Escolar Documentos
Profissional Documentos
Cultura Documentos
Shop Manual
WHEEL LOADER
SERIAL NUMBER WA500H20051 and up
l This shop manual may contain attachments and optional equipment that are not available in your area.
Please consult your local KOMATSU distributor for those items you may require. Materials and specifications
are subject to change without notice.
© 2001
All Rights Reserved
Printed in Europe 10-01
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
00-2 WA500-3H
FOREWORD CONTENTS
12
00 CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
WA500-3H 00-3
FOREWORD SAFETY
12
00 SAFETY
00 SAFETY NOTICE
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
00 GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE
operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with
buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding
work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting.
Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct
places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert
the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers
and hang warning signs on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
00-4 WA500-3H
FOREWORD SAFETY
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad-
ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe footing.
2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and
water to cool before carrying out any work on the oil or water circuits.
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
WA500-3H 00-5
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from
damage. Always use lifting equipment which has ample
capacity. Install the lifting equipment at the correct
places. Use a hoist or crane and operate slowly to pre-
vent the component from hitting any other part. Do not
work with any part still raised by the hoist or crane.
00-6 WA500-3H
FOREWORD GENERAL
12
00 GENERAL
This shop manual has been prepared as an aid to improve the charts correlating “Problems” to “Causes” are also
quality of repairs by giving the serviceman an accurate included in this section.
understanding of the product and by showing him the correct
way to perform repairs and make judgements. Make sure DISASSEMBLY AND ASSEMBLY
you understand the contents of this manual and use it to full
effect at every opportunity. This section explains the order to be followed when
removing, installing, disassembling or assembling each
This shop manual mainly contains the necessary technical component, as well as precautions to be taken for these
information for operations performed in a service workshop. operations.
For ease of understanding, the manual is divided into the fol-
lowing sections. These sections are further divided into each MAINTENANCE STANDARD
main group of components.
This section gives the judgement standards when
GENERAL inspecting disassembled parts.
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
WA500-3H 00-7
FOREWORD HOW TO READ THE SHOP MANUAL
12
00 HOW TO READ THE SHOP MANUAL
00 VOLUMES
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is
necessary that chassis, engine, electrical and attachment be available.
00 FILING METHOD
1. See the page number on the bottom of the page. File the pages in correct order.
2. Following examples show how to read the page number:
Example:
10 - 3
3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the
example.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
00 REVISIONS
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
00 SYMBOLS
00-8 WA500-3H
FOREWORD HOW TO READ THE SHOP MANUAL
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following
symbols.
WA500-3H 00-9
FOREWORD HOISTING INSTRUCTIONS
12
00 HOISTING INSTRUCTIONS
00 HOISTING
• If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the relative parts.
2. Check for existence of another part causing interface with the part to be removed.
00 WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire ropes
(Standard “Z” or “S” twist ropes without galvanizing)
Rope diameter Allowable load
mm kN tons
10 9.8 1.0
11.2 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.
00-10 WA500-3H
FOREWORD HOISTING INSTRUCTIONS
2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the
hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
3. Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
4. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more
ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of
allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at
various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This
weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an
excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°
WA500-3H 00-11
FOREWORD COATING MATERIALS
12
00 COATING MATERIALS
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
• Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene • Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
• Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g • Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive • Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
500 g
Adhesives
Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container
Holtz • Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
• Quick hardening type adhesive.
Three
Polyethylene • Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container • Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
• Quick hardening type adhesive.
Aron- • Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 • Used mainly for adhesion of rubbers, plas-
tics and metals.
• Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high tem-
648-50 container
perature.
• Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
• Features: Resistance to heat
Gasket seal- • Used as sealant for flange surfaces and bolts
ant at high temperature locations; used to pre-
LG-3 790-129-9070 1 kg Can vent seizure.
• Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-12 WA500-3H
FOREWORD COATING MATERIALS
vent squeaking).
disulphide
lubricant
WA500-3H 00-13
FOREWORD STANDARD TIGHTENING TORQUE
12
00 STANDARD TIGHTENING TORQUE
mm mm Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
00-14 WA500-3H
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING
00 TORQUE OF HOSE NUTS
Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5
WA500-3H 00-15
FOREWORD ELECTRIC WIRE CODE
12
00 ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
00 CLASSIFICATION BY THICKNESS
Copper wire
Nominal num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 WA500-3H
FOREWORD CONVERSION TABLES
12
00 CONVERSION TABLES
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as j, then draw a horizontal line from j.
B. Locate the number 5 in the row across the top, take this as k, then draw a perpendicular line down from k.
C. Take the point where the two lines cross as l. This point l gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
k
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
l
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
j
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
WA500-3H 00-17
FOREWORD CONVERSION TABLES
12
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
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-18 WA500-3H
FOREWORD CONVERSION TABLES
12
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
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
WA500-3H 00-19
FOREWORD CONVERSION TABLES
12
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 WA500-3H
FOREWORD CONVERSION TABLES
12
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
WA500-3H 00-21
FOREWORD CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, con-
sider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column
at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
00-22 WA500-3H
01 GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
FUEL, COOLANT AND LUBRICATNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
ARCTIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14
WA500-3H 01-1
GENERAL
12
01-2 WA500-3H
12
SPECIFICATIONS
Travel speed:
FORWARD 1st 7.1 km/h (4.4 mph)
FORWARD 2nd 12.6 km/h (7.8 mph)
Performance
Gradeability 25 deg
Maximum torque (gross) @ 1400 rpm 908 N•m (670 lbf ft)
modulation type
Service brakes Front / rear wheel braking, separate front/rear wheel, wet disc,
Brakes
hydraulically actuated
Parking brake Drive shaft, wet type disc brake, hydraulically released spring type
01-4 WA500-3H
GENERAL SPECIFICATIONS
Control valve Set pressure for work equipment Spool type 210 kg/cm2 (2986.9 lbf/in2)
Set pressure for steering Orbit-roll valve type 210 kg/cm2 (2986.9 lbf/in2)
Cylinder Boom cylinder qty. - bore x stroke Reciprocating piston 2-200 x 839 (mm)
WA500-3H 01-5
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
Transmission with torque con- 2,524 lb (1,145 kg) Switch and PPC pump 42 lb (19 kg)
verter
Torque converter assembly 474 lb (215 kg) Steering pump 27 lb (12.2 kg)
Damper 201 lb (91 kg) Main control valve 199 lb (90 kg)
Upper drive shaft 40 lb (18 kg) Steering cylinder (each) 104 lb (47 kg)
Center drive shaft 73 lb (33 kg) Boom cylinder (each) 600 lb (272 kg)
Front drive shaft 99 lb (45 kg) Bucket cylinder 631 lb (286 kg)
Rear drive shaft 86 lb (41 kg) Engine hood (w/side panels) 496 lb (225 kg)
Front axle assembly 4,277 lb (1,940 kg) Rear frame 4,817 lb (2,185 kg)
Rear axle assembly 4,138 lb (1,877 kg) Bucket link 234 lb (106 kg)
Axle pivot (Rear axle) 114 lb (251 kg) Bellcrank 1,151 lb (522 kg)
Tire and wheel (each) 1,740 lb (789 kg) Boom including bushings 4,449 lb (2,018 kg)
Wheel (each) 591 lb (268 kg) Bucket with bolt on cutting edge 5,997 lb (2,720 kg)
Front differential assembly 591 lb (268 kg) Fuel tank 531 lb (241 kg)
Rear differential assembly 612 lb (278 kg) Battery (each) 117 lb (53 kg)
Planetary carrier (each) 137 lb (62 kg) Floor, dash, console 472 lb (214 kg)
Planetary hub (each) 227 lb (103 kg) Cab (ROPS) 1,005 lb (456 kg)
Steering valve 52 lb (23.5 kg) Air conditioner unit 117 lb (53 kg)
Brake valve (Tandem) 19 lb (8.5 kg) Front support 209.4 lb (95 kg)
Brake valve (Single) 12 lb (5.3 kg) Rear support 253.5 lb (115 kg)
01-6 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS
12
FUEL, COOLANT AND LUBRICATNTS
SAE 30
SAE 15W-40
Cooling 99 liters
Coolant See "COOLANT SPECIFICATIONS" on page 01-12. ---
system 26.2 gal
Other equipment will be necessary when operating the machine at temperatures below -20o C (-4o F). Consult your Komatsu
distributor for your needs.
