire (5) to the
bearing for Bowden pull wire (6).
10) Install the Bowden pull wire (5) to the han-
dle for vertical shock absorber adjustment
(1).
11) Install the handle for vertical shock
absorber adjustment (1) to the upper part
of the suspension (4).
12) Tighten Torx screw (2).
3 Torx screw: 2.25 Nm {0.23 kgm}
13) Install the bellows off by referring to "3.
Removal and installation of bellows".
14) Install the top cover by referring to "1.
Removal and installation of top cover".
30 WA500-6R
5. Removal and installation of vertical shock Installation

absorber 1) Move the suspension system to the high-
est position.
structure and lower part of the
suspension system with suitable
spacers.
2) Install the vertical shock absorber (4).
a When re-installing the vertical shock
absorber (4), make sure the labeling
is on top.
3) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (3).
4) Install circlip (5) to the stud (3).
a Apply acid-free multi-purpose lubri-
cant to the entire external surface (F)
of the stud (3).
5) Install the fixation (2) and bearing (1) to
the vertical shock absorber (4).
6) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (6).
cant to the entire external surface (F)
of the stud (6).
7) Install the circlip (8) to the stud (6).
8) Install the bellows by referring to "3.
Removal 10) Install the upper part of the seat by refer-
1) Remove the upper part of the seat by ring to "I. Upper seat".
referring to "I. Upper seat".
2) Remove the top cover by referring to "1.
3) Take the bellows off by referring to "3.
est position.
ers.
5) Remove circlip (8) from stud (6).
6) Pull the stud (6) out of swinging structure
(7) and vertical shock absorber (4).
7) Take the fixation (2) and bearing (1) off the
vertical shock absorber (4).
8) Remove circlip (5) from stud (3).
9) Pull the stud (3) out of the swinging struc-
ture (7) and the vertical shock absorber
(4).
10) Remove the vertical shock absorber (4) in
an upward direction.
WA500-6R 31
6. Removal and installation of compressor
Removal 11) Pull the compressed-air hose (7) off the

1) Remove the upper part of the seat by compressor (3).
referring to "I. Upper seat". a Do not use a screwdriver to lift the
2) Remove the top cover by referring to "1. compressed-air hose (7) off the spike
Removal and installation of top cover". of the compressor (3).
3) Take the bellows off by referring to "3. a Heat the compressed-air hose (7) at
Removal and installation of bellows". the head of compressor (3) (e.g.
4) Move the suspension system to the high- using a hot-air blower) and then, pull
est position. it off in one move.
k Risk of crushing! Secure the sus- 12) Pull out the compressor cable (5) in a
pension between the swinging downward direction and remove compres-
structure and lower part of the sus- sor (3) to the front.
pension system with suitable spac- 13) Remove the support (9) from the lower
ers. part of the suspension (2).
5) Mark the points where the compressor
cable (5) is fastened with the 6 cable ties
(6) and remove the cable ties (6).
6) Disconnect the right-angle plug (10) from
the height level control unit (1).
7) Disconnect the electric connector of the
flat plug (11).
8) Mark the points where the compressed-air
hose (7) is fastened with the cable tie (12)
and remove the cable tie (12).
9) Mark the points where the compressor (3)
is fastened with the 2 cable ties (4) and
remove the cable ties (4).
10) Pull the fitting (8) out of the spike of the
compressor (3) and push it backwards off
the compressed-air hose (7).
32 WA500-6R
Installation
est position.
ers.
2) Install the support (9) to the lower part of
the suspension (2).
3) Install the compressor (3) to the support
(9).
4) Install the compressed-air hose (7) and fix
it with cable tie (4) at the marked points.
a Loosely apply the cable tie (4) until
the locking head of the cable tie (4) is
located slightly over the front curve of
compressor (3) and while the com-
pressor (3) can be still moved.
a Align the compressor (3) and use the
pliers to tighten the locking head of
the cable tie (4) to 310 Nm{31.6 kgm}
in the direction shown (arrow).
5) Put the fitting (8) to the compressed-air
hose (7).
6) Install them to the spike of the compressor
(3).
7) Fix the compressor (3) with the cable ties
(4) at marked points.
a Fix the cable tie according to the
marking.
8) Fix the compressed-air hose (7) with cable
tie (12) at the marked points.
9) Connect the electric connector of the flat
plug (11).
10) Connect the right-angle plug (10) to the
height level control unit (1).
11) Install the compressor cable (5) and fix it
with cable tie (6) at the marked points.
a Tie back any excess length of the
compressor cable (5).
12) Install the bellows off by referring to "3.
WA500-6R 33
7. Removal and installation of height level

controller
Removal 9) Pull the air input hoses (10) and (11) off
1) Remove the upper part of the seat by the pneumatic spring (see "8. Removal
referring to "I. Upper seat". and installation of air hose").
2) Remove the top cover by referring to "1. 10) Mark the place where the cable is fas-
Removal and installation of top cover". tened with the right-angle plugs (13) and
3) Take the bellows off by referring to "3. (14) and the cable tie and then remove the
Removal and installation of bellows". cable tie.
4) Move the suspension system to the high- 11) Mark the place where the Bowden pull
est position. wire (19) is fastened with the cable tie and
k Risk of crushing! Secure the sus- remove the cable tie.
pension between the swinging 12) Unhook the Bowden pull wires (3) and
structure and lower part of the sus- (19) from the height level control (1).
pension system with suitable spac- 13) Mark and then disconnect the right-angle
ers. plugs (13) and (14) from the height level
5) Loosen up the 2 circlips (17) from the stud control unit (1).
(18) and then remove them. 14) Remove the 2 hexagon nuts (4) from the
6) Knock out the stud (18) from the lower thread of the height level control (1).
part of the suspension (15) and then 15) Remove the plate (7), loop of the webbing
remove it. (5) and the edge protection strip (6).
a Firmly hold the webbing (5) and let it 16) Remove the height level control (1) from
carefully roll back to the rewinder on the upper part of the suspension (8).
the height level controller (1). 17) Undo the Torx screw (9) and take the
7) Remove the 2 buffers (16) from the loop of attachment for Bowden pull wire (2) off the
the webbing (5). height level valve (1).
8) Mark the points where the air input hoses a To do this, first release the 2 catchers
(10) and (11) are fastened with 5 cable on the backside of the attachment for
ties (12) and remove the cable ties (12). Bowden pull wire (2) and take the
attachment for Bowden pull wire (2)
off the height level valve (1).
34 WA500-6R
18) Pull the Bowden pull wire (3) out of the

attachment for Bowden pull wire (2).
19) Remove the height level controller in an
upward direction.
Installation
est position.
ers.
2) Install the height level controller.
3) Install the Bowden pull wire (3) to the
attachment for Bowden pull wire (2).
4) Install the attachment for Bowden pull wire
(2) to the height level controller (1).
5) Tighten the Torx screw (9) to height level
controller (1).
a Finger-tighten the Torx screw (9).
6) Install the height level control (1) to the
upper part of the suspension (8).
7) Install the plate (7), loop of the webbing
(5) and the edge protection strip (6).
8) Install the 2 hexagon nuts (4) to the thread
of the height level controller (1).
9) Connect the right-angle plugs (13) and
(14) to the height level controller (1) at the
marked point.
10) Install the Bowden pull wires (3) and (19)
to the height level controller (1).
11) Install the Bowden pull wire (19) and fix it
with the cable tie at the marked points.
12) Install the right-angle plugs (13) and (14)
and fix them with the cable tie at the
marked points.
13) Install the air input hoses (10) and (11) to
the pneumatic spring (see "8. Removal
and installation of air hose").
14) Fix the air input hoses (10) and (11) with
the 5 cable ties (12) at the marked points.
15) Install the 2 buffers (16) to the loop of the
webbing (5).
16) Install the stud (18) to the lower part of the
suspension (15).
17) Install the 2 circlips (17) to the stud (18)
and then remove them.
WA500-6R 35
Adjustment 7) Adjust the output level (2) as follows.

1) Remove the upper part of the seat by Adjust the clearance between valve lever
referring to "I. Upper seat". (6) and cam disc (7) by turning the cross-
2) Remove the top cover by referring to "1. head screw (10).
Removal and installation of top cover". q Specified value: The valve lever (6)
3) Take the bellows off by referring to "3. must seat on the cam disc without
Removal and installation of bellows". pressure (7).
4) Move the suspension system to the high- q Turn the cross-head screw (10) to the
est position. left, the valve lever (6) is moving
k Risk of crushing! Secure the sus- towards the cam disc (7). This
pension between the swinging increases the pressure on the valve
structure and lower part of the sus- tappets (4) at the output valve (2) and
pension system with suitable spac- the air escapes the output valve (2)
ers. earlier.
5) Loosen the self-tapping screw (9) a half q Turn the cross-head screw (10) to the
turn. right, the valve lever (6) is moving
6) Adjust the micro-switch (3) as follows. away from the cam disc (7). This
Adjust the clearance between cam switch decreases the pressure on the valve
(5) and cam disc (7) by turning the cross- tappets (4) at the output valve (2) and
head screw (8). the air escapes the output valve (2)
q Specified clearance (A) = 0.5 mm. later.
q Turn the cross-head screw (8) to the 8) Tighten the self-tapping screw (9) after the
left, the cam switch (5) is moving adjustment has been completed.
towards the cam disc (7). 9) Install the bellows off by referring to "3.
q Turn the cross-head screw (8) to the Removal and installation of bellows".
right, the cam switch (5) is moving 10) Install the top cover by referring to "1.
away from the cam disc (7). Removal and installation of top cover".
q When the cam switch (5) seats on the 11) Install the upper part of the seat by refer-
cam disc (7) under pressure, the com- ring to "I. Upper seat".
pressor (11) turns too early and runs
already during the compression and
expansion of the seat suspension.
36 WA500-6R
8. Removal and installation of compressed-air

hoses
a Disconnect the hose not more than 1 to 2 7) Pull the compressed-air hose (11) off the
times. Check the hose for damage before con- compressor (5) and remove it. (Refer to
necting it. "6. Removal and installation of compres-
sor")
8) Pull the compressed-air hose with angle
Removal (8) off the pneumatic spring (9) and then
1) Remove the upper part of the seat by off the air tank (10).
referring to "I. Upper seat". a When pulling the hoses out, the
2) Remove the top cover by referring to "1. retaining ring of the quick coupling
Removal and installation of top cover". (13) must first be completely pressed
3) Take the bellows off by referring to "3. back (e.g. using a flat pliers) to avoid
Removal and installation of bellows". marks.
4) Move the suspension system to the high- 9) Mark the points where the compressed-air
est position. hose with angle (8) is fastened with cable
k Risk of crushing! Secure the sus- ties (6), (7) and (12) and then remove the
pension between the swinging cable ties (6), (7) and (12).
structure and lower part of the sus- 10) Remove the air hose with angle (8).
pension system with suitable spac- 11) Mark the points where the air input hoses
ers. (3) and (4) are fastened with the cable ties
5) Mark the points where the compressed-air (2) and (6) and remove the cable ties (2)
hose (11) is fastened with the cable tie and (6).
(12) and remove the cable tie (12). 12) Pull the air input hoses (3) and (4) out of
6) Pull the compressed-air hose (11) off the the pneumatic spring (9).
pneumatic spring (9). 13) Remove the height level controller (1) with
a When pulling the hoses out, the air input hoses (3) and (4).
retaining ring of the quick coupling a To ensure the tightness, the air input
(13) must first be completely pressed hoses (3) and (4) cannot be removed
back (e.g. using a flat pliers) to avoid from the height level control (1).
marks.
WA500-6R 37
Installation a Apply pressure to insert the air hose

a Always replace a damaged (marks) hose with with angle (8) into the pneumatic
a new one. It is possible to cut the damaged spring (9) and air tank (10) up to the
part off (about 12 mm) using special tools (14) blue marking.
only once. After the cut off, the blue marking 6) Fix the compressed air hose with angle (8)
should be (arrow) set back by the length of the with cable ties (6), (7) and (12) at the
cut off piece. marked points.
a Do not fix the cable tie (12) at the
1) Move the suspension system to the high- angle.
est position. 7) Install the compressed-air hose (11) to the
k Risk of crushing! Secure the sus- compressor (5). (Refer to "6. Removal and
pension between the swinging installation of compressor")
structure and lower part of the sus- 8) Install the compressed-air hose (11) to the
pension system with suitable spac- pneumatic spring (9).
ers. 9) Fix the compressed-air hose with the
2) Install the height level controller (1) with cable tie (12) at the marked points.
air input hoses (3) and (4). 10) Install the bellows by referring to "3.
a Cut the air input hose (3) or (4) off at Removal and installation of bellows".
the leaky area and connect the new 11) Install the top cover by referring to "1.
air input hose (3) or (4) to an appro- Removal and installation of top cover".
priate adapter. Subsequently, cut the 12) Install the upper part of the seat by refer-
excess length off. ring to "I. Upper seat".
3) Install the air input hoses (3) and (4) to the
pneumatic spring (9). Hydrostatic test
4) Fix the air input hoses (3) and (4) with the a After the installation of a compressed-air hose,
cable ties (2) and (6) at the marked points. the hydraulic test of the suspension should be
5) Install the compressed-air hose with angle performed.
(8) to the pneumatic spring (9) and then q Apply 60 kg load to the suspension for 24
off the air tank (10). hours.
a To avoid kinking, always install the q The lowering within this time may not
compressed-air hose with angle (8) exceed 15 mm.
first on the pneumatic spring (9). a The compressed-air hoses are locked after
they have been connected.
38 WA500-6R
9. Removal and installation of Bowden pull 8) Undo the 3 cross-head screws (7).
wires and handle for height adjustment 9) Take the Bowden pull wires (1) and (6) off
the holder for Bowden pull wire (4), and
then pull them out of the upper part of the
suspension (2).
10) Remove the holder (4) for Bowden pull
wire.
11) Replace the handle (5), if required.
a The handle (5) and holder for Bowden
pull wire (4) are wedged into the 2
latching noses (arrow) at the lower
part of the holder for Bowden pull wire
(4). Carefully separate the parts.
a To remove the handle, use a screw-
driver to bend open the handle (5)
between the handle (5) and holder for
Bowden pull wire (4) so that the 2
latching noses are released from the
handle (5).
a Take the handle (5) off the holder for
Bowden pull wire (4).
Installation
1) Install the handle (5) to holder (4), if
removed.
a When the handle (5) is deformed,
replace it.
2) Install the Bowden pull wires (1) and (6) to
the holder for Bowden wire (4).
a Adjust the new Bowden pull wire to
Removal the length of the old one (excess
1) Remove the upper part of the seat by length of the wire).
referring to "I. Upper seat". 3) Install the holder (4) to the upper part of
2) Remove the top cover by referring to "1. the suspension (2) and tighten the 3
Removal and installation of top cover". cross-head screws (7).
3) Take the bellows off by referring to "3. 4) Install the Bowden pull wire (6) to the
Removal and installation of bellows". height level controller. (See "7. Removal
4) Mark the points where the Bowden pull and installation of height level controller".)
wire (1) is fastened with the 2 cable ties 5) Install the Bowden pull wire (1) to the
(3), and then remove the cable ties (3). height level controller (See "7. Removal
5) Mark the points where the Bowden pull and installation of height level controller".)
wire (6) is fastened with the 2 cable ties 6) Fix the Bowden pull wire (6) with the 2
(8), and then remove the cable ties (8). cable ties (8) at the marked points.
6) Take the Bowden pull wire (1) off the a Loosely fix the Bowden pull wire with
height level controller and pull it out of the the cable ties at the marked points
holder for Bowden pull wire (See "7. and make sure it is not distorted.
Removal and installation of height level 7) Fix the Bowden pull wire (1) with the 2
controller".) cable ties (3) at the marked points.
a To release the tension of the Bowden a Loosely fix the Bowden pull wire with
pull wire (1), press the handle for the cable ties at the marked points
height adjustment (5) upwards. and make sure it is not distorted.
7) Take the Bowden pull wire (6) off the 8) Install the bellows by referring to "3.
height level controller. (See "7. Removal Removal and installation of bellows".
and installation of height level controller") 9) Install the top cover by referring to "1.
a To release the tension of the Bowden Removal and installation of top cover".
pull wire (6), press the handle for 10) Install the upper part of the seat by refer-
height adjustment (5) upwards. ring to "I. Upper seat".
WA500-6R 39
Checking and adjustment 5) Check the clearance between the Bowden

a When checking and adjustment is performed wire lever (10) and holder for Bowden wire
through removal and installation, pass proce- end cap (9).
dures 1) and 2) of "Checking". q Specified value: Distance (A) between
(Checking) 1 and 3.5 mm with the handle for
1) Remove the upper part of the seat by height adjustment (2) in the up posi-
referring to "I. Upper seat". tion.
2) Remove the top cover by referring to "1. q When the specified value exceeds
Removal and installation of top cover". 3.5 mm, the suspension cannot be
3) Operate the handle for height adjustment lifted above the middle position.
(2) several times in both directions and
check the following: (Adjustment)
q Bowden pull wires (1) and (3) for 1) Adjustment of the Bowden pull wire (3):
easy-running. 1] Loosen the counternut (6) and adjust
q Bowden wire lever (10), valve lever the clearance between the Bowden
(14) and valve tappets (13) at the out- wire lever (10) and holder for Bowden
put valve (12) for smoothness of run- wire end cap (9) using the locknut (5).
ning. q Turn the locknut (5) inwards, the
4) Check the neutral position of the handle Bowden pull wire gets longer.
for seat height adjustment (2) and the ten- q Turn the locknut (5) outwards,
sile force of the retracting spring (11) on the Bowden pull wire gets
the height level valve (4): shorter.
q The retracting spring (11) must fix the q Specified value: Clearance (A)
handle for seat height adjustment (2) between 1 and 3.5 mm.
in neutral position. 2] Secure the locknut (5) with the coun-
q The retracting spring (11) must tightly ternut (6) and make sure not to distort
pull the Bowden pull wires (1 and 3) the Bowden pull wire (3).
and keep the Bowden wire lever (10) 3] Operate the handle for seat height
in neutral position. adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.
40 WA500-6R
2) Adjustment of the Bowden pull wire (1):