API: American Petroleum Institute
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
WA500-3H 01-7
GENERAL FUEL, COOLANT AND LUBRICATNTS
12
ENGINE OIL
NORMAL OPERATION
Oil performance recommendations are as follows:
The use of a high quality engine lubricating oil combined with appropriate oil and filter change intervals are critical
factors in maintaining engine performance and durability. SAE 15W-40 multi-viscosity heavy duty engine oil meeting the
American Petroleum Institute (API) performance classification of CF-4 or CG-4 is recommended.
NOTE: CE oil may be used in areas where CF-4 or CG-4 oil is not yet available.
A sulfated ash content of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control.
The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all
engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead
to excessive oil consumption.
The API service symbol displays the following information: the upper half of the symbol displays the appropriate oil
categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the
SAE oil viscosity grade.
The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine cranking
in cold temperatures while maintaining lubrication at high operating temperatures. While SAE 15W-40 multi-viscosity oil
is recommended for most operating climates, refer to the table for oil viscosity recommendations for extreme climates.
Limited use of low viscosity oils, such as SAE 10W-30 is allowed to ease starting and provide sufficient oil flow at
ambient temperatures below -5°C (+23°F). However, continuous use of low viscosity oils can decrease engine life due to
wear.
Special "break-in" lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil during the
"break-in" as specified for normal operation.
Remark
Single grade oil may be mixed with multigrade oil (SAE 10W-30, SAE 15W-40), but make sure the single
grade oil matches the temperature range in the table. We recommend genuine Komatsu oil which has
been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Use of fuels with high sulfur content necessitates more frequent oil changes.
Additional information regarding lubricating oil availability throughout the world is available in the "E.M.A. Lubricating
Oils Data Book for Heavy Duty Automotive and Industrial Engines." The data book may be ordered from the Engine
Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601. The telephone
number is (312) 644-6610.
01-8 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS
12
Engine Oil
[CD or CE] Anti-freeze
Gear oil Grease
SAE10W, 30, 40, 10W30, Coolant
Supplier [GL-4 or GL-5] [Lithium base]
15W40 [ethylene glycol base]
SAE80, 90, 140 NLGI No. 2
(The 15W-40 oil marked Permanent Type
* is CE)
E010-CD G090 G2-LI AF-ACL
E030-CD G0140 G2-LI-S AF-PTL
Komatsu
E010-30CD AF-PT (winter, one-
E015-40CD season type)
Diesel sigma S super die- Rotra MP GR MU/EP
AGIP sel multi-grade -
*Sigma turbo
Amoco *Amoco 300 Multi-purpose gear oil PYKON premium grease -
Arcofleet S3 plus Arco HD gear oil Litholine HEP 2
ARCO -
Arco EP moly D
Vanellus C3 Gear oil EP Energrease LS-EP2 Anti-freeze
BP
Hypogear EP
*RPM delo 400 Universal thuban Marfak all-purpose 2 AF engine coolant
Caltex
RPM delo 450 Universal thuban EP Ultra-duty grease 2
*Turbomax EP MS3 Anti-freeze
*RX super EPX Spheerol EPL2
Castrol CRD Hypoy
Hypoy B
Hypoy C
Chevron *Delo 400 Universal gear Ultra-duty grease 2 -
*Fleet motor oil Universal gear lubri- Super-sta grease
Conoco -
cant
Multiperformance 3C Tranself EP Glacelf
ELF -
Performance 3C Tranself EP type 2
Essolube D3 Gear oil GP Beacon EP2 All-season coolant
Exxon *Essolube XD-3 Gear oil GX
(Esso) *Essolube XD-3 Extra
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Anti-freeze and coolant
Gulf
*Super Duty plus lubricant Gulfcrown EP special
Delvac 1300 Mobilube GX Mobilux EP2
Mobil *Delvac super Mobilube HD Mobilgrease 77 -
10W-30, 15W-40 Mobilgrease special
* Supreme duty fleet motor Multipurpose 4092 Multipurpose white grease
oil Multipurpose 4140 705 Anti-freeze and sum-
Pennzoil
707L White bearing mer coolant
grease
WA500-3H 01-9
GENERAL FUEL, COOLANT AND LUBRICATNTS
12
Engine Oil
[CD or CE] Anti-freeze
Gear oil Grease
SAE10W, 30, 40, 10W30, Coolant
Supplier [GL-4 or GL-5] [Lithium base]
15W40 [ethylene glycol base]
SAE80, 90, 140 NLGI No. 2
(The 15W-40 oil marked Permanent Type
* is CE)
Petrofine FINA kappa TD FINA potonic N Albania EP grease
-
FINA potonic NE
Shell Rimura X Spirax EP Albania EP grease
-
Spirax heavy duty
Sun Sunoco GL5 gear oil Sunoco ultra prestige 2EP Sunoco anti-freeze and
-
Sun prestige 742 summer coolant
Texaco *Ursa super plus Multigear Multifak EP2 Coda 2055 startex anti-
Ursa premium Starplex 2 freeze coolant
Total Rubia S Total EP Multis EP2 Antigal/anti-freeze
*Rubia X Total transmission TM
Union *Guardol MP gear lube LS Unoba EP -
Veedol *Turbostar Multigear Anti-freeze
*Diesel star Multigear B -
MDC Mutligear C
ARCTIC OPERATION
If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic API performance classification CE/SF engine oil with adequate low
temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the performance service specifications.
Remark
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change
intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
When using SAE 5W-20 engine oil in the work equipment hydraulic system in cold areas, return to SAE 10W when the cold
season ends.
AXLE OIL
For axle oil, use only the recommended oil as follows:
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL
* It is possible to substitute engine oil SAE 30W API classification CD for axle oil. Although increased brake noise may
result, durability should not be affected.
01-10 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS
GREASE
The recommended lubricating grease is No. 2 multi-purpose lithium grease with 3% molybdenum disulfide.
DIESEL FUEL
Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
Remark
The precise tolerances of diesel injection systems require that the fuel be kept clean and free of dirt and/or
water. Dirt or water in the system can cause severe damage to both the injection pump and nozzles.