1] Loosen the counternut (7) and adjust
the tension of the Bowden pull wire
(1) on the height valve (4) using the
locknut (8).
q Turn the locknut (8) inwards, the
Bowden pull wire gets longer.
q Turn the locknut (8) outwards,
the Bowden pull wire gets
shorter.
q Specified value: The Bowden
wire (8) must be tightened, but
not distorted on the suspension
device on the height level valve
(4).
2] Secure the locknut (8) with the coun-
ternut (7) and make sure not to distort
the Bowden pull wire (1).
3] Operate the handle for seat height
adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.
WA500-6R 41
10. Removal and installation of pneumatic

spring
Removal Installation
1) Remove the upper part of the seat by 1) Move the suspension system to the high-
referring to "I. Upper seat". est position.
2) Remove the top cover by referring to "1. k Risk of crushing! Secure the sus-
Removal and installation of top cover". pension between the swinging
3) Take the bellows off by referring to "3. structure and lower part of the sus-
Removal and installation of bellows". pension system with suitable spac-
4) Remove the 2 air input hoses, com- ers.
pressed-air hose and air input hose with 2) Turn the spring system by 180° and place
angle from the pneumatic spring (6) by it onto the upper part (1).
referring to "8. Removal and installation of 3) Slightly compress the pneumatic spring
compressed-air hoses". (6) and install the pneumatic spring (6) to
5) Undo the counter sunk screw (3) from the the swinging structure (5) and lower part
pneuma tic spr ing (6) and rem ove it of the suspension (2).
together with the washer (4). 4) Tighten the counter sunk screw (7) to the
6) Move the suspension system to the high- pneumatic spring (6).
est position. 3 Counter sunk screw (6):
k Risk of crushing! Secure the sus- 6 Nm {0.61 kgm}
pension between the swinging 5) Turn the spring system by 180° and place
structure and lower part of the sus- it onto the upper part (1).
pension system with suitable spac- 6) Put the washer (4) to the pneumatic spring
ers. (6) and tighten the counter sunk screw (3).
7) Turn the spring system by 180° and place 3 Counter sunk screw (3):
it onto the upper part (1). 6 Nm {0.61 kgm}
8) Undo the counter sunk screw (7) from the
pneumatic spring (6).
9) Slightly compress the pneumatic spring
(6) and remove it from the swinging struc-
ture (5) and lower part of the suspension
(2).
42 WA500-6R
7) Install the 2 air input hoses, compressed-

air hose and air input hose with angle to
the pneumatic spring (6) by referring to "8.
Removal and installation of compressed-
air hoses".
WA500-6R 43
11. Removal and installation of air tank for

additional air supply
2) Remove the top cover by referring to "1. k Risk of crushing! Secure the sus-
4) Move the suspension system to the high- ers.
est position. 2) Install the clamp (5) to the bracket (6), if
k Risk of crushing! Secure the sus- removed.
pension between the swinging a Replace the clamp with new one, if
structure and lower part of the sus- required.
pension system with suitable spac- 3) Install the air tank (3) to bracket (2) and
ers. clamp (5).
5) Remove the air hose with angle (4) from 4) Install the air hose with angle (4) to the air
the air tank (3) by referring to "8. Removal tank (3) by referring to "8. Removal and
and installation of compressed-air hoses". installation of compressed-air hoses".
6) Remove the air tank (3) from bracket (2) 5) Install the bellows by referring to "3.
and clamp (5). Removal and installation of bellows".
7) Take the clamp (5) off the bracket (6) in a 6) Install the top cover by referring to "1.
downward direction, if required. Removal and installation of top cover".
a To do this, use a screwdriver to press 7) Install the upper part of the seat by refer-
through the hole (arrow) in the ring to "I. Upper seat".
bracket against the catchers (arrow)
of the clamp (5) and pull the clamp (5)
out in a downward direction.
44 WA500-6R
12. Removal and installation of cable harness
2) Remove the top cover referring to "1. k Risk of crushing! Secure the sus-
4) Move the suspension system to the high- ers.
est position. 2) Connect the right-angle plug (6) to the
k Risk of crushing! Secure the sus- height level control unit (1).
pension between the swinging 3) Connect the electric connection (flat plug)
structure and lower part of the sus- of the compressor cable (4) to the cable
pension system with suitable spac- harness of the connector plug (2) and
ers. cable harness of the machine power con-
5) Mark the points where the cable of the nector (3).
machine power connector (3) is fastened 4) Fix the cable harness of the connector
with the cable tie (8) on the upper part of plug (2) and cable harness of the machine
the suspension (7) and remove the cable power connector (3) with the cable ties (5)
tie (8). at the marked points.
6) Mark places where the cable harness of a Run the cable harnesses (2) and (3)
the connector plug (2) and cable harness and fix them with the cable ties (5) so
of the machine power connector (3) are that they are neither squeezed nor
fastened with the cable ties (5) and otherwise damaged.
remove the cable ties (5). 5) Fix the cable of the machine power con-
7) Disconnect the electric connection (flat nector (3) with the cable tie (8) on the
plug) of the compressor cable (4) to the upper part of the suspension (7) at the
cable harness of the connector plug (2) marked points.
and cable harness of the machine power
connector (3).
8) Disconnect the right-angle plug (6) from
the height level control unit (1).
WA500-6R 45

46 WA500-6R
13. Disassembly and assembly of upper part of

the suspension system
Disassembly 8) Move the suspension system to the high-

1) Remove the upper part of the seat by est position.
referring to "I. Upper seat". k Risk of crushing! Secure the sus-
2) Remove the top cover referring to "1. pension between the swinging
Removal and installation of top cover". structure (7) and lower part of the
3) Take the bellows off by referring to "3. suspension system with suitable
Removal and installation of bellows". spacers.
4) Take the Bowden pull wire and handle off 9) Bore out 2 rivet heads and drive out blind
the upper part of the suspension (1) by rivets (10), remove the stops (9).
referring to "4. Removal and installation of 10) Push the upper part of the suspension (1)
Bowden pull wires and handle for vertical forwards until the cut-outs (arrow) on the
shock absorber". left and right sides at the guiding rails (2)
a The Bowden pull wire does not need are located at the same height with the
to be taken off the vertical shock front rollers (8) of the swinging structure
absorber. (7).
5) Remove the vertical shock absorber from 11) Remove the upper part of the suspension
the upper part of the suspension (1) by (1) on the front side over the rollers (8)
referring to "5. Removal and installation of and the back rollers (6) of the swinging
vertical shock absorber". structure (7).
6) Remove the height level controller from
the upper part of the suspension (1) by
referring to "7. Removal and installation of
height level controller".
a Air input hoses do not need to be
taken off the pneumatic spring.
7) Remove Bowden pull wires and handle for
height adjustment by referring to "9.
Removal and installation of Bowden pull
wires and handle for height adjustment".
WA500-6R 47
Assembly
est position.
ers.
2) Push the upper part of the suspension (1)
forwards until the cut-outs (arrow) on the
left and right sides at the guiding rails (2)
are located at the same height with the
front rollers (8) of the swinging structure
(7).
3) Install the upper part of the suspension (1)
on the back rollers (6) and the front rollers
(8) of the swinging structure (7).
cant to the side surfaces (F) of the 2
guiding rails (2) of the rollers (6).
4) Install the stops (9) and fix with the 2 rivets
(10).
5) Install Bowden pull wires and handle for
height adjustment by referring to "9.
Removal and installation of Bowden pull
wires and handle for height adjustment".
6) Install the height level controller to the
upper part of the suspension (1) by refer-
ring to "7. Removal and installation of
height level controller".
7) Install the vertical shock absorber to the
upper part of the suspension (1) by refer-
ring to "5. Removal and installation of ver-
tical shock absorber".
8) Install the Bowden pull wire and handle to
the upper part of the suspension (1) by
referring to "4. Removal and installation of
Bowden pull wires and handle for vertical
shock absorber".
48 WA500-6R
14. Lower part of the suspension system
Removal 8) Unscrew the 2 hexagon nuts (11), remove

1) Remove the upper part of the seat by washers (10) and counter sunk screws
referring to "I. Upper seat". (9).
2) Remove the top cover by referring to "1. 9) Undo the 2 corrugated-head screws (5)
Removal and installation of top cover". and take the U-shaped profiles (6) off the
3) Take the bellows off by referring to "3. guiding rail (8).
Removal and installation of bellows". 10) Push the upper part of suspension (1) with
4) Remove compressor from the lower part the swinging structure (3) backwards until
of the suspension (7) by referring to "6. the 2 fixed bearings (4) on the swinging
Removal and installation of compressor". structure (3) can be taken out through the
a Compressor cable and compressed- cut-outs (arrows) of the guiding rails (8) on
air hose do not need to be removed. the upper part of suspension (1).
a Protect the compressor against 11) Lift the upper part of the suspension (1)
shocks (impacts) by fixing it on the with the swinging structure (3) out and pull
swinging structure with adhesive it out together with the 2 rollers (2) from
tape. the guiding rails (8) by turning sideways.
5) Remove the webbing from the lower part
of the suspension (7) by referring to "7.
Removal and installation of height level Installation
controller". 1) Install the upper part of the suspension (1)
6) Undo the counter sunk screw from the with the swinging structure (3) together
pneumatic spring by referring to "10. with the 2 rollers (2) to the guiding rails
Removal and installation of pneumatic (8).
spring". a Apply acid-free multi-purpose lubri-
7) Remove the 2 cable ties for the vehicle cant to the bearing surface at the side
power connector cable on the lower part (F) of the 2 guiding rails (8) of the roll-
of suspension(7) by referring to "12. ers (2).
Removal and installation of cable har- 2) Install the U-shaped profile (6) to the guid-
ness". ing rail (8) and tighten the 2 corrugated-
head screws (5).
WA500-6R 49
3) Put the counter sunk screws (9) and the

washers (10), and tighten the 2 hexagon
nuts (11).
4) Install the 2 cable ties for the machine
power connector cable on the lower part
of suspension(7) by referring to "12.
Removal and installation of cable har-
ness".
5) Tighten the counter sunk screw to the
pneumatic spring by referring to "10.
Removal and installation of pneumatic
spring".
6) Install the webbing to the lower part of the
suspension (7) by referring to "7. Removal
and installation of height level controller".
7) Install compressor to the lower part of the
suspension (7) by referring to "6. Removal
and installation of compressor".
50 WA500-6R
15. Swinging structure
Removal 9) Take the Bowden pull wires for height

1) Remove the upper part of the seat by level adjustment off the height level valve
referring to "I. Upper seat". by referring to "9. Removal and installation
2) Remove the top cover by referring to "1. of Bowden pull wire and handle for height
Removal and installation of top cover". adjustment".
3) Take the bellows off by referring to "3. 10) Remove the pneumatic spring by referring
Removal and installation of bellows". to "10. Removal and installation of pneu-
4) Take the Bowden pull wire for vertical matic spring".
shock absorber adjustment off the vertical 11) Remove the air tank for additional air sup-
shock absorber by referring to "4. ply by referring to "11. Removal and instal-
Removal and installation of Bowden pull lation of air tank for additional air supply".
wire and handle for vertival shock 12) Remove the cable harness by referring to
absorber adjustment". "12. Removal and installation of cable har-
5) Take the vertical shock absorber off the ness".
swinging structure by referring to "5. 13) Take the upper part of the suspension off
Removal and installation of vertical shock the swinging structure by referring to "13.
absorber". Removal and installation of upper part of
6) Remove the compressor by referring to "6. the suspension".
Removal and installation of compressor". 14) Take the lower part of the suspension off
7) Take the webbing off the lower part of the the swinging structure by referring to "14.
suspension by referring to "7. Removal Removal and installation of lower part of
and installation of height level controller". the suspension".
8) Remove the cable tie for the air input 15) Take 4 rollers (5), 2 rollers (6), 2 fixed
hoses of the height level control and pull bearings (9) and 4 felt rings (4) off the
the air input hoses off the pneumatic swinging structure (1).
spring by referring to "8. Removal and 16) Pull the tube piece (8) out of the fixed
installation of compressed-air hoses". bearing (9).
17) Remove the 2 buffers (7) from the swing-
ing structure (1).
18) Remove the edge protection strip (2) from
the swinging structure (1).
WA500-6R 51
Installation 12) Install the Bowden pull wires for height

1) Check: maximum clearance (A) or (B) level adjustment to the height level valve
between the rollers (5) and guiding rails of by referring to "9. Removal and installation
the lower part of the suspension (11) or of Bowden pull wire and handle for height
upper part of the suspension (10) over the adjustment".
complete adjustment length. 13) Install the cable tie for the air input hoses
2) Place the washer compensating for clear- of the height level controller and pull the
ance (2) between the roller (5 or 6) and air input hoses to the pneumatic spring by
axle of the swinging structure (1), if neces- referring to "8. Removal and installation of
sary. compressed-air hoses".
a Clearance spacers (with thickness of 14) Install the webbing to the lower part of the
0.2 mm and 0.5 mm) are included in suspension by referring to "7. Removal
the wear parts set. and installation of height level controller".
3) Install the edge protection strip (2) to the 15) Install the compressor by referring to "6.
swinging structure (1). Removal and installation of compressor".
4) Install the 2 buffers (7) to the swinging 16) Install the vertical shock absorber to the
structure (1). swinging structure by referring to "5.
5) Put the tube piece (8) to the fixed bearing Removal and installation of vertical shock
(9). absorber".
6) Install 4 rollers (5), 2 rollers (6), 2 fixed 17) Install the Bowden pull wire for vertical
bearings (9) and 4 felt rings (4) to the shock absorber adjustment to the vertical
swinging structure (1). shock absorber by referring to "4.
7) Install the lower part of the suspension to Removal and installation of Bowden pull
the swinging structure by referring to "14. wire and handle for vertival shock
Removal and installation of lower part of absorber adjustment".
the suspension". 18) Install the bellows by referring to "3.
8) Install the upper part of the suspension to Removal and installation of bellows".
the swinging structure by referring to "13. 19) Install the top cover by referring to "1.
Removal and installation of upper part of Removal and installation of top cover".
the suspension". 20) Install the upper part of the seat by refer-
9) Install the cable harness by referring to ring to "I. Upper seat".
"12. Removal and installation of cable har-
ness".
10) Install the air tank for additional air supply
by referring to "11. Removal and installa-
tion of air tank for additional air supply".
11) Install the pneumatic spring by referring to
"10. Removal and installation of pneu-
matic spring".
52 WA500-6R
WA500-6R 53
SEN02913-03


© 2017 KOMATSU
All Rights Reserved
54
SEN02914-00
WA500-6R

WA500-6R 60001 and up
Electrical system
Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of transmission controller assembly........................................................................ 3
Removal and installation of work equipment controller assembly .................................................................. 4
Removal and installation of air conditioner unit assembly .............................................................................. 5
WA500-6R 1

engine controller assembly 1
removal.
Removal
k Disconnect the cable from the negative (–) [*1]
terminal of the battery. a When installing each heavy duty wire connec-
tor, check that it is locked.
1. Remove the right side panel. 3 Connectors (2), (3) and (4):
2.54 – 3.01 Nm {0.259 – 0.317 kgm}
2. Open the right side door.
4. Disconnect wiring harness connectors E18 (2),

(3) and E19 (4). [*1]
5. Remove engine controller assembly (5).
2 WA500-6R

transmission controller assembly 1
removal.
Removal
terminal of the battery. a Before connecting each connector, check that
its inside is free from dirt, dust and water.
1. Remove the cover under the operator's seat. a When installing each heavy duty wire connec-
tor, check that it is locked. (When it is locked, it
2. Disconnect wiring harness clamps (1) and (2). clicks.)
3 Connectors (3), (4) and (5):
3. Disconnect wiring harness connectors L04 (3), 2.54 – 3.01 Nm {0.259 – 0.317 kgm}
L03 (4) and L02 (5). [*1]
4. Remove transmission controller assembly (6).
WA500-6R 3
Removal and installation of work Installation

equipment controller assembly 1
removal.
Removal
terminal of the battery. a Before connecting each connector, check that
its inside is free from dirt, dust and water.
1. Remove the cover under the operator's seat. a When installing each heavy duty wire connec-
tor, check that it is locked. (When it is locked, it
2. Disconnect wiring harness clamps (1) and (2). clicks.)
3 Connectors (3), (4) and (5):
3. Disconnect wiring harness connectors L05 (3), 2.54 – 3.01 Nm {0.259 – 0.317 kgm}
L06 (4) and L07 (5). [*1]
4. Remove work equipment controller assembly

(6).
4 WA500-6R
Removal and installation of air 2. Remove filter (3) and filter cover (4).
conditioner unit assembly 1
Removal
chocks.
k In this case that you do not drain the cool-

ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k
3. Disconnect wiring harness connector (5).
Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
4. Remove blower assembly (6).
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
atomosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight.
Accordingly, put on protective goggles
fied person.
1. Remove covers (1) and (2). 5. Remove front windshield wiper (7).
WA500-6R 5
6. Remove left side cover (8). 11. Disconnect wiring harness connector C12 (15)
and remove wiper motor (16).
7. Remove door lock (9), ashtray (10), holder (11)
and right side cover (12). 12. Disconnect wiper washer hose (17).
8. Remove cover (13). 13. Remove ducts (18) and (19).
9. Disconnect the cigarette lighter wiring harness

connector.
14. Remove 4 mounting bolts (20) and disconnect

steering wheel stand (21) from the bracket.
10. Disconnect the 7 wiring harness connectors 15. Disconnect 2 wiring harness clamps (22).
and remove monitor assembly (14).
6 WA500-6R
17. Remove covers (24) and (25). 22. Disconnect drain hose (33).
23. Disconnect wiring harness connectors L17

(34), C50 (35), C49 (36) and AL1 (37).
24. Remove the mounting bolts and disconnect

fuse (38).
18. Disconnect heater hose (26).
19. Disconnect wiring harness connector (27).
20. Disconnect drain hose (28).
25. Remove air conditioner unit assembly (39).

[*2]
21. Disconnect air conditioner pipes (29) and (30)

and clamps (31) and (32). [*1]
WA500-6R 7
Installation
removal.
[*1]
a When installing the air conditioner circuit
hoses, take care that dirt, dust, water, etc. will
not enter them.
a Before connecting each air conditioner hose,
check that the O-rings are fitted to its joints.
a Check that each O-ring is not damaged or
deteriorated.
2 O-ring: ND-OIL8 or equivalent
q Charge the air conditioner circuit with refriger-
ant (R134a).
[*2]
3 Air conditioner unit mounting bolt:
8 – 12 Nm {0.81 – 1.22 kgm}
8 WA500-6R
WA500-6R 9
SEN02914-00

© 2007 KOMATSU
All Rights Reserved
10
SEN06712-00
WA500-6R

WA500-6R 60001 and up
80 Appendix 1
Air conditioner
Precautions for refrigerant .............................................................................................................................. 3
Troubleshooting procedure ............................................................................................................................. 4
Circuit diagram and arrangement of connector pins ....................................................................................... 6
System diagram .............................................................................................................................................11
Detail of air conditioner unit .......................................................................................................................... 13
Parts and connectors layout ......................................................................................................................... 15
Testing with self-diagnosis function (indication on control panel) ................................................................. 19
Testing temperature control .......................................................................................................................... 22
Testing vent (mode) changeover................................................................................................................... 23
Testing Fresh/Recirc changeover ................................................................................................................. 25
Testing inside air temp. sensor and outside air temp. sensor ....................................................................... 27
Testing evaporator temperature sensor ........................................................................................................ 29
Testing sunlight sensor ................................................................................................................................. 30
Testing relays ................................................................................................................................................ 31
Troubleshooting chart 1 ................................................................................................................................ 32
Troubleshooting chart 2 ................................................................................................................................ 33
Information in troubleshooting table .............................................................................................................. 36
Troubleshooting for power supply system (Air conditioner does not operate) .............................................. 37
Troubleshooting for compressor and refrigerant system (Air is not cooled).................................................. 40
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .................................. 43
Troubleshooting for temperature control ....................................................................................................... 49
Troubleshooting for vent (mode) changeover ............................................................................................... 52
Troubleshooting for Fresh/Recirc air changeover ......................................................................................... 55
WA500-6R 1
SEN06712-00 80 Appendix
Troubleshooting with gauge pressure ........................................................................................................... 57

Connection of service tool............................................................................................................................. 59
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ............................ 60
Handling of compressor oil............................................................................................................................ 62
2 WA500-6R
Precautions for refrigerant 1
k Collect the refrigerant (Air conditioner gas:

R134a) from air conditioner circuit before
disconnecting air conditioner hose to
replace air conditioner unit, air conditioner
compressor or air conditioner condenser
and so on.
a Ask a qualified person for collecting, adding
a nd fillin g oper atio ns of the refrige rant
(R134a).
atmosphere.
you may lose your sight. And if it touches
your skins, you may suffer from frostbite.
Accordingly, put on the safety glasses,
gloves and working suits with long sleeves
fied person.
q Refrigerant (R134a) refilling level: 1,250 ± 50 g
WA500-6R 3
Troubleshooting procedure 1
The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function,
you can inspect the operation of sensor and actuators in the system.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Find the troubled section with the self-diagnosis function (See "Inspection with self-diagnosis").
If the air conditioner unit or control panel does not operate at all, check that the power supplied to the
control panel is normal.
If any part of the air conditioner unit or control panel operates, the power supply does not need to be
checked.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic flow of troubleshooting
4 WA500-6R
*1: By LCD blink on air conditioner control panel (Failure code may be displaied on the temperature display
area in the case of auto air conditioner.)
*2: Simple checking of refrigerant volume by sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding
with the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant
or no refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the con-
dition is normal.
S: Sight glass condition

R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit
will definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for discon-
necting nd connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
WA500-6R 5
Circuit diagram and arrangement of connector pins 1
q Manual air conditioner
6 WA500-6R
a W/L and WL are same meaning.
WA500-6R 7
q Auto air conditioner
8 WA500-6R
a W/L and WL are same meaning.
WA500-6R 9
q Fuse parts number: q T-adapter number

5A: 08041-00500 DT-2:799-601-9020
15A:08041-01500 DT-3:799-601-9030
20A:08041-02000 DT-6:799-601-9050
DT-8:799-601-9070
DT-12:799-601-9110 (GRAY) or 9120 (BLACK)
10 WA500-6R
System diagram 1
WA500-6R 11
12 WA500-6R
Detail of air conditioner unit 1
1. Evaporator
2. Evaporator temperature sensor
3. Sensor holder
4. Heater core
5. Pressure switch
6. Fuse
AMA: Air mix actuator
BR: Blower off relay
BA: Blower amplifier
CR: Compressor relay
P: Top position of the sensor

*: To blower harness under floor
WA500-6R 13

a Auto air conditioner has mode actuator (MA).
1. Evaporator
2. Evaporator temperature sensor
3. Sensor holder
4. Heater core
5. Pressure switch
6. Fuse
AMA: Air mix actuator
BR: Blower off relay
BA: Blower amplifier
CR: Compressor relay
MA: Mode actuator
P: Top position of the sensor

*: To blower harness under floor
14 WA500-6R
Parts and connectors layout 1
a Fuses are installed at two places in the air con- 4. Machine wiring harness connectors C49, C50
ditioner unit (wiring harness) and in the fuse and AL1 are on the left of the air conditioner
box at the left rear of the operator's seat (dupli- unit.
cated). q [3] – [8] are symbols in the circuit diagram.
1. Open the fuse box cover at the left rear of the
operator's seat. (See the fuse locations in
Troubleshooting.)
q No. 10 of fuse box A: 20A
For power supply of blower (fan) and air
conditioner unit
q No. 11 of fuse box A: 5A
For air conditioner compressor
q Fuse part Nos.
5A: 08041-00500
20A:08041-02000
5. Pressure switch (PRESS SW) connector [11] is

installed on the air conditioner hose on the
right of air conditioner unit (A/C U).
2. Remove covers (1) and (2)

q A/C U: Air conditioner unit
q B/I U: Blower intake unit
6. Remove left side cover (3).
3. Two 5A fuses and one 15A fuse are on the left

of the air conditioner unit (A/C U).
a Identify the 5A fuse by its wiring harness
color. (See the circuit diagram.)
q Fuse part Nos.
5A: 08041-00500
15A:08041-01500
WA500-6R 15
7. Take out filter (4) and remove box (5). a Connector FL1 is DRC-70 and must be
handled with care.
q How to disconnect connector FL1
Disconnect the connector straight slowly
and check the seal for breakage, peeling
and sticking foreign matter.
a If the seal is damaged, replace it.
q How to connect connector FL1

1) Check that the seal is correctly
installed to the plug.
2) Check that the key is positioned to be
matched to the groove of the recepta-
cle (key is not positioned oppositely).
3) Set the plug connector to the recepta-
cle straight (since the seal is pro-
jected) and fit it a little, while check
8. Connectors [19] and [20] are connected to the that the seal is not rolled up.
blower intake unit (B/I U) under the left of the 4) Tighten the hexagon bolt at the center
operator's cab. of the connector by 2 - 3 turns.
D: Recirc/Fresh changeover damper 5) Fit the plug connector to the end and
q Connectors [23] and [24] (See the circuit adjust it so that the clearance
diagram) are in the blower intake unit. You between it and the fitted receptacle
cannot access them unless the blower will be even when seen from each
intake unit is disassembled. direction.
6) Tighten the lock bolt to the specified
torque.
3 Hexagon lock bolt:
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
a If the lock bolt is tightened to strongly,
it will be broken and cannot lock.
Take care
9. Intermediate connector FL1 is at the lower left

side of the floor frame.
16 WA500-6R
10. Connectors C47 and C48 are on the back side

of the air conditioner control panel (CP).
a The figure of control panel (CP) is for
manual air conditioner, but connectors are
common to auto air conditioner.
WA500-6R 17
11. Disconnect connectors S01 (9), S02 (10), C17

(11) and C21 (12) in the lower right side of the
front cover.
12. Disconnect connectors S31 (13), S32 (14), L07

(15) and L08 (16) in the lower left side of the
front cover.
13. Disconnect connector C10 inside cigar lighter

(17).
14. Disconnect front cover (18).
15. Connector C60 is below sunlight sensor (SLS).
q Sunlight sensor connector (C60)
(machine equipped with automatic air con-
ditioner)
18 WA500-6R
Testing with self-diagnosis function (indication on control panel) 1
Outline 2. Fresh/Recirc mark (2) blinks

The self-diagnosis system checks the following Opening and closing of the Fresh/Recirc
three items and shows the failed part by blinking changeover damper do not reach the target
the symbol on the air conditioner control panel value (locking of the damper is detected since
(CP). the limiter input is not received).
a Once a problem is detected, indication of the a Action of control panel: Stopping output to
problem is not reset even if it is repaired. The the Fresh/Recirc changeover damper.
indication can be reset (blinking of the LCD a Problem: Fresh/Recirc selector switch (5)
can be stopped) by turning the starting switch does not work.
OFF. a Even if the lever comes off and the
damper does not rotate, the self-diagnosis
1. HOT mark (1) blinks assumes that the Fresh/Recirc change-
The drive line of the temperature control air over actuator is normal if it rotates nor-
mix actuator has a problem (disconnection, mally.
short circuit, etc.) or opening and closing of the a See "Testing Fresh/Recirc changeover".
temperature control air mix actuator do not
reach the target value (locking of the damper is 3. There is a problem (disconnection, short cir-
detected since the input voltage of potentiome- cuit, etc.) in evaporator temperature sensor
ter is low or limiter input are not received). input circuit ··· A/C mark (3) blinks.
a Action of control panel: Stopping output to a Problem: Air conditioner does not work.
the air mix actuator a See "Testing evaporator temperature sen-
a Problem: Temperature control switch (4) sor".
does not work. a Resetting control panel: Turn starting
a Even if the link comes off and the damper switch OFF.
d o e s n o t r o ta t e , t h e s e l f - d i a g n o s i s
assumes that the air mix actuator is nor-
mal if it rotates normally.
a See "Testing temperature control".
WA500-6R 19
q Auto air conditioner 2. Man-shaped mark (2) blinks

The drive line of the vent (mode) changeover
Outline actuator has a problem (disconnection, short
The self-diagnosis system checks the following six circuit, etc.) or opening and closing of the vent
items and shows the failed part by blinking the sym- (mode) changeover actuator do not reach the
bol or displaying not number but alphabet at tem- target value (locking of the damper is detected
perature display area on the air conditioner control since the potentiometer input and limiter input
panel (CP). are not received).
a Once a problem is detected, indication of the a Action of control panel: Stopping output to
problem is not reset even if it is repaired. The the mode actuator
indication can be reset (blinking of the LCD a Problem: Defroster switch (3) and mode
can be stopped) by turning the starting switch switch (4) does not work.
OFF. a Even if the link comes off and the damper
1. Display of "HL, E" (1) at temperature display assumes that the mode actuator is normal
area if it rotates normally.
The drive line of the temperature control air a See "Testing vent (mode) changeover".
mix actuator has a problem (disconnection,
short circuit, etc.) or opening and closing of the
temperature control air mix actuator do not
reach the target value (locking of the damper is
detected since the potentiometer input and lim-
iter input are not received).
a Action of control panel: Stopping output to
the air mix actuator
a Problem: Temperature control switch does
not work.
a Even if the link comes off and the damper
assumes that the air mix actuator is nor-
mal if it rotates normally. 3. Fresh/Recirc mark (5) blinks
a See "Testing temperature control". Opening and closing of the Fresh/Recirc
changeover damper do not reach the target
value (locking of the damper is detected since
the limiter input is not received).
a Action of control panel: Stopping output to
the Fresh/Recirc changeover damper.
a Problem: Fresh/Recirc selector switch (6)
does not work.
a Even if the lever comes off and the
damper does not rotate, the self-diagnosis
assumes that the Fresh/Recirc change-
over actuator is normal if it rotates nor-
mally.
a See "Testing Fresh/Recirc changeover".
20 WA500-6R
4. A/C mark (7) blinks and display of "E" (8) at

decimal point first of temperature display area.
There is a problem (disconnection, short cir-
cuit, etc.) in evaporation sensor input circuit.
a Problem: Air conditioner does not work.
a See "Testing evaporator temperature sen-
sor".
a Resetting control panel: Turn starting
switch OFF.
5. Display of "E" (8) at decimal point first of tem-

perature display area.
cuit, etc.) in outside air temperature sensor
input circuit.
a Problem: Auto air conditioner is controlled
without outside air temperature sensor.
a See "Testing inside air temp. sensor and
outside air temp. sensor".
switch OFF.
6. Display of "HL.*" (9) at temperature display

area.
cuit, etc.) in inside air temperature sensor input
circuit.
a Problem: Auto air conditioner does not
work.
a See "Testing inside air temp. sensor and
outside air temp. sensor".
switch OFF.
WA500-6R 21
Testing temperature control 1
2. Check contacts of connectors C47, C50 (See