For normal service above -12°C (+10°F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40 is
recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions.
Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent
misfires and excessive smoke.
At operating temperatures below -12°C (+10°F), use ASTM Grade No. 1-D diesel fuel. The use of lighter fuels can reduce fuel
economy.
Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel.
However, it is the supplier's responsibility to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud
point is the temperature at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3 cSt at 100°C (212°F) to provide adequate fuel system lubrication.
WA500-3H 01-11
GENERAL FUEL, COOLANT AND LUBRICATNTS
COOLANT SPECIFICATIONS
GENERAL
Selection and maintenance of the engine coolant is important to long engine life. The following information provides
recommendations for selecting the engine coolant and maintaining the supplemental coolant additive (SCA).
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additive.
Supplemental coolant additive recommendations are included in the section entitled See “SUPPLEMENTAL COOLANT
ADDITIVES” on page 14. The coolant mixture must be drained and replaced at the specified service interval shown in the
"MAINTENANCE SCHEDULE CHART" in your ORPERATION AND MAINTENANCE MANUAL or every two years of
operation, whichever comes first.
WATER
Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must
meet the following standards:
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water
containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause
scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale
deposits, corrosion or a combination of these.
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water
supplies meet these standards, water samples can be tested by water treatment laboratories. "Softened" water that is prepared
using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.
Remark
Never use water alone in the cooling system because corrosion will occur.
ANTIFREEZE
In climates where the temperature is above -37°C (-34°F), use a coolant mixture that contains 50 percent antifreeze.
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and
by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is
required. Never use more than 68 percent antifreeze under any condition.
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze
concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and should
not be used due to reduced heat transfer rates.
Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali
metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can
occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive.
DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain
corrosion protection.
Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
01-12 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS
12
Remark
Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection
against freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this system.
Sealer or anti-leak additives will cause plugging problems in the cooling system.
Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection
against freezing.
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
-70°F(-57°C) 62 1.092
-80°F(-62°C) 65 1.095
-90°F(-68°C) 67 1.097
-92°F(-96°C) 68 1.098
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor SCA, to protect the engine cooling
system.
WA500-3H 01-13
GENERAL FUEL, COOLANT AND LUBRICATNTS
2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer.
3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best
coolant.
4. SCA is recommended to inhibit corrosion in the cooling system for the following reasons:
• Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over-concentration occurs
• Provides engine protection in the following areas:
- Solder corrosion/bloom - Copper corrosion/erosion/stress cracking
- Oil fouling - Cylinder liner cavitation corrosion
- Aluminum cavitation corrosion - Seal and gasket degradation
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES
Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion.
New machines are delivered with antifreeze protection. Service at regular scheduled interval specified in the
"MAINTENANCE SCHEDULE CHART" in your ORPERATION AND MAINTENANCE MANUAL with a service DCA4
filter.
Each time the coolant is drained and replaced, the coolant must be recharged with SCA. New coolant can be correctly charged
with supplemental coolant additives by using a DCA4 service filter or SCA concentrate listed in the table entitled, “DCA4
Unit Guide”.
When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The SCA
concentration must not fall below 1.0 unit per 3.8 liters (1 US gal) or exceed 2.0 units per 3.8 liters (1 US gal) of coolant. The
only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis.
For this reason, the coolant inhibitor should be maintained as shown in the "GUIDES TO MAINTENANCE" in your
ORPERATION AND MAINTENANCE MANUAL.
Remark
Inadequate concentration of the supplemental coolant additive can result in major corrosive damage to
cooling system components. Over concentration can cause formation of "gel" that can cause restriction,
plugging of passages and overheating.
REPLENISHING COOLANT CONDITIONER
Install a “precharge” DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs. Install a
service DCA4 filter as specified in the "MAINTENANCE SCHEDULE CHART" in your ORPERATION AND
MAINTENANCE MANUAL. When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8 liters (1 US gal) of
antifreeze.
Remark
Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no
test kit available to measure concentration levels with mixed chemical solutions.
01-14 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze
alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection must
be supplied through periodic additions of supplemental coolant additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per U.S. gallon] of
coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant filter at each engine oil and
filter change interval.
Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant additives. Use the
appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be drained and replaced as defined under
“General”.
The amount of replacement inhibitor is determined by the length of the service interval and the cooling system capacity. Refer
to the DCA4 Unit Guide for the selection of the correct filter to replenish the SCA.
If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentration level
anytime make-up coolant is added to the system. The SCA concentration must not fall below 0.13 units per liter or exceed 0.5
units per liter [0.5 units per U.S. gallon or exceed 2.0 units per U.S. gallon].
DCA4 Powder 20
DCA95
NOTE 1:After draining and replacing coolant, always precharge the cooling system to maintain the SCA concentration
between 1.0 and 2.0 units per 3.8 liters (1 US gal).
WA500-3H 01-15
GENERAL FUEL, COOLANT AND LUBRICATNTS
Remark
When performing service which requires draining the cooling system, discard the coolant. Reusing coolant
can introduce contaminates or over concentrated chemicals, resulting in premature failure of cooling
system components.
NOTE 2: To precharge cooling systems larger than 114 liters (30 gal) do the following:
• Install appropriate service filter listed in the above table based on cooling system capacity.
• The answer represents the additional units required to precharge the cooling system. Four bottles of powder, part number
DCA95, will provide a sufficient amount of SCA units (80) to precharge the example cooling system.
• Install the appropriate service filter at the next and subsequent maintenance intervals.
NOTE 3: Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
Maintain a nominal SCA concentration of 1.0 unit per 3.8 liters (1 US gal) of coolant in the system. Less than 0.5 unit per 3.8
liters (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 liters (1 US gal) indicates an
over-concentrated coolant solution.
To check the SCA concentration level, use coolant test kit, CC-2606. Instructions are included with the test kit.
11 - 16 Drops Marginally under-concentrated -0.45 Add SCA liquid units to maintain 1.0
to 0.8 SCA units per 3.8 liters (1 US SCA unit per 3.8 liters (1 US gal)
gal) minimum or change the DCA 4 coolant
filter.