Outline the connector locations) and [15] (for discon-
q Temperature is controlled by mixing ratio of the nection).
air from the heater and from the evaporator by
changing the damper angle in the air mix sec- 3. If the HOT mark blinks or "HL, E" is displayed
tion. The damper angle is set to different eight on temperature indicator (See "Testing with
levels by the air mix actuator through the link self-diagnosis function"), check if links (2) – (4)
and rod. Check the link visually. have stopped halfway. If the links have
a To reset the self-diagnosis system (stop blink- stopped, remove the cause (hitch, interfer-
ing of the LCD), the starting switch must be ence, foreign matter, etc.) and repair.
turned OFF (While the LCD is blinking, no sig-
nals are output to the air mix actuator since the 4. Turn the power of the air conditioner OFF and
self-diagnosis system has detected a prob- then turn the starting switch OFF. (Resetting of
lem). problem)
1. Remove cover (1). 5. Turn the starting switch ON and then turn the
q A/C U: Air conditioner unit power of the air conditioner ON.
6. Operate the temperature control switch (See

the self-diagnosis) and check that link (2)
moves to the eight steps normally together
with links (3) and (4) between COOL MAX and
HOT MAX.
a If the above parts do not move smoothly,
clean them and apply grease to the links.
2 Link: Grease (G2-LI)
a The figure of control panel (CP) is for manual

air conditioner, but links for temperature control
are common to auto air conditioner.
q AMA: Air mix actuator
q BA: Blower amplifier
a For electric problems, see "Troubleshooting for

temperature control".
22 WA500-6R
Testing vent (mode) changeover 1
a Auto air conditioner equipped only. 2. Check contacts of connectors C47, C50 (See
the connector locations), [16] and (2) (for dis-
Outline connection).
q Vent (modes) are changed over to defroster,
foot and face by changing the three damper 3. If the man-shaped mark blinks (See the self-
angle. The damper angle is set by the mode diagnosis), check if links (3) – (5) have stopped
actuator through the link and rod. Check the halfway with operation of mode switch and
link visually. defroster switch. If the links have stopped,
a To reset the self-diagnosis system (stop blink- remove the cause (hitch, interference, foreign
ing "man-shaped mark" on the LCD), the start- matter, etc.) and repair.
ing switch must be turned OFF (While "man-
shaped mark" on the LCD is blinking, no sig- 4. Turn the power of the air conditioner OFF and
nals are output to the mode actuator since the then turn the starting switch OFF. (Resetting of
self-diagnosis system has detected a prob- problem)
lem).
5. Turn the starting switch ON and then turn the
1. Remove cover (1). power of the air conditioner ON.
6. Operate the mode switch and defroster switch
(See the self-diagnosis) and check that link (3)
- (5) moves normally together.
a If the above parts do not move smoothly,
clean them and apply grease to the links.
2 Link: Grease (G2-LI)
q MA: Mode actuator
WA500-6R 23
a The position of link (4) is following.

q FACE q FOOT/DEF
q DEF
q FACE/FOOT
a For electric problems, see "Troubleshooting for

q FOOT vent (mode) changeover".
24 WA500-6R
Testing Fresh/Recirc changeover 1
Outline 4. If the self-diagnosis result is abnormal, check

Recirculated air or fresh air is selected by changing Fresh/Recirc changeover damper (D) has
the damper angle 90° in the intake section of the stopped halfway. If the damper has stopped,
blower intake unit. The damper angle is changed by remove the cause (hitch, interference, foreign
the Fresh/Recirc changeover actuator through the matter, etc.) and repair.
link and rod. Check the opening and closing opera- q For check after repair, see step 5 below.
tions of the damper visually. q When disassembling, see step 7 below.
a The self-diagnosis system checks only the
motor for locking (It does not check for discon- 5. If the self-diagnosis result is normal, turn the
nection and short circuit). power of the air conditioner ON and operate
a To reset the self-diagnosis system (stop blink- the Fresh/Recirc selector switch to see if
ing of the LCD), the starting switch must be Fresh/Recirc changeover damper (D) opens
turned OFF (While the LCD is blinking, no sig- and closes normally.
nals are output to the Fresh/Recirc changeover
actuator since the self-diagnosis system has 6. If Fresh/Recirc changeover damper (D) does
detected a problem). not open or close, check along wiring harness
1. Remove cover (1). and check blower intake unit (B/I U) connec-
tors [19] and [20] (for disconnection).
2. Remove fresh air filter (2).

3. Remove box (3).
WA500-6R 25
7. When connectors [19] and [20] are connected a Auto air conditioner
securely,
1) Remove the blower intake unit (B/I U).
2) Referring to Structure and function or
Parts book, disassemble blower intake
unit (B/I U) (only the blower side).
3) Check lever (5) between damper (D) and
damper actuator (4) to see if it has come
off and repair it if necessary.
4) Check connector [23] (damper actuator
connector) (for disconnection).
5) Assemble the blower unit and connect
connectors [20] and [23].
6) Turn starting switch ON, turn the power of
the air conditioner ON, and perform step
4. (After checking, assemble and install
the blower intake unit (B/I U).
a For electric problems, see "Trouble-
shooting for FRESH/RECIRC air
changeover".
a Manual air conditioner
*: To blower
*: To blower
26 WA500-6R
Testing inside air temp. sensor

and outside air temp. sensor 1
a Auto air conditioner equipped only machine

only.
q If an error is detected by the self-diagnosis,
perform these tests.
q To reset the self-diagnosis system (detection of
trouble), the starting switch must be turned
OFF.
1. See "Testing Fresh/Recirc changeover",

remove cover (1), fresh air filter (2) and box
(3).
a If an error is detected by the self-diagnosis
q Inside air temperature sensor (ITS)
and the inside air temp. sensor (ITS) is
2. Check contacts of connectors [20] and [21] (for
normal, the control panel or wiring har-
disconnection).
ness is abnormal.
3. Turn the starting switch OFF and disconnect
connectors [21].
connector C48 ([2]) (See the circuit diagram
4. Measure the resistance between the terminals
and arrangement of connector pins) from the
of connector [26] (on the inside air temp. sen-
control panel. Between terminals (6) (RG) and
sor (ITS) side).
(2) (W) of connector [2].
Normal resistance:
Normal resistance:
0°C:7.2 kz
7.2 kz (at 0°C)
25°C:2.2 kz
2.2 kz (at 25°C)
IU: Intake unit
a If the result of step 5 above is normal, the
BU: Blower unit
control panel is abnormal. If the former is
D: FRESH/RECIRC air changeover damper
abnormal, the wiring harness is abnormal.
FA: FRESH air
RA: RECIRC air
q Outside air temperature sensor (OTS)
a See left figure
disconnection).
connectors [22].
of connector [22] (on the outside air temp. sen-
sor (OTS) side).
Normal resistance:
7.2 kz (at 0°C)
2.2 kz (at 25°C)
WA500-6R 27

and the outside air temp. sensor (OTS) is
ness is abnormal.
and connector locations) from the control
panel. Between terminals (4) (BrW) and (2)
(W) of connector [2].
Normal resistance:
7.2 kz (at 0°C)
2.2 kz (at 25°C)
28 WA500-6R
Testing evaporator temperature sensor 1
q If an error is detected by the self-diagnosis, q If the result is abnormal, remove the air
perform these tests. conditioner unit (See Disassembly and
q To reset the self-diagnosis system (detection of assembly, "Removal and installation of air
trouble), the starting switch must be turned conditioner unit") and replace the evapo-
OFF. rator temperature sensor (3) from evapo-
rator (2) (See the disassembly drawing in
1. Remove cover (1). Structure and function).
q A/C U: Air conditioner unit a Precautions for exchanging evaporator
temperature sensor (installed position (P)
of evaporator temperature sensor)
With the flange outlet (OUT) of the evapo-
rator on the right side, install the evapora-
tor temperature sensor so that its top will
be 100 ± 5 mm above the fin top face and
its body will be at the center (P) of the 8th
stage of the fins. (Insert and attach the
sensor holder (4) to the 10th and 11th
stages of the fins.)

disconnection).
connectors [18] and [26].
of connector [26] (on the evaporator tempera-
ture sensor side).
Normal resistance:
7.2 kz (at 0°C)
2.2 kz (at 25°C)
and the evaporator temperature sensor is
ness is abnormal.
and arrangement of connector pins) from the
control panel. Between terminals (5) (GY) and
(2) (W) of connector [2].
Normal resistance:
7.2 kz (at 0°C)
2.2 kz (at 25°C)
WA500-6R 29
Testing sunlight sensor 1
a Auto air conditioner equipped machine only. 4. Disconnect connector C48 from the air condi-
tioner control panel in line with item 10 from
q When sunlight is strong, control panel compen- "Parts and connectors layout".
sates air mix actuator and lower the blowing 5. Ensure that the female terminals of the con-
out target temperature. nector C60 (harness side) are not being
shorted. (If the terminals are shorted, the har-
a If sunlight sensor (S) is mesured with resis- ness is defective.)
tance range of tester, sunlight sensor may be 6. Confirm whether the condition between the
destroyed, so measure it with voltage range of female terminal of the connector C60 (harness
tester. side) (2) (LgR) and the terminal of connector
C48 (harness side) (15) (LgR) is 1 z or less.
1. Disconnect connector C10 inside cigar lighter (If not, the wiring harness is defective.)
(1). 7. Confirm whether the condition between the
2. Remove cover (2) and inspect the connector female terminal of connector C60 (harness
C60 for the sunlight sensor (S) (Check whether side) (1) (RB) and the terminal of connector
the connector has been partially discon- C48 (harness side) (13) (RB) is 1 z or less. (If
nected.) this is not the case, the harness is defective.)
3. Disconnect connector C60, and using a tester 8. Connect all the connectors.
set to the voltage range, measure the voltage 9. Turn the starting switch to ON position, and if
between the male side terminals on the sun- target temperature dose not change when the
light sensor (S). sunlight sensor is exposed to the sunlight at
q Approximate voltage of sunlight sensor auto air conditioner, replace the air conditioner
unit control panel.
0.45 V: Direct sunlight
0.35 V: Cloudy
0.2 V: Indoors
30 WA500-6R
Testing relays 1
q If the air conditioner compressor is normal (air 4. If either relay seems to be abnormal, perform
is cooled) and air comes out, the relays are the following procedure.
normal. Accordingly, skip these relay tests. 1) Turn the main power of the air conditioner
q Bring your ear to each relay to check its opera- OFF and disconnect the battery ground
tion by sound. wire.
2) Remove the relay mounting screws and
There are two relays. exchange the blower-off relay (BR) and
q Blower-off relay: Used to turn the fan motor ON compressor relay (CR).
and OFF 3) Connect the battery ground wire and per-
q Compressor relay: Used to turn the air condi- form steps 2 and 3 above and see if the
tioner compressor (clutch) ON and OFF conditions of the relays are reversed.

q Checking relay unit

1) The resistance of the coil between
2. Turn the starting switch ON (do not start the terminals (1) and (2) is 320 z.
engine) and turn the main power of the air con- 2) Without voltage (DC20 – 30 V) applied
ditioner ON. If the blower-off relay is normal, it between terminals (1) and (2), termi-
is turned ON. Check its click. nals (3) and (4) are disconnected
3. Turn the air conditioner switch ON. If the com- from each other.
pressor relay is normal, it is turned ON. Check 3) With the voltage (DC20 – 30 V) applied
its click. between terminals (1) and (2), termi-
a Control panel does not turn the compres- nals (3) and (4) are connected to
sor relay ON in the following cases. each other.
1)When the evaporator temperature is
below 3°C (depending on the input
voltage from the evaporator tempera-
ture sensor).
2)When the pressure switch detects
abnormality (it is turned OFF).
a If the fan sound is so loud that you cannot
hear the sound of the compressor relay,
perform the following.
1) Turn the main power of the air conditioner
OFF and disconnect the battery ground
wire.
2) Disconnect connector [12].
3) Connect the battery ground wire and
check the compressor relay.
WA500-6R 31
Troubleshooting chart 1 1
a The numbers in the boxes are the item numbers in the troubleshooting table.
1. Cooling trouble
2. Heating trouble
32 WA500-6R
Troubleshooting chart 2 1
1. Blower fan motor does not revolve or its speed is different from set value.
a See "Troubleshooting for blower motor system (No air comes out or air flow is abnormal)".
Possible cause Check method Remedy

Defective BLOWER OFF relay See "Testing relays" Replace
Check connector of blower fan motor for disconnec-
Disconnection of wire or defec- Repair broken parts and con-
tion. See “Troubleshooting for blower motor system“
tive connection nect correctly
and “Parts and connectors layout”
Check two lead wires of motor with circuit tester. If
there is not continuity, motor is defective. See “Trou-
Defective blower motor Replace
bleshooting for blower motor system“ and “Parts and
connectors layout”
Defective BLOWER amplifier
Move fan switches in sequence and check fan speed. Replace
(AMP)
2. Blower fan motor is normal but air flow is insufficient at cool.

Large duct resistance Check duct for crushing and filter for clogging Repair
Check duct joints for defective duct seal and discon-
Air leakage Replace
nection of duct
Obstruction on suction side of
Check evaporator for stain and obstruction Remove obstruction and clean
evaporator
Defective evaporator tempera- Evaporator is frozen. Check sensor clip. Check sen- Repair or replace
ture sensor, defective contact of sor for dirt (Evaporator temperature sen-
evaporator temperature sensor Check the frost on the hose near pressure switch  sor and expansion valve are in
or defective expansion valve (When freezing advances furthermore) air conditioner unit)
3. Low/high pressure

Repair leaking part, then
Insufficient refrigerant If R134a is used as refrigerant, its quantity cannot be charge with proper quantity of
checked through sight glass. refrigerant again
Accordingly, check by connecting gauge manifold. Collect refrigerant, then
Overcharge with refrigerant Purpose of sight glass is to check refrigerant flow. charge with proper quantity of
refrigerant again
Normal pressure range
Low pressure: 
Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2}
Judgment by pressure at inlet/ High pressure:  See Troubleshooting with
outlet of compressor Appox. 1.5 – 1.7 MPa {15 – 17 kg/cm2} gauge pressure
These values are for following condition, however.
Temperature in cab: 30 – 35°C
Engine speed: Appox. 1500 rpm
WA500-6R 33
4. Compressor does not revolve at all or its speed is low.

a See "Troubleshooting for compressor system (Air is not cooled)".
Troubled part Possible cause Check method Remedy

Compressor belt Loosened compressor belt Vibration amplitude of belt is large Adjust tension
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil or seizure
Heating of compressor See "Handling compressor oil"
in the compressor
Low battery voltage Slip of clutch Charge battery
Disconnection or short circuit in coil Inspect with circuit tester Replace
Magnet clutch
Check ground wire and connec-
Disconnection in wiring or defective
tions. See "Troubleshooting for Repair
connection of ground wire
compressor system"
Relay Defective compressor relay See “Testing relay” Replace
Refrigerant Low/high pressure Troubleshooting with gauge Troubleshooting with gauge
pressure (Operation of pressure switch) pressure pressure
See "Troubleshooting for com-
Pressure switch Defective pressure switch Replace
pressor system"
5. Blower fan motor is normal but air flow is insufficient.

Large duct resistance Check duct for crushing and filter for clogging Repair
Check duct joints for defective duct seal and dis-
Air leakage through duct joints Repair
connection of duct
Clogging of heater core fins Check heater core fins for clogging Repair
6. Check of hot water

Warm up engine, and then check engine coolant
Low engine coolant temperature Find out cause
temperature
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of engine Check engine coolant piping for clogging (Hose,
Bleed air and repair
coolant pipe, and core)
Contrary connection of IN and OUT
Check the destination of heater hoses Repair
heater hoses
7. Fan rotation speed

Fan rotation speed is low (Defective See "Testing and adjusting hydraulic drive fan" in
Repair
fan motor EPC or hydraulic system) chapter 30 "Testing and adjusting" of shop manual.
34 WA500-6R
8. Other items
Possible cause Check method Remark

See "Testing temperature control" and "Trouble-
Temperature cannot be adjusted
shooting for temperature control"
Vent (mode) can not be changed
See "Testing vent (mode) changeover" and "Trou- Common to cooling and
over (machine equipped with auto-
bleshooting for vent (mode) air changeover" heating
matic air conditioner)
Fresh/Recirc cannot be changed See "Testing Fresh/Recirc air changeover" and
over "Troubleshooting for Fresh/Recirc air changeover"
Excessive compressor oil See "Handling compressor oil"
Cooling only
Water leakage into the cab Clogging of drain hole
WA500-6R 35
Information in troubleshooting table

diagram. Before performing troubleshooting, understand that information fully.
Problem Problem on machine
Related
Information related to detected failure or troubleshooting
information

<Information described>
• Procedure
1 • Measuring location
Probable causes of trouble a "Between A - B" means "Measure voltage or resistance and so
(Perform troubleshooting on between A and B".
according to these.) • Standard value in normal condition to judge probable causes
• Remarks required for judgement
Possible causes 2
and standard <Notes on troubleshooting>
value in normal (1) Pin number description sequence and tester lead handling
state For troubleshooting, connect the plus (+) and minus (-) tester
leads as shown below unless otherwise specified.
•Connect the plus (+) lead to a pin or harness indicated in the
front.
3 - defective •Connect the minus(-) lead to a pin or harness indicated in the
rear.
(2) Example of troubleshooting by inspection of multiple items
aNormal in 1 but abnormal in 2
At this time " - defective" shown at left is applied
a If a wiring harness is burnt, replace it.
<Defective wiring harness>

q Open circuit
Connector is connected imperfectly or wiring harness is disconnected.
q Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) cir-
cuit accidentally.
q Short circuit
An independent wire in the harness abnormally comes into contact with one of another wire. (Defective
insulation in connector or others)
This is the excerpted circuit diagram related to troubleshooting

q Indicates connector No., and pin No.
q See "Circuit diagram and arrangement of connector pins" and "Parts and connector locations" for
connector location
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown,
Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q N.C.: Normally closed (Normally ON)
q [1], [2], ... are numbers of unlabeled connectors.
q Arrow (): Roughly indicates their mounting place on the machine.
36 WA500-6R
Troubleshooting for power supply system (Air conditioner does not

operate) 1
Problem Air conditioner does not operate due to power supply system failure.
Indication of • When main power of control panel is turned ON and switch is pressed, no LCD on control panel
problem on lights up.
machine • No air comes out (Blower motor does not rotate).
• Referring to "Parts and connectors layout", check fuse No. 10 (20A) in the fuse box A and 5A fuse
in air conditioner unit (wiring harness) for breakage.
Related
• Air conditioner ground wire is grounded together with that of machine wiring harness for machine
information
electric components.
• For each connector, see "Parts and connectors layout".

1) Turn starting switch OFF.
2) Disconnect battery ground cable.
Defective wiring harness 3) Disconnect connector C48 ([2]) from control panel and carry out
1 troubleshooting with starting switch kept OFF.
(ground)
Between [2]-(1) (black) on wiring harness Resis-
Max. 1 z
side of connector C48 and ground tance
a If any fuse referred to in the related information is broken,
replace it.
3) Disconnect connectors C47 ([1]) and C48 ([2]) from control
panel and carry out troubleshooting with starting switch kept
OFF.
Defective wiring harness or Between [2]-(1) (black) and (7)
2 Resis- Min. 1
defective air mix actuator (YW) on wiring harness side of A
tance Mz
connector C48
Approx.
Between [1]-(10) (BW) and (22) 4 kz
Resis-
Possible causes (red) on wiring harness side of (Potenti- B
tance
and standard connector C47 ometer
value in normal resistance)
state a If check result of cause 2-A is abnormal, find out abnormal wir-
ing harness.
1) – 3) See cause 2.
4) Disconnect connector C49 ([3]) and carry out troubleshooting
with starting switch kept OFF.
a If check result of C below is abnormal: Wiring harness between
air conditioner unit and control panel is abnormal.
Between [2]-(1) (black) and (7) Min. 1
Resis-
(YW) on wiring harness side of C
tance Mz
Ground fault in wiring har- connector C48
3 ness a If check result of cause 2-A is abnormal and check result of C
(Contact with GND circuit) above is normal, find out abnormal wiring harness.
4) Connect connector C49 ([3]).
5) Disconnect connector AL1 and carry out troubleshooting with
starting switch kept OFF.
a If check result of D below is abnormal: Wiring harness in air
conditioner unit is abnormal.
Between [2]-(1) (black) and (7) Min. 1
Resis-
(YW) on wiring harness side of D
tance Mz
connector C48
WA500-6R 37

a If check result of cause 2-A is abnormal and check results of C
and D are normal, machine wiring harness is abnormal. Check
for confirmation.
3) Disconnect connector AL1 and connect T-adapter to connector
[7] on machine wiring harness side.
4) Carry out troubleshooting with starting switch kept OFF.
Between [7]-(1) (green) and (5)
Resis-
(black) on machine wiring Min. 1 Mz
tance
Ground fault in wiring har- harness side of connector AL1
3 ness a If check result of cause 2-B is abnormal, check to see if wiring
(Contact with GND circuit) harness is cause.
4) Disconnect connector [15] and carry out troubleshooting with
a If check results of cause 2-B and E below are abnormal, discon-
nect connector [5] and check again in the same way to find
abnormal wiring harness.
Between [1]-(10) (BW) and (22) Min. 1
Resis-
(red) on wiring harness side of E
tance Mz
connector C47
Possible causes 1) Turn starting switch OFF.
and standard 2) Disconnect battery ground cable.
value in normal 3) Disconnect relay connectors [12] and [14] and carry out
state troubleshooting with starting switch kept OFF.
Defective relay a See Testing relays.
4
(Short circuit in relay coil) Between blower-off relay (1) – Resis-
320 z
(2) tance
Between compressor relay (1) – Resis-
320 z
(2) tance
a If any fuse referred to in the related information is broken,
replace it.
3) Disconnect connectors C47 ([1]) and C48 ([2]) from control
panel.
5 Defective control panel 4) Connect battery ground cable, turn starting switch ON, and
carry out troubleshooting.
a Leave control panel disconnected.
Between [2]-(7) (YW) and (1)
(black) on wiring harness side of Voltage 20 – 30 V
connector C48
Defective air mix actuator
6 (Short circuit in potentiome- When check results of causes 2-B and 3-E are normal.
ter resistor)
Disconnection in wiring har- Referring to circuit diagram, check power supply line (if voltage is
7
ness not applied when cause 5 is checked).
38 WA500-6R
a Manual air conditioner does not have sunlight sensor, inside air temperature sensor and outside air tem-
perature sensor.
WA500-6R 39
Troubleshooting for compressor and refrigerant system (Air is not

cooled) 1
Problem Air is not cooled due to compressor system failure.

Indication of • When main power of control panel is turned ON and air conditioner switch is pressed, LCD on con-
problem on trol panel lights up but air is not cooled.
machine • Air conditioner compressor does not operate.
• Check if "A/C mark" or "HOT mark" is blinking and "HL. E" or "**. E" is displayed at the temperature
indicator with self-diagnosis function on the control panel. Then, see "Testing with self-diagnosis
function" and repair abnormality by self-diagnosis. (*: Any character or number.)
• Referring to "Parts and connectors layout", check fuse No. 11 (5A) in the fuse box A for breakage.
Related
• Pressure switch is turned OFF when refrigerant pressure is abnormally low or high (See Structure
information
and function).
• Referring to "Testing temperature control", check angle of air mix damper (link section).
• Air conditioner may not be turned ON even when ambient temperature is below 3°C (Normal).
• For each connector, see "Parts and connectors layout".

2) Disconnect connector E16 from air conditioner compressor and
Defective wiring harness carry out troubleshooting with starting switch kept OFF.
1
(ground)
Between (1) (black) on wiring harness side Resis-
Max. 1 z
of connector E16 and ground tance
1 Turn starting switch to OFF position.
2 Disconnect the connector E16 from the air-conditioner
compressor and connect a T-adapter at the male side.
a Ensure connection of air conditioner compressor ground cable
Defective air conditioner terminal.
2
compressor
Between connector E16 (male)
(1) and the machine ground. Resis-
Approx. 15 z
(i.e., air conditioner compressor tance
coil resistance)
a If no fuse referred to in related information is broken, skip all
checks for cause 3.
Possible causes 2) Disconnect connector E16 from air conditioner compressor and
and standard carry out troubleshooting with starting switch kept OFF.
value in normal
Between (1) and (2) on wiring Resis- Min. 1
state A
harness side of connector E16 tance Mz
a If check result of A above is abnormal, find out abnormal wiring
harness.
2) Disconnect battery ground terminal.
Ground fault in wiring har- 3) Disconnect connector E16 from air conditioner compressor.
3 ness 4) Disconnect connector AL1 and carry out troubleshooting with
(Contact with GND circuit) starting switch kept OFF.
Between (1) and (2) on wiring Resis- Min. 1
B
harness side of connector E16 tance Mz
a If check result of A above is abnormal and check result of B
above is normal, perform following procedure.
1) – 4) See above.
a If check result C below is abnormal: Machine wiring harness
between fuse and air conditioner unit is abnormal.
Between [7]-(3) (white) and (5) Min. 1
Resis-
(black) on wiring harness side of C
tance Mz
connector AL1
40 WA500-6R

a If check result of A above is abnormal and check results of B
and C above are normal, perform following procedure.
4) Disconnect compressor relay connector [14].
Ground fault in wiring har- a If check result D below is abnormal: Wiring harness in air condi-
3 ness tioner unit is abnormal.
(Contact with GND circuit)
Between [8]-(3) (red) and (5)
(black) on air conditioner unit Resis- Min. 1
D
wiring harness side of connector tance Mz
AL1
3) Replace blower-off relay with compressor relay.
a See check of relay.
Defective compressor relay 4) Connect battery ground terminal.
4 5) Turn starting switch ON.
(Relay is not turned ON)
6) Turn main power of control panel ON and press air conditioner
switch.
If air conditioner compressor operates and air does not come out,
original compressor relay is defective.
Possible causes 2) Disconnect battery ground terminal.
and standard 3) Disconnect pressure switch connector [11] and carry out
value in normal troubleshooting.
a Pressure switch may operate normally and turn off itself.
state
Accordingly, if following is abnormal (if switch is turned OFF),
5 Defective pressure switch
install pressure gauge to low pressure side of air conditioner
compressor and check refrigerant pressure.
Between (1) and (2) on pressure Resis-
Min. 1 Mz
switch side of connector tance
k When replacing pressure switch, collect refrigerant in advance.
3) Disconnect connectors C47 ([1]) from control panel.
4) Connect battery ground terminal and turn starting switch ON.
a Leave only connector C48 connected to control panel.
6 Defective control panel 5) Turn main power of control panel ON and press air conditioner
switch.
Between (15) on control panel
side of connector C47 and Voltage Max. 1 V
ground
Disconnection in wiring har-
7 Refer to circuit diagram, check wiring harness for disconnection.
ness
Lowering of fan rotation See "Testing hydraulic drive fan" in chapter 30 "Testing and adjust-
8 speed (wind speed at con- ing" of shop manual.
denser) Fan rotation speed at engine low idle Min. 500 rpm
WA500-6R 41
42 WA500-6R
Troubleshooting for blower motor system (No air comes out or air flow
is abnormal) 1
Problem No air comes out or air flow is abnormal due to blower motor system failure.
Indication of • When main power of control panel is turned ON, LCD on control panel lights up but air does not
problem on come out.
machine • Air flow does not match fan switch setting of control panel.
• This trouble cannot be checked with self-diagnosis function.
• Referring to "Parts and connectors layout", check 15A fuse in air conditioner unit for breakage.
• If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. In this case,
the probable causes are as follows.
1)Defective compressor relay, (stuck close) See "Testing relays".
Related
2)Evaporator temperature sensor mounting clip may have come off.
information
3)Expansion valve may not be adjusted correctly. (Remove and disassemble air conditioner unit.)
• If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
• If air flow is also abnormal in heating mode, replace blower amplifier first.
• For each connector and relay, see "Parts and connectors layout".
• Since blower intake unit is independent (under cab), disconnect it first.
2) Disconnect connector [20] from under cab and connect T-
adapter to it.
3) Carry out troubleshooting with connector [19] disconnected and
Between wiring harness (1) (R/W) and (3)
(orange) of connector [20] (on blower motor There is continuity
side)
Defective blower (fan) motor
1 or defective wiring harness in 1) Turn starting switch OFF.
blower intake unit 2) Disconnect connector [20] from under cab and insert T-adapter
(Connect connectors [19] and [20]).
3) Turn starting switch ON, turn main power of control panel ON,
set fan switch to HI-MAX, and carry out troubleshooting.
a If following voltage is not applied, go to cause 4.
Between wiring harness (1) (R/
W) and (3) (orange) of
Voltage 20 – 30 V
Possible causes connector [20] (on blower motor
and standard side)
value in normal a If check result of cause 1 is abnormal (continuity is broken or
state motor does not rotate while voltage is normal), perform follow-
ing procedure.
2) Remove blower intake unit.
3) Referring to Structure and function, disassemble blower intake
Defective wiring harness in unit. (Disconnect connector [24])
2
blower intake unit Orange line between connectors Resis-
Max. 1 z
[20] and [24] tance
RW line between connectors Resis-
Max. 1 z
[20] and [24] tance
Between (1) (RW) and (3) Resis-
Min. 1 Mz
(orange) of connector [20] tance
a If check result of cause 1 is abnormal (continuity is broken or
motor does not rotate while voltage is normal) and check result
3 Defective blower (fan) motor of cause 2 is normal, blower (fan) motor is defective.
a If blower (fan) motor coil is burnt and broken because of short
circuit, fuse (15A) is also broken.
WA500-6R 43

a If no fuse referred to in the related information is broken, skip all
checks for cause 4.
3) Disconnect connectors AL1, [12], [19] and [13].
4) Connect T-adapter to connector [19] and [8] on air conditioner
unit side of AL1 and carry out troubleshooting with starting
switch kept OFF.
Defective wiring harness Between [8]-(5) on air

conditioner unit side of Resis-
4 (Contact with GND circuit or Min. 1 Mz
connector AL1 and (3) of tance
another line) connector [12]
Between [8]-(5) on air
Min. 1 Mz
connector [12]
Between (2) and (3) of Resis- Min. 1 Mz
connector [12] tance
• Referring to check of relay, check if turn- Click is heard.
ON sound of blower-off relay is heard.
a If "click is not heard" in above troubleshooting, perform following
procedure.
Defective blower-off relay, 3) Replace blower-off relay with compressor relay.
5
etc. (Relay is not turned ON) a See check of relay.
4) Connect battery ground cable.
5) Turn starting switch ON.
Possible causes 6) Turn main power of control panel ON.
and standard a If air comes out, original blower-off relay is defective.
value in normal
a If check result of cause 5 is abnormal but relay is normal, go to
state
cause 7.
2) Insert T-adapter between connectors [13] and [25].
4) Turn main power of control panel ON.
a Check about 10 V between terminals (B) and (C) (base voltage)
of blower amplifier input connector [13].
Between (A) and (C) of Voltage Max. 10 V
connector [13]
5) Operate fan switch on control panel from LO to HI.
a Between terminals (B) and (C) (base voltage) of blower ampli-
fier input connector [13].
Between (A) and (C) of Change is 10 V or
Voltage
connector [13] less
6 Defective blower amplifier a If blower amplifier is normal, all of following are normal. Reverse
is not always satisfied, however (Amplifier cannot be checked
by checking each unit).
3) Connect T-adapter to connector [25] and carry out
troubleshooting (Leave connector [13] disconnected).
Between (B) and (C) of Resis-
4.7 kz ± 5 %
No continuity
Between (A) (+) and (C) (–) of connector
[25] * Measure at diode
range
Continuity
Between (A) (–) and (C) (+) of connector
range
44 WA500-6R