17 - 25 Drops Acceptable - 0.85 to 1.3 SCA units per None
3.8 liters (1 US gal)
01-16 WA500-3H
10 STRUCTURE AND FUNCTION
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
RADIATOR AND OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
TORQUE CONVERTER AND TRANSMISSION PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
HYDRAULIC CIRCUIT FOR POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
TORQUE CONVERTER AND PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
TRANSMISSION CUTAWAY FOLDOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
OPERATION OF CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
FORWARD 2ND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
FORWARD 3RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
FORWARD 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
REVERSE 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
TRANMISSION CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
ECMV (ELECTRONIC CONTROL MODULATION VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
OUTLINE OF ECMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
ECMV AND PROPORTIONAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
ECMV AND FILL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
ACTUATION OF ECMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
LUBRICATING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
TORQUE CONVERTER OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
PILOT FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
NORMAL - (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
LIMITED SLIP (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
TIRE AND WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
STEERING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
STEERING COLUMN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
STEERING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
DEMAND VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
STEERING SPOOL AT NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
WA500-3H 10-1
STRUCTURE AND FUNCTION
STEERING SPOOL OPERATED - ENGINE AT LOW SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
STEERING SPOOL OPERATED - ENGINE AT HIGH SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
FLOW AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
FLOW AMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
STEERING VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
STEERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
RELIEF VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69
SAFETY VALVE (WITH SUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
ORBIT-ROLL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
STOP VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
DIVERTER VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
BRAKE CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
RIGHT BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
LEFT BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
CHARGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
ACCUMULATOR (FOR BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
PARKING BRAKE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
MACHINES WITH STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
WORK EQUIPMENT LEVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
OIL FILTER BY-PASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
ACCUMULATOR (FOR PPC VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
FOR BUCKET / BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
FOR OPTIONAL ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
PPC VALVE NEUTRAL POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
PPC VALVE POSITIONS FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
CUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
2-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
3-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
SAFETY VALVE (WITH SUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
FLOAT SELECTOR VALVE AND UNLOAD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
BOOM AND DUMP SPOOLS AT HOLD POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
BOOM SPOOL AT RAISE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
BOOM SPOOL AT LOWER POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
BOOM SPOOL AT FLOAT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
BUCKET SPOOL AT DUMP POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
BUCKET SPOOL AT TILT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
10-2 WA500-3H
STRUCTURE AND FUNCTION
BUCKET POSITIONER AND BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
PROXIMITY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
AIR CONDITIONING (GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
BASIC INFORMATION ON AIR CONDITIONERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-153
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
HUMIDITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
PRINCIPLE OF COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
REFRIGERANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
FREON-TYPE GASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
REFRIGERATOR OIL (LUBE OIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
AIR CONDITONING CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165
RECEIVER WITH SIGHT GLASS (LIQUID TANK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
MONITOR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
MAIN MONITOR DISPLAY FUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
MAIN MONITOR SWITCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
TROUBLE DATA DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173
MAINTENANCE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
MAINTENANCE MONITOR DISPLAY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
MAINTENANCE MONITOR SWITCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC
TRANSMISSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
SYSTEM STRUCTURE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
TRANSMISSION CONTROLLER POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
INPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
OUTPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
LED DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
ECSS SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
CONNECTOR SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
SPEEDOMETER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
ENGINE OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
RADIATOR WATER LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
ENGINE OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-199
ENGINE WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200
TORQUE CONVERTER OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-202
ENGINE STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-202
SAFETY RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-203
ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
ELECTRICAL TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
WA500-3H 10-3
STRUCTURE AND FUNCTION
COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
KICK-DOWN / HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
KICK-DOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
WHEN KICK-DOWN SWITCH IS OPERATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
KICK-DOWN SWITCH OPERATION CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211
ELECTRIC PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-213
PARKING BRAKE EMERGENCY RELEASE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215
EMERGENCY BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215
PARKING SAFETY RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
NEUTRALIZER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
ECSS WIRING DIAGRAM - FOLDOUT 10-225-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
JOYSTICK STEERING WIRING DIAGRAM - FOLDOUT 10-225-2 . . . . . . . . . . . . . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-3, (Sheet 1) (Part 1 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-4, (Sheet 1) (Part 2 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-5, (Sheet 1) (Part 3 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-6, (Sheet 1) (Part 4 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-7, (Sheet 1) (Part 5 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-8, (Sheet 2) (Part 1 of 4) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-9, (Sheet 2) (Part 2 of 4) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-10, (Sheet 2) (Part 3 of 4) . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-11, (Sheet 2) (Part 4 of 4) . . . . . . . . . . . 10-225
ENGINE FLOOR HARNESS DIAGRAM - FOLDOUT 10-225-12 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
CAB ELECTRICAL DIAGRAM - FOLDOUT 10-225-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
ENGINE HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-226
ENGINE - FRAME - FLOOR HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-227
10-4 WA500-3H
STRUCTURE AND FUNCTION GENERAL
12
GENERAL
OUTLINE
The power from the engine (1) is transmitted from the flywheel to damper (2) through the ring gear. The damper alleviates the
torsional vibration caused by the variation of the engine torque and transmits the power to torque converter (4) through drive
shaft (3). The torque converter converts the delivered torque according to the variation in the load on the oil used as the
medium, and transmits the power to the input shaft of transmission (10). The engine power then is transmitted to PPC pump
(7), steering pump (9), hydraulic pump (8), switch pump (6), and torque converter charging pump (5) through the pump driv-
ing gear in torque converter (4).
In transmission (10), the six hydraulic clutches are operated by the forward-reverse spool and the speed change spools in the
transmission valves, which are themselves activated by solenoid valves. Thus, the desired travel speed can be selected from
among the 4 forward and 4 reverse gear speeds.
A multiple disc parking brake is installed to the output shaft of transmission (10). At the front end, the power from the output
shaft passes through center drive shaft (12) and front drive shaft (14) and is transmitted to front differential (15), at the rear end
it is transmitted to rear differential (20) by rear drive shaft (19).
The power transmitted to front differential (15) and rear differential (20) is transmitted to the axle shafts.
The power from the axle shafts has its speed reduced by final drives (16) and (21), and it is then transmitted to tires (18) and
(23) through the planetary carrier.
WA500-3H 10-5
STRUCTURE AND FUNCTION GENERAL
12
3. Upper drive shaft 11. Parking brake 19. Rear drive shaft
5. Torque converter charging pump 13. Center support 21. Rear final drive
10-6 WA500-3H
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
1. Radiator SPECIFICATIONS:
2. Coolant level sensor Radiator
3. Fan guard • Radiator core type: G7 type
4. Torque converter oil cooler • Total heat dissipation area: 98.44 m2
5. Hydraulic oil cooler • Cross-sectional area of water flow: 193.8 cm2
WA500-3H 10-7
STRUCTURE AND FUNCTION DAMPER
12
DAMPER
1. Coupling 5. Bearing
FUNCTION
The damper reduces the twisting and vibration caused by the variations in the engine torque, and acts to protect the engine and
other parts from such twisting and vibration.
10-8 WA500-3H
STRUCTURE AND FUNCTION DAMPER
12
OPERATION
The engine power is transmitted to the flywheel and outer body (6) and rubber cushion (7) absorbs the twist and vibration of
the engine. The engine power is then transmitted through the inner body (8) to output shaft (2). From here, the engine power is
transmitted through the coupling to the torque converter and drive shaft.
WA500-3H 10-9
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
12
TORQUE CONVERTER AND TRANSMISSION PIPING
10-10 WA500-3H
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
12
MEMORANDUM
WA500-3H 10-11
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT FOR POWER TRAIN
12
HYDRAULIC CIRCUIT FOR POWER TRAIN
10-12 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
12
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
1. Transmission case 11. Pilot oil filter 22. Flow detector valve
2. Strainer 12. Parking brake solenoid valve 23. Pressure control valve
6. Torque converter relief valve 16. FORWARD ECMV 27. 4th clutch
8. a. Oil cooler (water-cooled type) 18. 3rd ECMV 29. 1st clutch
WA500-3H 10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER AND PTO
12
TORQUE CONVERTER AND PTO
10-14 WA500-3H
STRUCTURE AND FUNCTION TORQUE CONVERTER AND PTO
12
Flow of motive force
The motive force of pump (10) uses oil to rotate turbine (8). This transmits
motive force to transmission input shaft (12).