2) Disconnect connector C49 and insert T-adapter (since there is
not T-adapter for connector C47).
Possible causes 4) Turn main power of control panel ON (Turn blower-OFF relay
ON (Output = GND) to apply voltage of about 10 V to gate of
and standard 7 Defective control panel blower amplifier.)
value in normal
state Between (6) and (11) of
Voltage Max. 1 V
connector C49
Between (5) and (11) of
Voltage Approx. 10 V
connector C49
Disconnection in wiring har- Referring to circuit diagram, check wiring harness for disconnec-
8
ness tion.
Related circuit diagram (manual air conditioner)
WA500-6R 45

2) Disconnect connector [20] from under cab and connect T-
adapter to it.
3) Carry out troubleshooting with connector [19] disconnected and
Between wiring harness (8) (R/W) and (5)
(orange) of connector [20] (on blower motor There is continuity
side)
Defective blower (fan) motor
1 or defective wiring harness in 1) Turn starting switch OFF.
blower intake unit 2) Disconnect connector [20] from under cab and insert T-adapter
(Connect connectors [19] and [20]).
3) Turn starting switch ON, turn main power of control panel ON,
set fan switch to HI-MAX, and carry out troubleshooting.
a If following voltage is not applied, go to cause 4.
Between wiring harness (8) (R/
W) and (5) (orange) of
Voltage 20 – 30 V
Possible causes connector [20] (on blower motor
and standard side)
value in normal a If check result of cause 1 is abnormal (continuity is broken or
state motor does not rotate while voltage is normal), perform follow-
ing procedure.
2) Remove blower intake unit.
3) Referring to Structure and function, disassemble blower intake
Defective wiring harness in unit. (Disconnect connector [24])
2
blower intake unit Orange line between connectors Resis-
Max. 1 z
[20] and [24] tance
RW line between connectors Resis-
Max. 1 z
[20] and [24] tance
Between (1) (RW) and (3) Resis-
Min. 1 Mz
(orange) of connector [20] tance
motor does not rotate while voltage is normal) and check result
3 Defective blower (fan) motor of cause 2 is normal, blower (fan) motor is defective.
a If blower (fan) motor coil is burnt and broken because of short
circuit, fuse (15A) is also broken.
46 WA500-6R

a If no fuse referred to in the related information is broken, skip all
checks for cause 4.
3) Disconnect connectors AL1, [12], [19] and [13].
4) Connect T-adapter to connector [19] and [8] on air conditioner
unit side of AL1 and carry out troubleshooting with starting
switch kept OFF.
Defective wiring harness Between [8]-(5) on air

4 (Contact with GND circuit or Min. 1 Mz
another line) connector [12]
Between [8]-(5) on air
Min. 1 Mz
connector [12]
• Referring to check of relay, check if turn- Click is heard.
ON sound of blower-off relay is heard.
a If "click is not heard" in above troubleshooting, perform following
procedure.
Defective blower-off relay, 3) Replace blower-off relay with compressor relay.
5
etc. (Relay is not turned ON) a See check of relay.
4) Connect battery ground cable.
Possible causes 6) Turn main power of control panel ON.
and standard a If air comes out, original blower-off relay is defective.
value in normal
a If check result of cause 5 is abnormal but relay is normal, go to
state
cause 7.
2) Insert T-adapter between connectors [13] and [25].
a Check about 10 V between terminals (B) and (C) (base voltage)
of blower amplifier input connector [13].
Between (A) and (C) of Voltage Max. 10 V
connector [13]
5) Operate fan switch on control panel from LO to HI.
a Between terminals (B) and (C) (base voltage) of blower ampli-
fier input connector [13].
Between (A) and (C) of Voltage Change is 10 V or
connector [13] less
6 Defective blower amplifier a If blower amplifier is normal, all of following are normal. Reverse
is not always satisfied, however (Amplifier cannot be checked
by checking each unit).
3) Connect T-adapter to connector [25] and carry out
troubleshooting (Leave connector [13] disconnected).
Between (B) and (C) of Resis- 4.7 kz ± 5 %
No continuity
Between (A) (+) and (C) (–) of connector
range
Continuity
Between (A) (–) and (C) (+) of connector
range
WA500-6R 47

Possible causes 4) Turn main power of control panel ON (Turn blower-OFF relay
ON (Output = GND) to apply voltage of about 10 V to gate of
and standard 7 Defective control panel blower amplifier.)
value in normal
state Between (6) and (11) of
Voltage Max. 1 V
connector C49
Between (5) and (11) of
Voltage Approx. 10 V
connector C49
Disconnection in wiring har- Referring to circuit diagram, check wiring harness for disconnec-
8
ness tion.
Related circuit diagram (auto air conditioner)
48 WA500-6R
Troubleshooting for temperature control 1
Problem Temperature cannot be controlled

Indication of
problem on • When temperature control switch on control panel is operated, temperature does not change.
machine
a Temperature control means “Air Mix” of cooled air and hot air.
• When main power of control panel is turned ON, HOT mark (LCD) on the control panel blinks or
“HLE” is displayed on the temperature display area. (See "Testing with self-diagnosis function".)
• Self-diagnosis system checks air mix actuator for disconnection and short circuit and checks con-
tacts (LIMIT terminal) in air mix actuator each time main power of control panel is turned ON.
• Even if link is disconnected (See "Testing temperature control", self-diagnosis system assumes that
Related
temperature control system is normal, if air mix actuator rotates when switch is operated.
information
• Operating angle of air mix actuator (COOL-MAX – HOT-MAX) is 90°.
• Referring to "Testing temperature control", check that there is not mechanical trouble (disconnection
or interference of link, etc.)
• To replace air mix actuator, link section must be removed. (See parts book and Structure and func-
tion.)

Since there is no T-adapter for connector [15], check with
connectors C49 and C50.
2) Disconnect connectors C49 and C50 and connect T-adapter to
connectors [4] and [6] (on air conditioner unit side).
3) In the case of "Auto air conditioner" equipped machine,
disconnect mode actuator connector [16]
4) Carry out troubleshooting with connectors [3] and [5] (on control
panel side) disconnected and starting switch kept OFF.
Defective air mix actuator or
Between (1) of connector [4] and Resis- Approx. 110 z
1 defective wiring harness in (12) of connector [6] tance (Motor coil)
air conditioner unit
Between (1) and (10) of Resis-
Approx. 4 kz
connector [6] tance
Approx. 500 z
Between (7) and (10) of Resis- (COOL-MAX) –
Possible causes connector [6] tance Approx. 3.5 kz
and standard (HOT-MAX)
value in normal a Contact input cannot be checked with removed unit (See related
state information).
resistance is abnormal), perform following procedure.
Defective wiring harness in 2) Disconnect connectors C49, C50 and [15] and connect T-adapter
2
air conditioner unit to connectors [4] and [6] (on air conditioner unit side) and carry
out troubleshooting.
Referring to circuit diagram, check wiring harness for defect.
3 Defective air mix actuator resistance is abnormal) and check result of cause 2 is normal, air
mix actuator is defective.
Defective wiring harness 2) Disconnect connectors C47, C49 and C50 and connect T-adapter
4 (extended) between control to connectors [3] and [5] (on extended wiring harness side) and
panel and air conditioner unit carry out troubleshooting.
WA500-6R 49

a If self-diagnosis system does not blink LCD, output to actuator is
not stopped, thus control unit can be checked.
2) Disconnect connectors C49 and C50 and insert T-adapter (since
there is not T-adapter for connector C47).
5) Press temperature control switch and check if voltage is applied
in about 3 seconds (while damper is moving). (Voltage stops
when damper stops.)
a Polarities (+, –) in changing from COOL to HOT are reverse to
those in changing from HOT to COOL.
Approx. 24 V (For
Between connector C49 (1) (+)
about 3 seconds after
and C50 (2) (–) Voltage
temperature control
a COOL o HOT
switch is pressed)
Possible causes Approx. 24 V (For
and standard Between connector C49 (1) (–)
about 3 seconds after
value in normal and C50 (2) (+) Voltage
5 Defective control panel temperature control
a HOT o COOL
state switch is pressed)
Voltage 5V
and (10) (–)
5) Measure each time you press temperature control switch.
(Measure 8 times in total from COOL-MAX to HOT-MAX.)
a If damper rotates, potentiometer resistance changes and voltage
changes consequently.
Between (7) and (10) of Change between
Voltage
connector C50 0 and 5 V
50 WA500-6R
WA500-6R 51
Troubleshooting for vent (mode) changeover 1
(Machine equipped with automatic air conditioner)

Problem Vent (mode) cannot be controlled
Indication of
• When mode selector switch or defroster switch on control panel is operated, vent (mode) does not
problem on
change.
machine
• When main power of control panel is turned ON, man-shaped mark (LCD) on the control panel
blinks or “HLE” is displayed on the temperature display area. (See "Testing with self-diagnosis
function".)
• Self-diagnosis system checks mode actuator for disconnection and short circuit and checks con-
tacts (LIMIT terminal) in mode actuator each time main power of control panel is turned ON.
Related • Even if link is disconnected (See "Testing vent (mode) changeover", self-diagnosis system
information assumes that vent (mode) changeover is normal, if mode actuator rotates when switch is operated.
• Referring to "Testing vent (mode) changeover", check that there is not mechanical trouble (discon-
nection or interference of link, etc.)
• To replace mode actuator, link section must be removed. (See parts book and Structure and func-
tion.)

Since there is no T-adapter for connector [16], check with
connectors C49 and C50.
2) Disconnect connectors C49 and C50 and connect T-adapter to
connectors [4] and [6] (on air conditioner unit side).
3) In the of "Auto air conditioner" equipped machine, disconnect
mode actuator connector [16]
4) Carry out troubleshooting with connectors [3] and [5] (on control
Defective mode actuator or panel side) disconnected and starting switch kept OFF.
1 defective wiring harness in Between (2) of connector [4] and Resis- Approx. 110 z
air conditioner unit (8) of connector [6] tance (Motor coil)
Between (1) and (10) of Resis-
Approx. 4 kz
connector [6] tance
Between (11) and (10) of Resis- Approx. 500 z – 3.5
Possible causes connector [6] tance kz
and standard a Contact input cannot be checked with removed unit (See
value in normal related information).
state
Defective wiring harness in 2) Disconnect connectors C49, C50 and [16] and connect T-
2
air conditioner unit adapter to connectors [4] and [6] (on air conditioner unit side)
3 Defective mode actuator resistance is abnormal) and check result of cause 2 is normal,
mode actuator is defective.
Defective wiring harness 2) Disconnect connectors C47, C49 and C50 and connect T-
4 (extended) between control adapter to connectors [3] and [5] (on extended wiring harness
panel and air conditioner unit side) and carry out troubleshooting.
52 WA500-6R

a If self-diagnosis system does not blink LCD, output to actuator
is not stopped, thus control unit can be checked.
2) Disconnect connectors C49 and C50 and insert T-adapter
(since there is not T-adapter for connector C47).
5) Press mode switch and check if voltage is applied in about 3
seconds (while damper is moving). (Voltage stops when damper
stops.)
a Polarities (+, –) are reverse by pushing the mode switch.
Between connector C49 (2) (+) Approx. 24 V (For
and C50 (8) (–) about 3 seconds
a FACEoFACE/FOOTo Voltage
after switch is
FOOT/DEFoDEF pressed)
Possible causes Between connector C49 (2) (–) Approx. 24 V (For
and standard and C50 (8) (+) about 3 seconds
a DEFoFOOT/DEFo FOOTo Voltage
value in normal after switch is
5 Defective control panel
state FACE/FOOT oFACE pressed)
Voltage 5V
and (10) (–)
a If self-diagnosis system does not blink LCD, output to actuator
is not stopped, thus control unit can be checked.
5) Measure each time you press mode selector switch or defroster
switch. (Measure 5 times in total.)
a If damper rotates, potentiometer resistance changes and volt-
age changes consequently.
Between (11) and (10) of Change between
Voltage
connector C50 0 and 5 V
WA500-6R 53
54 WA500-6R
Troubleshooting for Fresh/Recirc air changeover 1
(Machine equipped with automatic air conditioner)

Problem Fresh/Recirc cannot be changed over.
Indication of
• When Fresh/Recirc switch on control panel is operated, recirculated or fresh air does not change
problem on
over (Fresh/ Recirc changeover damper does not rotate).
machine
• When main power of control panel is turned ON, Fresh/Recirc mode LCD blinks. (See "Testing with
self-diagnosis function".)
• Self-diagnosis system checks contacts (LIMIT terminal) in Fresh/Recirc changeover actuator each
time main power of control panel is turned ON.
a Since self-diagnosis system does not check Fresh/Recirc changeover actuator line for disconnection
and short circuit, it does not indicate all troubles of Fresh/Recirc changeover actuator by blinking
Related LCD.
information • Referring to "Testing Fresh/Recirc changeover", check that there is not mechanical trouble (removal
or interference of lever, etc.)
• Operating angle of Fresh/Recirc changeover actuator is 90°.
• To replace Fresh/Recirc changeover actuator, blower intake unit must be removed and disassem-
bled. (See "Testing Fresh/Recirc changeover".)
• Resistance (Potentiometer) in Fresh/Recirc changeover actuator is not used.

Since there is no T-adapter for connector [23], check with connector
C49.
2) Disconnect connector C49 and connect T-adapter to connector
Defective Recirc/Fresh [4] (on air conditioner unit side).
changeover actuator or 3) Carry out troubleshooting with connector [3] (on control panel
side) disconnected and starting switch kept OFF.
defective wiring harness in
1
air conditioner unit or defec- Between (3) and (7) of connector Resis- Approx. 110 z
tive wiring harness in blower [4] tance (Motor coil)
intake unit There is one way
Between (3) and (8) of connector [4]
a Measure in diode range continuity. 
(Because one of
a Check continuity on both directions by
internal switch is
changing polarity of tester probes OFF.)
Possible causes Defective wiring harness in 2) Disconnect connectors C49 and [19] and connect T-adapter to [4]
2
and standard air conditioner unit and [19] of connector C49 (on air conditioner unit side) and carry
value in normal out troubleshooting.
state
resistance is abnormal) and check result of cause 2 is normal,
perform following procedure.
Defective wiring harness in 1) Turn starting switch OFF.
3 2) Referring to "Testing Recirc/Fresh changeover", remove and
blower intake unit
disassemble blower intake unit.
3) Carry out troubleshooting with connector [23] disconnected.
Defective Fresh/Recirc
4 resistance is abnormal) and check results of causes 2 and 3 are
changeover actuator
normal, Fresh/Recirc changeover actuator is defective.
Defective wiring harness 2) Disconnect connectors C47, C48 and C49 and connect T-adapter
5 (extended) between control to connector [3] (on extended wiring harness side) and carry out
panel and air conditioner unit troubleshooting.
WA500-6R 55

not T-adapter for connectors C47 and C48).
Possible causes 3) Turn starting switch ON.
and standard 4) Turn main power of control panel ON.
value in normal 5) Press Recirc/Fresh selector switch and check if voltage is applied
6 Defective control panel in about 3 seconds (while damper is moving). (Voltage stops
state
when damper stops.)
a Polarities (+, –) in changing from Recirc to Fresh are reverse to
those in changing from Fresh to Recirc.
Approx. 24 V (For
Between (7) and (8) of connector about 3 seconds after
Voltage
C49 Recirc/Fresh selector
switch is pressed)
56 WA500-6R
Troubleshooting with gauge pressure 1
Referring to "Connection of service tool", carry out <Measurement condition for pressure>
troubleshooting by reading the high and low gauge Item Condition value
pressures of the cooling cycle.
Atmospheric temperature 20 – 50°C
a The gauge pressure varies largely with the Engine speed Low idle
weather condition and operating condition of Air conditioner switch ON
the machine. Take care. Fan switch Hl
q High pressure is too high: Set temperature Full cool

Above approx. 2.5 MPa {25 kg/cm2}
q High pressure is too low: q Dual pressure switch
Below approx. 1 MPa {10 kg/cm2} a Normally "ON", abnormal pressure "OFF" for
q Low pressure is too high: compressor.
Above approx. 0.3 MPa {3 kg/cm2}
q Low pressure is too low:
Below approx. 0.05 MPa {0.5 kg/cm2}
a (Dual) pressure switch on high pressure side

protects air conditioner circuit with OFF:
See right
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If there is any trouble (cooling trouble), there is another
Pressure is normal
cause. –
High pressure: Approx. 1.5 – 1.7 MPa {15 – 17 kg/cm2}
Low pressure: Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2}
Collect refrigerant, then fill
Bubble can be seen in the
Insufficient refrigerant up with proper quantity of
sight glass (*1, *3)
refrigerant again (*2)
There is a temperature dif-
ference between inlet and Replace
Clogging of receiver drier
outlet pipes of receiver drier. (*2)
Tank is frosty
Clean or replace
Clogging of expansion valve Expansion valve is frosty
(*2)
Both high pressure and low
pressure are too low Gas leakage at heat sens- Low pressure gauge Replace
ing tube of expansion valve becomes vacuum (*2)
Low pressure becomes vac- Repair or replace
Evaporator is frozen
uum Defective evaporator sensor Replace receiver drier
Air flow is down by freezing
or defective contact of sen- Collect refrigerant, then fill
(At cool max. and HI speed
sor (removal of mounting up with proper quantity of
of fan, later it becomes not to
clip) refrigerant again
cold.)
(*2)
Piping between receiver
drier and compressor is
Clogging or flattening or pip- clogged or flattened. If Clean or replace
ing clogged completely, low (*2)
gauge pressure becomes
vacuum
WA500-6R 57
Indicated gauge pressure Cause Check method Remedy

Collect refrigerant, then fill
Filling too much with refriger- up with proper quantity of
Connect gauge manifold
ant refrigerant again
(*2)
Stain of condenser, clogging Clean, repair fins, or repair
Defective cooling of con-
or crushing of fins, or defec- or replace condenser
denser
Both high pressure and low tive revolution of cooling fan (*2)
pressure are too high Defective adjustment of
Bubble can be seen in the Replace
expansion valve (Valve is
sight glass (*3) (*2)
opened too wide)
Evacuate and then fill up with
Bubble can be seen in the proper quantity of refrigerant
Air in cycle
sight glass (*3) again
(*2)
Clogging or flattening of pip- There is a remarkable tem- Clean inside of cycle or
High pressure is too high
ing between compressor and perature difference between replace
and low pressure is too low
condenser before and after clogged part (*2)
Both high pressure and low
Defective compressor (Com- pressure are balanced while
High pressure is too low and Replace
pression trouble of compres- compressor is in operation.
low pressure is too high (*2)
sor) Compressor has seized and
is extremely hot.
*1 If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are
stained with oil. Increase tightening of the joints or replace parts.
*2. k When replacing a cooling cycle part, see "Caution about refrigerant" and collect refrigerant. After replacing it, fill
up the air conditioner system with refrigerant again.
*3. Sight glass is on the receiver drier.
58 WA500-6R
Connection of service tool 1

X 799-703-1200 Service tool kit
a Use the service tool kit for R134a. Connect the gauge manifold, hoses and other ser-
vice tools according to the following procedure.
Service tool kit
1. Gauge manifold 1. Close the high-pressure valve (HI) and low-
2. High pressure charging hose (red) pressure valve (LO) of gauge manifold (1).
3. Low pressure charging hose (blue) 2. Connect red charging hose (2) to the (HI) side
4. Quick joint (Hi) (Large diameter) and blue charging hose (3) to the (LO) side.
5. Quick joint (Lo) (Small diameter) 3. Connect quick joints (4) and (5) to each hose.
a. The thread is rough. So be careful not to loosen. 4. Connect the quick joints to the service valves
of the high and low-pressure pipings.
WA500-6R 59
Precautions for disconnecting and connecting hoses and tubes in air

conditioner circuit 1
Precautions for disconnection a Example of fitting of O-ring

k Collect the refrigerant (Air conditioner gas:
R134a) from the air conditioner circuit
before disconnecting air conditioner hoses
to replace the air conditioner unit, air con-
ditioner compressor, condensor or receiver
drier and so on.
a Ask a qualified person for collecting, adding
and fillin g oper ations of the refrige rant
(R134a). (Only registered person can work.)
atmosphere.
Table of tightening torque for refrigerant pipe joint.
you may lose your sight. And if it touches
your skins, you may suffer from frostbite. Thread size Tightening torque: Nm {kgm}
Accordingly, put on the protective eye- M6 x 1.0 8 to 12 {0.8 to 1.2}
glasses, gloves and working suits with long M8 x 1.25 20 to 25 {2.0 to 2.6}
sleeves while you are collecting or adding M16 x 1.5 12 to 15 {1.2 to 1.5}
the refrigerant (R134a). M22 x 1.5 20 to 25 {2.0 to 2.6}
q When loosening the air conditioner hose nut M24 x 1.5 30 to 35 {3.1 to 3.6}
after collecting the refrigerant, be sure to use
two wrenches.
Use one wrench to fix one nut and the other
wrench to loosen the other nut.
q For the disconnected air conditioner piping,
take measures to prevent dirt, dust, and water
from entering the hose.
Precautions for connection
q When connecting air conditioner piping, apply
compressor oil (SP-10) for use with R134a to
the O-ring.
(See "Handling of compressor oil".)
Do not apply oil to the threads of a bolt, nut or
union, however.
a An O-ring is fitted to every joint of the air
conditioner piping.
q Do not reuse an O-ring that was used once
because it is deformed and deteriorated. When
removing the O-ring, use a flexible tool (tooth
pick, etc.) in order not to damage the piping.
q When connecting the piping, press the pipe
until it is seated and finger-tighten the bolt or
nut fully.
q Be sure to use two wrenches to tighten each
nut. Use one wrench to fix one nut and the
other wrench (torque wrench) to tighten the
other nut to the specified torque.
60 WA500-6R
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit
WA500-6R 61
Handling of compressor oil 1
1. Control of compressor oil Check compressor oil in the following cases,

(SANDEN: SP-10: For R134a) and then add new oil if necessary.
Compressor oil does not need to be checked q When much refrigerant is discharged
or added so frequently as engine oil. Insuffi- because of leakage.
ciency or excess of compressor oil can cause q When the compressor is troubled and
the following troubles. replaced.
q When a cycle parts such as the air condi-
Condition Contents tioner unit, condenser, receiver drier,
Insufficiency of oil
Lubrication trouble and seizure evaporator unit, etc. is replaced.
of compressor
Cooling trouble (Excessive oil Quantity of oil to be added when cycle part is
Excess of oil stick to parts and lower heat replaced
exchange performance)
Quantity to be added
Air conditioner part
Accordingly, compressor oil must be filled to (cm3)
the specified level, similarly to refrigerant. Air conditioner unit,
Approx. 40
evaporator
2. Adding of compressor oil Condenser Approx. 40
k Since refrigerant is dangerous and bad Receiver drier Approx. 20
for environment, collect the refrigerant Each hose (Cab – M24
before disconnecting the air condi- Approx. 30
Joint – Compressor)
tioner hose. See "Caution about refrig-
Each hose (Cab – M16
erant". Joint – Receiver drier –
k If refrigerant gets in your eyes, you Approx. 15
condenser – compres-
may lose your sight. (Put on protective sor)
goggles.)
a If oil for CFC-12 (R-12) is used, lubrication
trouble will occur and the compressor may
be broken or seized.
Be sure to use the specified oil for R134a
(SANDEN: SP-10)
a Oil for R134a absorbs moisture very eas-
ily. Accordingly, fit the cap immediately
after using oil to stop the atmosphere.
Store the oil can in a dry and ventilated
place.
a Precautions for using oil
Oil for R134a (SP-10 in particular) may
dissolve acrylic resin and polystyrene
(excluding baked polystyrene paint film).
Accordingly, do not stick oil to those plas-
tics.
62 WA500-6R
3. Compressor replacement 4. Applying compressor oil for O-ring

q In case of compressor seizure or break- When connecting a pipe or hose, apply oil
age. (SP-10) to its O-ring to prevent refrigerant
Metal chips will circulate through the air leakage.
conditioner circuit and contaminate the k When discarding a can which still has
compressor oil extremely. some oil in it, make a hole on it to dis-
In this case, flush the air conditioner circuit charge gas and oil.
and replace the compressor and receiver
drier.
The compressor oil is removed from the
air conditioner circuit by flushing.
Accordingly, install a new compressor with
the oil of the specified quantity (135 cc)
filled in it.
q Other cases
New compressor has 135 cc compressor
oil in it. So drain excessive compressor oil
before installing new compressor in the
following.
1)Prepare an oil pan and drain oil from old
compressor.
2)Measure the quantity of the drained oil
with a graduated cylinder, and note
the quantity or mark the level.
3)Drain below-mentioned quantity of oil

from new compressor.
The drain quantity = 135 cc – "the
noted quantity".
EX.
If drained oil quantity from removed
compressor is 30cc, drain oil of
135 – 30 cc = 105 cc from new
one.
WA500-6R 63
SEN06712-00

©2018 KOMATSU
All Rights Reserved
64
SEN02901-03
WA500-6R

WA500-6R 60001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 3
Brake hydraulic circuit diagram....................................................................................................................... 7
Work equipment hydraulic circuit diagram .....................................................................................................11
WA500-6R 1
SEN02901-03 90 Diagrams and drawings
2 WA500-6R
Power train hydraulic circuit diagram 1
WA500-6R 3
(with lockup clutch)
WA500-6R 5
Brake hydraulic circuit diagram 1
WA500-6R 7
(Forced brake cooling system attached)
WA500-6R 9
Work equipment hydraulic circuit diagram 1
WA500-6R 11
WA500-6R 13
SEN02901-03