The motive force of drive case (7) passes through PTO gear (drive) (13)
and is also used as the motive force to drive the gear pump.
Flow of oil
The oil pressure is adjusted by the torque converter relief valve and then
enters inlet port A, passes through the oil passage in housing (9) and flows
to pump (10). In pump (10) centrifugal force is applied. The oil enters tur-
bine (8) and the energy of the oil is transmitted to the turbine.
Turbine (8) is fixed to transmission input shaft (12), so the motive force is
transmitted to the transmission input shaft (12).
The oil from turbine (8) is sent to stator (11) and again enters the pump.
However, part of the oil passes from the stator through outlet port B and is
sent to the cooler.
WA500-3H 10-15
STRUCTURE AND FUNCTION TRANSMISSION
12
TRANSMISSION
10-16 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12
A. To torque converter I. Mount port for parking brake actuation pilot lamp
WA500-3H 10-17
STRUCTURE AND FUNCTION TRANSMISSION
12
TRANSMISSION CUTAWAY FOLDOUT
Refer to FOLDOUT 10-18 in Section 90.
1. Input shaft 11. No. 3 clutch 21. No. 6 gear (90 teeth)
2. No. 1 sun gear (22 teeth) 12. No. 3 ring gear (75 teeth) 22. No. 6 clutch
3. No. 1 planet gear (24 teeth) 13. No. 4 sun gear (33 teeth) 23. No. Output shaft
4. No. 1 ring gear (90 teeth) 14. No. 4 planet gear (21 teeth) 24. No. 5 carrier
5. No. 1 clutch 15. No. 4 ring gear (21 teeth) 25. No. 3, 4 carrier
6. No. 1 idler gear (70 teeth) 16. No. 4 clutch 26. No. 2 planet gear (23 teeth)
7. Lubrication relief valve 17. No. 5 sun gear (39 teeth) 27. No. 2 sun gear (23 teeth)
8. No. 2 clutch 18. No. 5 planet gear (21 teeth) 28. No. 2 carrier
10. No. 3 planet gear (30 teeth) 20. No. 5 clutch 30. No. 2 ring gear (75 teeth)
10-18 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12
OUTLINE
The transmission consists of a 4-FORWARD, 4-REVERSE speed Speed range Clutch combination
planetary gear transmission, transfer, and transmission F1 No.2, No. 6
control valve. In the transmission, the motive force of the input shaft is
changed by the combination of No.1 or No.2 clutch with No. 3, 4, 5 or 6 F2 No.2, No. 5
clutch to give FORWARD 1 - 4 or REVERSE 1 - 4 speed, and is
transmitted to the output shaft F3 No.2, No. 4
F4 No.2, No. 3
R1 No.1, No. 6
R2 No.1, No. 5
R3 No.1, No. 4
R4 No.1, No. 3
OPERATION OF CLUTCH
Engaged
The oil sent from the transmission control valve passes through the oil
passage inside the transmission. When it reaches the rear piston (1), it
moves the piston (1).
When the piston (1) moves, disc (2) and plate (3) are pressed together. Ring
gear (4) is meshed with disc (2), so the rotation is stopped.
Disengaged
When the supply of oil from the transmission control valve is shut off, the
pressure of the oil is acting on the rear of piston (1) is reduced. The piston
is then pushed back to the right by return spring (5), and disc (2) and plate
(3) are separated. Ring gear (4) then rotates freely, and no motive force is
transmitted.
WA500-3H 10-19
STRUCTURE AND FUNCTION TRANSMISSION
12
FORWARD 1ST
In 1st FORWARD, No. 2 clutch and No. 6 clutch are engaged. The motive force transmitted from the torque converter by input
shaft (2) is transmitted to output shaft (31).
No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gear (15) in position. No. 6
clutch is actuated by the hydraulic oil pressure applied to the clutch piston and holds gear (29) to carrier (32).
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft (2) is
transmitted to planetary gear (14) through sun gear (13).
Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). This carrier is connected to No. 5 carrier (32) through No. 4 ring gear (23, so when No. 6 clutch is
actuated, the rotation of carrier (32) is transmitted to gear (29) and rotates output shaft (31).
10-20 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12
FORWARD 2ND
In 2nd FORWARD, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter by
input shaft (2) is transmitted to output shaft (31).
No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15) and (27) in position.
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft (2) is
transmitted to planetary gear (14) through sun gear (13).
Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). The rotation of carrier (33) is transmitted through ring gear (23) to carrier (32).
Ring gear (27) is held in position by No. 5 clutch, so the rotation of carrier (32) rotates planetary gear (26). The planetary gear
rotates on the inside of ring gear (27), and rotates sun gear (25). The sun gear rotates output shaft (31).
WA500-3H 10-21
STRUCTURE AND FUNCTION TRANSMISSION
12
FORWARD 3RD
In 3rd FORWARD, No. 2 clutch and No. 4 clutch are engaged. The motive force transmitted from the torque converter by
input shaft (2) is transmitted to output shaft (31).
No. 2 clutch and No. 4 clutch are actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15)
and (23) in position.
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to
planetary gear (14) through sun gear (13).
Ring gear (15) is held in position by No. 2 clutch, so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). Ring gear (23) is held in position by No. 4 clutch, so the rotation of carrier (33) is transmitted to
planetary gear (22) rotates on the inside of ring gear (23), and rotates sun gear (21). The sun gear rotates output shaft (31).
10-22 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12
FORWARD 4TH
In 4th FORWARD, No. 2 clutch and No. 3 clutch are engaged. The motive force transmitted from the torque converter by
input shaft (2) is transmitted to output shaft (31).
No. 2 clutch and No. 3 clutch are actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15)
and (19) in position.
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to
planetary gear (14) through sun gear (13).
Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). Ring gear (19) is held in position by No. 3 clutch, so the rotation of carrier (33) is transmitted to
planetary gear (18). The planetary (18) rotates on the inside of ring gear (19), and rotates sun gear (17), which forms one unit
with output shaft (31).
WA500-3H 10-23
STRUCTURE AND FUNCTION TRANSMISSION
12
REVERSE 1ST
In 1st REVERSE, No. 1 clutch and No. 6 clutch are engaged. The motive force transmitted from the torque converter by input
shaft (2) is transmitted to output shaft (31).
No. 1 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks carrier (35) in position. No. 6 clutch
is actuated by the hydraulic pressure applied to the clutch piston and hold ring gear (29) in position.
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to
planetary gear (10) through sun gear (9).
Carrier (35) is held in position by No. 1 clutch, so the rotation of planetary gear rotates the ring gear. Ring gear (15) rotates in
the opposite direction from the input shaft. Ring gear (15) rotates carrier (34), and the rotation of carrier (34) rotates ring gear
(23), which then rotates carrier (32). Carrier (32) rotates No. 6 clutch (30). When No. 6 clutch is actuated, the rotation of car-
rier (32) is transmitted to gear (29) and rotates output shaft (31).
10-24 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12
MEMORANDUM
WA500-3H 10-25
STRUCTURE AND FUNCTION TRANMISSION CONTROL VALVE
12
TRANMISSION CONTROL VALVE
10-26 WA500-3H
STRUCTURE AND FUNCTION TRANMISSION CONTROL VALVE
Clutch
Speed range
FORWARD REVERSE 3rd 4th 2nd 1st
Auto ● ●
N
Manual ● ● ● ●
F1 ● ●
F2 ● ●
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When at manual N, the clutch of the speed range where the gear shift lever is placed, is ON.
WA500-3H 10-27
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
A. To clutch 1. Connector
P. From pump
10-28 WA500-3H
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
3. Spring 7. Pin
6. Fill switch
WA500-3H 10-29
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
OUTLINE OF ECMV
The ECMV (Electronic Control Modulation Valve) consist of two valves:
The pressure control valve and the flow detection valve.
Pressure control valve
The proportional solenoid receives the flow of electricity sent from the
transmission controller, and the pressure control valve converts this into
hydraulic pressure.
Flow detection valve
This valve is actuated by a trigger from the pressure control valve and has
the following functions:
1. When the clutch is filled with oil, it sends a signal (fill signal) to the
controller to inform the controller that the filling is completed.
10-30 WA500-3H
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
ACTUATION OF ECMV
The ECMV is controlled by the command current from the transmission
controller to the proportional solenoid and the fill switch output signal. The
relationship between ECMV proportional solenoid command current and
the clutch input pressure and fill switch output signal is as shown in the
diagram on the right.
WA500-3H 10-31
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
2. Start of fill (when trigger command is input to pressure control valve) -
Range B in graph (See graph on page prior).
When there is no oil inside the clutch, if the trigger current is applied
to proportional solenoid (5) (if the maximum current is applied), the
proportional solenoid moves and pressure control valve spool (4)
moves to the left.
As a result, the circuit between pump port P and the pressure control
valve output port B opens, and oil passage through orifice “a” of flow
direction valve spool (9) and starts to fill the clutch.
B. When the clutch is filled with oil, the oil stops flowing from
pressure control valve output port B to clutch port A. The area
receiving the pressure on the left and right sides of orifice a of
flow detection valve spool (9) is different. The left side is larger,
so when the oil pressure on both sides of orifice a becomes equal,
fill switch spring (8) is compressed, and as a result, pin (7)
contacts fill switch (6) and sends the clutch fill completion signal
to the shift controller. At this point, the default pressure current is
flowing to proportional solenoid (5), and the oil pressure is set to
the default pressure setting by pressure control valve spool (4).
10-32 WA500-3H
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
4. Adjusting pressure (Range D in graph)
When electric current flows to proportional solenoid (5), the solenoid
generates a force proportional to the current. The total of this
propulsion force of the solenoid and the propulsion force of the oil
pressure at the clutch port and the reaction force of pressure control
valve spring (3) is balanced. Flow detection valve spool (9) is pushed
to the right by the difference in the force of the oil pressure applied to
both sides of orifice a, and it continues to send the fill signal to the
shift controller.
WA500-3H 10-33
STRUCTURE AND FUNCTION MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
12
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
1. Body 6. Main relief valve A. Drain port (torque converter relief) P1 Main relief oil pressure detection port
OUTLINE
Specified pressure
1. Main relief valve
Main relief valve (6) sets the pressure of the transmission oil. 35.9 kgf/cm2 (510.6 lbf/
Main relief pressure
in2) engine at rated speed
2. Torque converter relief valve
Torque converter relief valve (2) acts to protect the torque converter Torque converter inlet 8.5 kgf/cm2 (120.8 lbf/in2)
port pressure cracking pressure
from abnormally high pressure. It relieves the pressure when the
pressure at the port of the torque converter goes above the inlet
specified pressure.
10-34 WA500-3H
STRUCTURE AND FUNCTION MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
12
MAIN RELIEF VALVE
OPERATION
The oil from the torque converter charging pump passes through the filter,
enters port A of the main relief valve, and then passes through orifice a and
enters port B. When the oil from the pump fills the circuit, the pressure
starts to raise. When the oil pressure in the circuit rises, the oil entering port
B pushes piston (4). The reaction compresses spring (7) and moves main
relief valve (6) to the left to open the passage between port A and port C.
When this happens, the oil from the pump is relieved from port A to port C
and flows from port C into the torque converter. The oil pressure at port A
at this point is 35.9 kgf/cm2 (510.6 lbf/in2) when the engine is at rated
speed.
The oil relieved from the main relief valve flows from port C into the
torque converter, and at the same time, passes through orifice b and enters
port D. When the oil fills the circuit to the torque converter, the oil pressure
starts to raise.
When the oil pressure in the circuit to the torque converter rises, the oil
entering port D pushes piston (9). The reaction compresses spring (3), and
moves relief valve (2) to the right to open the passage between port C and
port E. When this happens, the oil from port C is relieved to port E and
flows to the transmission lubrication circuit. The oil pressure at port C at
this point is 8.5 kg/cm2 (120.8 lbf/in2) cranking (starting) pressure.
WA500-3H 10-35
STRUCTURE AND FUNCTION LUBRICATING RELIEF VALVE
12
LUBRICATING RELIEF VALVE
2. Spring B. Drain
OUTLINE
Unit: kgf/cm2 (lbf/in2)
The lubricating relief valve is assembled to the left face of the REVERSE
clutch housing, and protects the lubricating circuit and oil cooler
Specified value
10-36 WA500-3H
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
12
TORQUE CONVERTER OIL FILTER
OPERATION
The oil from the torque converter charging pump enters the filter inlet port
A and passes from the outside of element (2) to the inside. It then flows to
the outlet port B.
If the element (2) is clogged with dirt, or the oil temperature is low, the
pressure at the inlet port A rises. When this happens, the oil from the inlet
port A opens relief valve (1) and flows directly to the outlet port B. This
prevents damage to the pump or element (2).
WA500-3H 10-37
STRUCTURE AND FUNCTION PILOT FILTER
12
PILOT FILTER
SPECIFICATIONS
OUTLINE
The oil flows from the transmission case to pump to torque converter oil filter, and is then divided and flows to the torque
converter and transmission control valve.
There is a pilot filter installed at the inlet port of the transmission control valve, and this filters the dirt out of the oil flowing to
the control valve.
10-38 WA500-3H
STRUCTURE AND FUNCTION TRANSFER
12
TRANSFER
OUTLINE
The transfer is installed at the power output end of the transmission and is secured to the transmission case by bolts.
TRANSMISSION PATH
Output shaft (1) of the transmission is coupled to transfer input gear (2) by a spline. The motive force is transmitted to output
gear (4) through idler gear (3) and output shaft (5).
Part of the power transmitted to the output shaft is transmitted to the front axle through the center drive shaft and front drive
shaft. The rest of the power is transmitted to the rear axle through the rear drive shaft.
WA500-3H 10-39
STRUCTURE AND FUNCTION DRIVE SHAFT
12
DRIVE SHAFT
OUTLINE
The motive force from the engine passes through the damper, upper drive shaft (5), torque converter, transmission and transfer.
Part of this motive force passes through rear drive shaft (4) and goes to the rear axle: the rest of the motive force passes
through center drive shaft (3), center support (2) and front drive shaft (1) and is sent to the front axle. In addition to transmit-
ting the motive force, the drive shafts have the following purposes.
When the body is articulated, or when there is shock from the road surface during traveling, or when there is shock during
operations, the axle in front and behind the engine and transmission change position.
To allow the motive force to be transmitted without damage to parts of the machine when there is shock or when the
components move position, the drive shafts have a universal joint and a sliding joint. This allows them to handle changes in
angle and length.
10-40 WA500-3H
STRUCTURE AND FUNCTION CENTER SUPPORT
12
CENTER SUPPORT
FUNCTION
The center support is installed to the front frame between the center drive shaft and the front drive shaft.
With the articulating frame, this part is constantly twisting from side to side, so there is liable to be a large amount of stress on
the drive shafts. Therefore, the center support is used to transmit the power smoothly, to reduce the stress on the drive shafts,
and improve the durability of the drive shafts.
WA500-3H 10-41
STRUCTURE AND FUNCTION AXLE
12
AXLE
FRONT
10-42 WA500-3H
STRUCTURE AND FUNCTION AXLE
12
REAR
WA500-3H 10-43
STRUCTURE AND FUNCTION DIFFERENTIAL
12
DIFFERENTIAL
NORMAL - (STANDARD)
FRONT
10-44 WA500-3H
STRUCTURE AND FUNCTION DIFFERENTIAL
12
REAR
WA500-3H 10-45
STRUCTURE AND FUNCTION DIFFERENTIAL
12
OUTLINE
The motive force from the drive shaft passes through bevel pinion (1) and
is transmitted to the bevel gear (5). The bevel gear changes the direction of
the motive force by 90° and at the same time reduces the speed. It then
transmits the motive force through the differential (4) to the sun gear shaft
(2).
When the machine is driven straight forward, the rotating speed of the left
and right wheels is the same, so the pinion gear (4) inside the differential
assembly (6) is sent through the pinion gear (4) and the side gear (3) and is
transmitted equally to the left and right sun gear shafts (2).
WHEN TURNING
When turning, the rotating speed of the left and right wheels is different, so
the pinion gear (4) and side gear (3) inside the differential assembly rotate
in accordance with difference between the rotating speed of the left and
right wheels. The motive force of the carrier (6) is then transmitted to the
sun gear shafts (2).
10-46 WA500-3H
STRUCTURE AND FUNCTION DIFFERENTIAL
12
LIMITED SLIP (OPTION)
The power transmitted from the transmission goes from bevel pinion (11) to case (9), pressure ring (4), shaft (8), pinion (10),
side gear (7) and is then divided and sent to left and right shafts (6). A brake mechanism consisting of disc (2) and
washer (1) is assembled at the rear face of side gear (7), and the brake torque is generated in proportion to the torque
transmitted from pressure ring (4) to shaft (8).
In order for this brake torque to act to suppress the rotation in relation to side gear (7) and case (9), it is made difficult for left
and right side gears (7) to rotate mutually, and the action of the differential is suppressed.
WA500-3H 10-47
STRUCTURE AND FUNCTION DIFFERENTIAL
12
Mechanism for generation of brake torque of left and right side
gears (6)
Shaft (8) is supported by the cam surface cut into the mating surfaces of
left and right pressure rings (4). The power (= torque) transmitted from
pressure ring (4) to shaft (8) is transmitted by the cam surface, but force Fa
to separate left and right pressure rings (4) is generated in proportion to the
torque transmitted by the angle of this cam surface. This separation load Fa
acts as a brake on the rear face of left and right side gears (7) and
generates brake torque.
10-48 WA500-3H
STRUCTURE AND FUNCTION DIFFERENTIAL
12
2. When there is imbalance between drive force of left and right wheels
[The road surface condition (friction coefficient) for the left and right
wheels and the load on the wheels are not uniform and the wheel on
one side tends to slip more than the wheel on the other side.]
The power from the transmission is divided uniformly to the left and
right by the actuating gear. However, if the divided drive force exceeds
the wheel slip limit on the side where the wheel is slipping, a drive
force equal to the excess is sent through the brake at the rear face of
the side gear and the case to the brake on the opposite side (side where
wheel is locked), and is supplied to the wheel on the side which is
locked. If this excess drive force becomes greater than the braking
force, the differential starts to be actuated.
Limited slip
differential 1 2.64 3.64 (1.82)
(option)
Torque
proportioning
1 1.38 2.38 (1)
differential
(standard)
Normal
1 1 2 (0.84)
differential
On road surfaces where the wheel on one side is likely to slip, the limited slip differential increases the drive force 1.82 times
that of the torque proportioning differential supplied as standard.
When turning
The actuating gear built into the limited slip differential is the same as the gear used on the normal differential, so the
difference in rotation of the inside and outside wheels generated when turning can be generated smoothly.
WA500-3H 10-49
STRUCTURE AND FUNCTION FINAL DRIVE
12
FINAL DRIVE
OUTLINE
To gain a large drive force, the final drive uses a planetary gear system to reduce speed and send drive force to the tires.
10-50 WA500-3H
STRUCTURE AND FUNCTION FINAL DRIVE
12
OPERATION
The motive force transmitted from the differential through axle shaft (1) to
sun gear (5) is transmitted to planetary gear (2). The planetary gear rotates
around the inside of a fixed ring gear (3) and in this way transmits rotation
at a reduced speed to the planetary carrier (4). This motive force is then
sent to the wheels (6) which are installed to the planetary carriers (4).
WA500-3H 10-51
STRUCTURE AND FUNCTION AXLE MOUNT
12
AXLE MOUNT
10-52 WA500-3H
STRUCTURE AND FUNCTION AXLE MOUNT
12
3. Front frame
FRONT AXLE
The front axle (1) receives the force directly during operations, so it is fixed directly to the front frame (3) by axle mounting
bolts (5).
REAR AXLE
The rear axle (2) has a structure which allows the center of the rear axle to float, so that all tires can be in contact with the
ground when traveling over soft ground.
WA500-3H 10-53
STRUCTURE AND FUNCTION CENTER HINGE PIN
12
CENTER HINGE PIN
OUTLINE
The front frame (3) and rear frame (4) are connected through a bearing by the center hinge pin (5) and (6). The steering cylin-
ders are connected to the left and right front and rear frames, so when the cylinders are operated, the frame bends at the middle
to give the desired angle, that is the desired turning radius.
10-54 WA500-3H
STRUCTURE AND FUNCTION TIRE AND WHEEL
12
TIRE AND WHEEL
The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with
the ground to gain the power which drives the machine. Various types of tires are available to suit the purpose. Therefore it is
very important to select the correct tires for the type of work and bucket capacity.
3. Air valve
SPECIFICATIONS
WA500-3H 10-55
STRUCTURE AND FUNCTION STEERING PIPING
12
STEERING PIPING
3. Stop valve (R.H.) 7. Switch pump and PPC pump 11. Steering cylinder (L.H.)
See Section 90 for illustration, Joystick Steering Assembly Diagram and Steering Line Assembly Diagram,
FOLDOUTS 10-54-1 thru 10-54-2.
10-56 WA500-3H
STRUCTURE AND FUNCTION STEERING COLUMN
12
STEERING COLUMN
WA500-3H 10-57
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING VALVE
3. Steering spool
10-58 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
DEMAND VALVE OPERATION
STEERING SPOOL AT NEUTRAL
The oil from the steering pump enters port A, and the oil from the switch pump enters port B. When steering spool (2) is at
neutral, pressure-receiving chamber II is connected to the drain circuit through orifice b, and notch c is closed. Notch c is
closed, so the pressure of the oil at port A and port B rises. This pressure passes through orifice a, goes to pressure-receiving
chamber I, and moves demand spool (1) to the left in the direction of the arrow.
When the pressure at pressure-receiving camber I reaches a certain value (set by spring {5}), notch f opens, and the oil from
the steering pump flows to the drain circuit. At the same time, notch g closes, and the oil from the switch pump all flows to the
main control valve.
WA500-3H 10-59
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING SPOOL OPERATED - ENGINE AT LOW SPEED
When steering spool (2) is pressed (operated), pressure-receiving chamber III and the drain circuit are shut off, and at the same
time notch c opens. When this happens, the pressure in pressure-receiving chamber III rises, and demand spool (1) moves to
the right in the direction of the arrow until notch h closes. The passage from port B to the main control valve is shut off, so the
oil from switch pump pushes up merge check valve (3), and merges with the oil at port A from the steering pump.
The merged oil passes through notch c and notch d, pushes up load check valve (4), and flows to the cylinder. The oil returning
from the cylinder passes through notch e and enters the drain circuit. In this condition, the pressure before passing through
notch c goes to pressure-receiving chamber I, and the pressure after passing notch c goes to pressure-receiving chamber II.
Demand spool (1) moves to maintain the pressure difference on the two sides of notch c at a constant value. Therefore, a flow
corresponding to the amount of opening notch c is discharged from the cylinder port. These pressure differences (control
pressure) are set by spring (5).
10-60 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING SPOOL OPERATED - ENGINE AT HIGH SPEED
The extra oil from the switch pump is not needed, so the steering pump pressure rises until notch g closes, and shuts off the
merge passage at port B. The pressure difference on the two sides of notch c is controlled only by notch f, so the excess oil
from the steering pump is drained from notch f to drain the circuit (when this happens, notch g is completely closed.
The oil from steering pump passes through notch c and notch d, pushes up load check valve (4), and flows to the cylinder. The
oil returning from the cylinder passes through notch e and flows to the drain circuit. Notch g is closed, so the oil from the
switch pump is sent from port B to the main control valve.
WA500-3H 10-61
STRUCTURE AND FUNCTION STEERING VALVE
12
FLOW AMP
4. Return spring
When the Orbit-roll valve is not actuated, both pilot port PiA and pilot port PiB are connected through the Orbit-roll to the
drain (return) circuit, so steering spool (1) is kept at neutral by return spring (4).
10-62 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
2. Spool actuated (oil flows to port PiA)
When oil flows to port PiA, the pressure inside the cap end A rises and moves steering spool (1) in the direction of the arrow.
The oil entering from port PiA passes through the hole in spring seat (3), through orifice (7) in steering spool (1), and then
flows to the opposite end (B end).
Port PiB is connected to the drain circuit through the Orbit-roll valve, so the oil flowing to end B is drained. The pressure
generated at port PiA is proportional to the amount of oil flowing in, so steering spool (1) moves to a position where the
opening of the flow amp notch balances the pressure generated with the force of return spring (4).
WA500-3H 10-63
STRUCTURE AND FUNCTION STEERING VALVE
12
3. Spool returning (steering wheel stopped, flow of oil to port PiA cut)
When steering wheel (Orbit-roll valve) is stopped, ports PiA and PiB are both connected to the drain circuit through the
Orbit-roll valve. For this reason, steering spool (1) is returned to neutral position by return spring (4).
10-64 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING VALVE OPERATION
NEUTRAL
The steering wheel is not being operated, so steering spool (1) does not move. The oil from the steering pump enters port A,
the oil from the switch pump enters port B.
When the pressure at ports A and B rises, demand spool (4) moves to the left in the direction of the arrow. The oil from the
steering pump passes through port C of the spool and is drained. The oil from the switch pump passes through port D and
flows to the main control valve.
WA500-3H 10-65
STRUCTURE AND FUNCTION STEERING VALVE
12
TURNING RIGHT
When the steering wheel is turned to the right, the pressure oil from the Orbit-roll valve acts on steering spool (1), and steering
spool (1) moves to the left in the direction of the arrow.
The oil from the steering pump enters port A, passes through demand spool (2), and flows to steering spool (1). It pushes open
load check valve (4) of the spool, and the oil flows to the bottom end of the left cylinder and the rod end of the right cylinder to
turn the machine to the right.
The oil from the left and right cylinders passes through load check valve (3) of the steering spool, and is drained.
The oil from the switch pump enters port B, flows through demand spool (2), pushes open check valve (5), and merges with
the oil from the steering pump.
10-66 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
TURNING LEFT
When the steering wheel is turned to the left, the pressure oil from the Orbit-roll valve acts on steering spool (1), and steering
spool (1) moves to the right in the direction of the arrow.
The oil from the steering pump enters port A, passes through demand spool (2), and flows to steering spool (1). It pushes open
load check valve (3) of the spool, and the oil flows to the bottom end of the right cylinder and the rod end of the left cylinder to
turn the machine to the left.
The oil from the left and right cylinders passes through load check valve (4) of the steering spool, and is drained.
The oil from the switch pump enters port B, flows through demand spool (2), pushes open check valve (5), and merges with
the oil from the steering pump.
WA500-3H 10-67
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot popper
5. Valve seat
FUNCTION
The steering relief valve is inside the steering valve, and sets the maximum circuit pressure of the steering circuit when the
steering valve is actuated. When the steering valve is being actuated, if the steering circuit goes above the set pressure of this
valve, oil is relieved from this valve. When the oil is relieved, the flow control spool of the demand valve is actuated, and the
oil is drained to the steering circuit.
10-68 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
RELIEF VALVE OPERATION
When the pressure in the circuit rises, and it reaches the pressure set by adjustment screw (1) and spring (2), pilot poppet (4)
opens, and the oil is drained. When this happens, the balance in pressure between pressure-receiving chamber I and
pressure-receiving chamber II is lost, so demand spool (6) moves to the left in the direction of the arrow.
When demand spool (6) moves, the oil from the steering pump is drained, and the oil from the switch pump is released to the
main control valve. This prevents the pressure in the steering circuit from going above the set value.
WA500-3H 10-69
STRUCTURE AND FUNCTION STEERING VALVE
12
SAFETY VALVE (WITH SUCTION)
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
FUNCTION
The safety valve is installed to the steering valve. It has the following two
functions:
OPERATION
When the pressure at port A reaches the set pressure of the relief valve,
pilot poppet (4) opens. The oil flows around pilot poppet (4), passes
through the drill hole, and flows to port B.
When pilot poppet (4) opens, the pressure at the back of poppet (1) drops,
so poppet (1) moves and is seated with pilot poppet (4).
10-70 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
Compared with the pressure at port A, the internal pressure is low, so relief
valve poppet (2) opens. When this happens, the oil flows from port A to
port B, and prevents any abnormal pressure from forming.
WA500-3H 10-71
STRUCTURE AND FUNCTION STEERING VALVE
12
ORBIT-ROLL VALVE
10-72 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
OUTLINE
The steering valve is connected directly to the shaft of the steering