© 2017 KOMATSU
All Rights Reserved
14
SEN02902-03
WA500-6R

WA500-6R 60001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Engine electrical circuit diagram ..................................................................................................................... 2
Air conditioner electrical circuit diagram ......................................................................................................... 3
Electrical circuit diagram ................................................................................................................................. 5
Connector arrangement diagram .................................................................................................................. 19
WA500-6R 1
SEN02902-03 90 Diagrams and drawings
Engine electrical circuit diagram 1
2 WA500-6R
Air conditioner electrical circuit diagram 1
WA500-6R 3
Electrical circuit diagram (1/7)
Electrical circuit diagram WA500-6R 1
(1/7)
SEN02902-03
WA500-6R 5
(2/7) WA500-6R
SEN02902-03
WA500-6R 7
(3/7) WA500-6R
SEN02902-03
WA500-6R 9
(4/7) WA500-6R
SEN02902-03
WA500-6R 11
(5/7) WA500-6R
SEN02902-03
WA500-6R 13
(6/7) WA500-6R
SEN02902-03
WA500-6R 15
(7/7) WA500-6R
SEN02902-03
WA500-6R 17
Connector arrangement diagram
WA500-6R
Connector arrangement diagram WA500-6R
Connector Number Address of Connector Number Address of Connector Number Address of Connector Number Address of
Model Component name Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram No. of pins stereogram
1.PS DT2 2 1st ECMV solenoid AI-3 E15 DT2 2 Dust indicator AD-9 JT2 DT2 6 Junction connector AI-6 LS2 DT2(Gr) 12 Intermediate connector (Floor – right console) U-2
1.SW DT1 2 1st ECMV fill switch AI-3 E16 DT2 2 Air conditioner compressor AD-1 JT3 DT2 6 Junction connector AN-7 LS3 DT2(Br) 12 Intermediate connector (Floor – right console) V-2
2.PS DT2 2 2nd ECMV solenoid AK-1 E17 DT2 2 Diode AE-5 KOM DT2(Gr) 12 Intermediate connector (KOMTRAX) Y-7 LS4 DT2(G) 12 Intermediate connector (Floor – right console) V-2
2.SW DT1 2 2nd ECMV fill switch AL-2 E18 DRC26 50 Engine controller AH-2 L01 Terminal 1 GND (Floor frame) X-4 LS8 DT2 4 Intermediate connector (3-spool valve EPC lever)
3.PS DT2 2 3rd ECMV solenoid AM-5 E19 DTP 4 Engine controller AG-1 L02 DRC26 24 Transmission controller W-7 LT1 HD24 31 Intermediate connector (Floor – transmission) AI-6
3.SW DT1 2 3rd ECMV fill switch AM-5 E21 DT2 3 CAN terminal resistance AH-2 L03 DRC26 40 Transmission controller X-7 NE FRAMATOME 3 Ne speed sensor AH-2
4.PS DT2 2 4th ECMV solenoid AL-2 E22 Terminal 1 GND (Engine unit) AD-2 L04 DRC26 40 Transmission controller X-7 PAMB AMP 3 Ambient pressure sensor AH-2
4.SW DT1 2 4th ECMV fill switch AM-3 E23 DT2 2 Electrical priming pump timer AG-1 L05 DRC26 24 Work equipment controller V-8 PB.PS DT2 2 Parking brake solenoid AN-6
AL1 DT2 6 Intermediate connector (Air conditioner unit) R-1 E24 DT2 6 Electrical priming pump AG-1 L06 DRC26 40 Work equipment controller W-8 PB.SW DT2 2 Parking brake indicator switch AJ-2
B01 DT2 3 Left brake oil pressure sensor N-4 E25 Terminal 1 Electrical priming pump timer GND AG-1 L07 DRC26 40 Work equipment controller W-7 PCV1 SUMITOMO 2 Supply pump AD-2
B02 DT2 2 Lift arm EPC cut-off solenoid N-4 E31 Terminal 1 Heater AD-3 L08 DT2(Gr) 12 Intermediate connector (VHMS wiring harness) X-5 PCV2 SUMITOMO 2 Supply pump AD-2
B03 DT2 2 Diode N-3 E32 Terminal 1 Heater relay L-9 L10 M 6 Intermediate connector (Printer wiring harness) W-8 PFUEL AMP 3 Common rail pressure sensor AF-1
B04 DT2 2 Brake accumulator low pressure switch (Rear) L-2 ENG DRC 60 Engine controller AH-1 L11 DT2 2 Pneumatic suspension seat W-7 PIM SUMITOMO 3 Charge pressure (Boost pressure) sensor AH-4
B05 DT2 2 Brake accumulator low pressure switch (Front) K-3 ER1 DT2(B) 12 Intermediate connector (Engine) J-4, AD-5 L14 DT2 2 Spare O-2 POIL FRAMATOME 3 Engine oil pressure sensor AF-1
B06 DT2 2 Rear emergency brake switch L-2 ER2 DT2(Gr) 12 Intermediate connector (Engine controller) J-3, AD-5 L15 DT2 6 Accelerator pedal O-2 R.PS DT2 2 R (Reverse) ECMV solenoid AM-3
B07 DT2 2 Front emergency brake switch K-3 ER3 L 2 Intermediate connector (Engine controller) J-5, AD-5 L16 DT2 2 Stop lamp switch U-1 R.SW DT 2 R (Reverse) ECMV fill switch AM-4
B09 KES0 2 Front windshield washer N-5 F.PS DT2 2 F (Forward) ECMV solenoid AM-4 L17 M 4 DC24V/DC12V converter V-8 R01 Terminal 1 Circuit breaker SBF1 L-9
B10 Terminal 1 GND (Rear frame) K-5 F.SW DT1 2 F (forward) ECMV fill switch AM-4 L19 KES1 4 Flasher unit X-4 R02 Terminal 1 Circuit breaker SBF1 L-9
B11 KES0 2 Rear windshield washer N-6 F01 DT2 6 Intermediate connector (Right combination lamp, headlamp) A-5 L20 M 2 Caution buzzer X-6 R03 Terminal 1 Circuit breaker SBF2 N-9
B12 DT2 2 Diode K-4 F02 DT2 6 Intermediate connector (Left combination lamp, headlamp) A-3 L21 KES1 6 Interval wiper timer X-5 R04 Terminal 1 Circuit breaker SBF2 N-9
B13 DT2 2 Diode K-5 F03 AMP 090 2 Horn Lo A-4 L22 S 10 Front/Rear wiper switch R-1 R05 Terminal 1 Circuit breaker SBF2 N-8
BL1 DT2(B) 12 Intermediate connector (Brake component box) N-5 F05 AMP 090 2 Horn Hi A-5 L25 X 1 Optional connector X-5 R06 Terminal 1 Circuit breaker SBF3 N-8
C01 YAZAKI 9 AM/FM radio D-8 F07 DT2 2 Lift arm raise EPC solenoid B-2 L26 DT1 1 Optional connector U-8 R07 Terminal 1 Slow blow fuse SBF3
C02 M 2 Speaker (Right) F-9 F08 DT2 2 Lift arm lower EPC solenoid C-1 L26 DT2(B) 8 Intermediate connector (3rd EPC) R08 Terminal 1 Slow blow fuse SBF2
C03 M 2 Speaker (Left) F-9 F09 DT2 2 Bucket tilt EPC solenoid C-1 L27 SWP 6 Spare (Wiper) R09 Terminal 1 GND (Rear frame) J-6
C04 M 2 Front working lamp (Right) C-7 F10 DT2 2 Bucket dump EPC solenoid B-1 L31 Terminal 1 Emergency parking release switch X-6 R10 Terminal 1 GND (Rear frame) I-8
C05 M 2 Front working lamp (Left) B-7 F11 DT2 3 Bucket level positioner proximity switch A-4 L32 Terminal 1 Emergency parking release switch X-6 R11 Terminal 1 Disconnecting switch
C07 KES1 2 Room lamp F-9 F12 DT2 3 Bucket tilt sensor proximity switch A-3 L34 Terminal 1 Emergency parking release switch X-6 R11 DT2 2 Parking brake emergency release solenoid H-2
C08 M 1 Right door switch (Room lamp) C-8 F13 DT2 3 Lift arm angle sensor E-1 L35 Terminal 1 Emergency parking release switch X-6 R12 X 2 Transmission oil filter clogging sensor H-2
C09 M 1 Left door switch (Room lamp) B-7 F14 DT2 3 Lift arm bottom pressure sensor (Load meter specification) D-1 L36 YAZAKI 2 12V DC outlet V-8 R13 DT2 2 Coolant level sensor H-2
C10 YAZAKI 2 Cigarette lighter B-7 F15 DT2 3 Lift arm rod pressure sensor (Load meter specification) D-1 L45 D-sub 25 Printer (If equipped) R14 Terminal 1 Heater relay L-8
C12 M 6 Front wiper motor A-6 F16 DT2 3 Loader pump pressure sensor B-1 L46 HOSHIDEN 4 Printer (If equipped) R15 Terminal 1 Heater relay L-9
C15 M 4 Rear wiper motor G-9 F20 Terminal 1 Ground (Front frame) A-3 L51 AMP 20 Machine monitor P-1 R16 DT2 2 Fuel level sensor J-4
C17 SWP 6 Auto grease switch (If equipped) E-9 F21 DT2 2 3-spool valve (Attachment) EXT EPC solenoid (If equipped) L52 AMP 18 Machine monitor P-2 R17 DT2 2 Rear brake oil temperature sensor J-3
C18 DT 2 Warning lamp (If equipped) B-7 F22 DT2 2 3-spool valve (Attachment) RET EPC solenoid (If equipped) L53 AMP 12 Machine monitor O-2 R18 DT2 2 Battery electrolyte level sensor J-6
C18A M 1 Auto grease (If equipped) A-7 F24 DT2 2 E.C.C.S. solenoid A-2 L54 AMP 18 Machine monitor O-4 R38 DT2 6 Auto grease controller (If equipped)
C19 SWP 6 Rear glass heater switch E-9 F31 DT-T 2 Multi-coupler extension solenoid (If equipped) L55 AMP 12 Machine monitor O-5 R87 DT 2 Intermediate connector (Front frame GND)
C22 DT 3 Rotary lamp (If equipped) F32 DT-T 2 Diode (If equipped) L56 AMP 12 Machine monitor P-2 RES DT 2 Resistor AH-3
C25 X 4 Intermediate connector (Warning lamp, rotary lamp) C-8 F33 DT-T 2 Multi-coupler retraction solenoid (If equipped) L57 AMP 14 Machine monitor O-5 REV OUT1 DT2 2 Speed sensor 1 AK-8
C29 M 1 Glass heater (If equipped) D-8 F34 DT-T 2 Diode (If equipped) L58 SWP 6 Parking brake switch O-5 REV OUT2 DT2 2 Speed sensor 2 AI-4
C33 Terminal 1 Rear glass heater E-9 FL1 DRC16 40 Intermediate connector (Floor – front frame) X-3 L59 SWP 6 E.C.S.S. switch S-1 RG1 DT2 6 Intermediate connector (Auto grease (If equipped)) G-2
C35 Terminal 1 Rear glass heater G-9 FL4 DT2 4 Intermediate connector (Attachment EPC solenoid) L61 SWP 6 Light switch/Dimmer switch Q-1 RS1 DT2 2 Left side working lamp (If equipped) I-3
C39 Terminal 1 Radio GND D-8 G SUMITOMO 3 Bkup speed sensor AD-1 L62 SWP 6 Turn and hazard switch P-6 RS2 DT2 2 Right side working lamp (If equipped) I-3
C40 Terminal 1 Cab GND E-9 G01 DT2 6 Right rear combination lamp H-9 L63 SWP 14 Gearshift switch Q-1 RT1 DT2(Gr) 12 Intermediate connector (Rear frame – radiator guard) AI-4
C47 Terminal 1 Beacon GND (If equipped) C-7 G02 DT2 6 Left rear combination lamp J-7 L64 DT2 2 Steering wheel horn switch O-6 S01 DT2 2 Lift arm neutral lock switch P-6
C47 JAE IL-AG5 22 Manual air conditioner controller D-8 G03 DT2 2 Right rear working lamp G-9 L65 SWP 6 Character display item selector switch S-1 S02 DT2 4 Lift arm and bucket EPC lever Q-8
C48 JAE IL-AG5 14 Manual air conditioner controller D-8 G04 DT2 2 Left rear working lamp J-8 L66 SWP 6 Character display mode selector switch S-1 S03 DT2 4 Lift arm and bucket EPC lever Q-8
C49 DT2(B) 12 Intermediate connector (Air conditioner) G-1 G06 DT2 2 Backup buzzer H-9 L69 SWP 6 Load meter mode switch (If equipped) T-1 S04 DT2 2 Lift arm and bucket EPC lever Q-8
C50 DT2(Gr) 12 Intermediate connector (Air conditioner) G-1 G09 DT2 2 Fan reverse solenoid H-9 L70 SWP 6 Load meter display selector switch (If equipped) T-1 S05 DT2 2 Lift arm and bucket EPC lever Q-9
C52 S 3 Multi-coupler switch E-9 GR1 DT2(Gr) 12 Intermediate connector (Radiator guard wiring harness) J-6 L72 SWP 6 Beacon lamp switch (If equipped) O-5 S06 DT2 2 Lift arm and bucket EPC lever P-7
C60 AMP 2 Daylight sensor I-3 HEAD DT2 3 Right headlamp A-5 L73 SWP 6 Left brake pedal switch R-1 S07 DT2 4 Lift arm kick-down switch and hold switch Q-8
C65 DT 3 Alarm buzzer (If equipped) HEAD DT2 3 Left headlamp F-1 L80 DRC 40 KOMTRAX Z-6 S08 DT2 4 Bucket control lever (Load meter specification) Q-8
C91 M 1 Intermediate connector (Warning lamp) C-8 INJ DT-T(B) 12 Intermediate connector (No. 1 – No. 6 injector) AG-1 L101 SHINAGAWA 5 Relay No. 1 Backup lamp AB-7 S09 DT2 4 Right gearshift switch (Steering wheel specification (If equipped)) Q-7
CAN1 DT2 3 CAN terminal resistance O-3 J1939 DT 3 CAN connector AG-6 L102 SHINAGAWA 6 Relay No. 2 Stop lamp AA-6 S10 SWP 6 Transmission cut-off ON/OFF switch R-7
CHK0 X 1 Intermediate connector (KOMTRAX) Z-6 JB1 DT2(B) 8 Junction connector K-4 L103 SHINAGAWA 5 Relay No. 3 Neutral safety AB-7 S11 SWP 6 RPM set ON/OFF switch S-8
CHK1 X 1 Intermediate connector (KOMTRAX) Y-7 JB2 DT2 6 Junction connector L-5 L104 SHINAGAWA 5 Relay No. 4 Lever AA-6 S12 SWP 6 RPM set idle up/down selector switch S-8
CL1 SWP 8 Intermediate connector (Floor – cab wiring harness) O-3 JB3 DT2 6 Junction connector N-3 L105 SHINAGAWA 5 Relay No. 5 Parking brake safety AB-8 S13 SWP 6 Lift arm position set switch R-7
CL2 SWP 12 Intermediate connector (Floor – cab wiring harness) O-3 JB4 DT2 6 Junction connector M-2 L106 SHINAGAWA 5 Relay No. 6 Preheating AA-6 S14 SWP 6 Bucket position set switch R-8
CL24 X 2 Intermediate connector (Multi-coupler solenoid) (If equipped) A-6 JE1 DT1 6 Junction connector AE-5 L107 SHINAGAWA 5 Relay No. 7 Dust indicator AA-8 S15 SWP 6 Hydraulic fan reverse switch S-8
CL26 X 2 Auto grease (If equipped) A-6 JE2 DT2 6 Junction connector AE-5 L108 SHINAGAWA 5 Relay No. 8 Horn Z-6 S16 DT2 4 Auto-shift mode switch Q-7
CN1 DT 2 No. 1 injector AD-3 JF1 DT2 6 Junction connector D-1 L109 SHINAGAWA 6 Relay No. 9 Front working lamp AA-8 S17 SWP 6 Engine power mode selector switch Q-7
CN2 DT 2 No. 2 injector AD-4 JF2 DT2(B) 8 Junction connector E-1 L110 SHINAGAWA 6 Relay No. 10 Rear working lamp Y-6 S18 SWP 6 Torque converter lockup switch Q-7
CN3 DT 2 No. 3 injector AF-5 JF3 DT2(B) 8 Junction connector E-1 L111 SHINAGAWA 5 Relay No. 11 Rear glass heater AA-8 S19 SWP 6 Transmission cut-off set switch R-7
CN4 DT 2 No. 4 injector AF-5 JF4 DT2 6 Junction connector A-4 L113 SHINAGAWA 5 Relay No. 13 Hazard AA-8 S20 SWP 6 Semi auto-digging selector switch S-8
CN5 DT 2 No. 5 injector AH-5 JG1 DT2(B) 12 Junction connector J-7 L114 SHINAGAWA 5 Relay No. 14 Fan motor Y-7 Right gearshift ON/OFF switch (Steering wheel specification
S21 SWP 6 R-8
(If equipped))
CN6 DT 2 No. 6 injector AH-5 JG2 DT2 6 Junction connector J-7 L115 SHINAGAWA 5 Relay No. 15 Headlamp Z-9
S25 DT2 4 3-spool valve (Attachment) EPC lever (If equipped)
COMBI DT2 3 Right front combination lamp A-6 JG3 DT2(B) 8 Junction connector J-8 L116 SHINAGAWA 5 Relay No. 16 Coolant level Y-8
S67 SWP 6 Front working lamp switch O-4
COMBI DT2 3 Left front combination lamp F-1 JL1 DT2(Gr) 8 Intermediate connector (Joystick steering) AB-2 L117 SHINAGAWA 5 Relay No. 17 Engine control cut 1 Z-9
S68 SWP 6 Rear working lamp switch O-4
D01 YAZAKI 3 Diode X-3 JL2 DTM 12 Joystick lever switch AB-3 L118 SHINAGAWA 5 Relay No. 18 Joystick cut-off Y-8
T01 DT2 2 Pump EPC solenoid AN-7
D01 Terminal 1 Right battery relay L-7 JL3 DT2 4 Intermediate connector (Joystick EPC solenoid) W-2 L119 SHINAGAWA 5 Relay No. 17 Engine control cut 2 Z-9
T02 DT2 2 Fan pump EPC solenoid AL-9
D02 YAZAKI 3 Diode X-4 JM01 — 5 Junction connector (Engine) AH-3 L120 SHINAGAWA 5 KOMTRAX engine cut relay Y-8
T03 DT2 2 Hydraulic oil temperature sensor AI-7
D02 Terminal 1 Left battery relay M-7 JM02 — 6 Junction connector (Engine) AH-2 L141 SHINAGAWA 5 Printer power supply relay (If equipped)
T04 DT2 2 Emergency steering drive switch AJ-7
D03 YAZAKI 2 Diode X-4 JM03 — 4 Junction connector (Engine) AH-2 L142 DT2 2 Diode (If equipped)
T05 DT2 2 Torque converter oil temperature sensor AK-8
D03 Terminal 1 Left battery relay L-8 JM04 — 4 Junction connector (Engine) AG-1 L143 DT2 2 Diode (If equipped)
TFUEL PACKARD 2 Fuel temperature sensor AH-4
D04 YAZAKI 2 Diode X-4 JM05 — 3 Junction connector (Engine) AH-3 L144 DT2 2 Diode (If equipped)
TGN Terminal 1 Transmission body GND AN-6
D04 Terminal 1 Right battery relay L-8 JM08 — 6 Junction connector (Engine) AG-6 L145 DT2 2 Diode (If equipped)
TIM PACKARD 2 Charge temperature (Boost temperature) sensor AH-4
D10 Terminal 1 Disconnecting switch JR1 DT2 6 Junction connector N-7 LC.PS DT2 2 Torque converter lockup ECMV solenoid AJ-2
TM.T DT2 2 Transmission oil temperature sensor AI-5
DIODE1 DT2 2 Diode AI-5 JR2 DT1(B) 8 Junction connector M-7 LR1 DTHD4 1 Intermediate connector (Slow blow fuse) W-3
TWTR PACKARD 2 Coolant temperature sensor AC-7
E01 DT2 2 Starting motor AC-5 JS1 SWP 6 Joystick ON/OFF switch (Joystick steering specification) AA-4 LR2 DT 2 Intermediate connector (Multi-coupler solenoid) (If equipped)
E03 Terminal 1 Alternator terminal R AF-7 JS2 SWP 6 Steering speed mode switch (Joystick steering specification) Z-4 LR2 L 2 Intermediate connector (Slow blow fuse) V-2
E04 Terminal 1 Alternator terminal B AF-7 JS3 DT2 4 Joystick lever potentiometer (Joystick steering specification) Y-4 LR3 L 2 Intermediate connector (Slow blow fuse) V-2
E05 Terminal 1 Alternator terminal E AF-7 JS4 DT2 2 Joystick neutral lock switch (Joystick steering specification) AA-2 LR4 L 2 Intermediate connector (Rear frame GND) X-3
E06 Terminal 1 Alternator GND AF-6 JS5 DT2 2 Joystick EPC solenoid (Joystick steering specification) Q-1 LR5 DRC16 70 Intermediate connector (Floor – rear frame) W-3
E08 Terminal 1 Starting motor AC-6 JS6 DT2 2 Joystick EPC solenoid (Joystick steering specification) Q-1 LR6 L 2 Intermediate connector (Engine controller) W-2
E11 DT2 2 Diode AE-5 JT1 DT2(B) 8 Junction connector AM-5 LS1 DT2(B) 12 Intermediate connector (Floor – right console) U-1
SEN02902-03
WA500-6R 19
WA500-6R 21
SEN02902-03

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SEN02876-12

WHEEL LOADER WA500 -6R

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

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

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02876-12

00 Index and foreword SEN02877-12

10 Structure, function and maintenance standard SEN02879-04

20 Standard value table SEN02880-02

30 Testing and adjusting SEN02881-07

Troubleshooting by failure code (Display of code), Part 1 SEN02933-00

50 Disassembly and assembly SEN02883-06

90 Diagrams and drawings SEN02884-06

10 Structure, function and maintenance standard

Steering system SEN02891-01

Engine stopping circuit............................................................................................................. 8

20 Standard value table

30 Testing and adjusting

Bleeding air from brake circuit ................................................................................................. 30

Failure code [2G42ZG] (Front accumulator: Low oil pressure) ................................................. 32

Failure code [DXHLKY] (Joystick steering right EPC solenoid:

H-29 Hydraulic drifts of bucket occur often .............................................................................. 37

50 Disassembly and assembly

Power train, Part 3 SEN02908-01

Troubleshooting chart 2 ........................................................................................................... 33

90 Diagrams and drawings

WA500-6R Wheel loader

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2007/03)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector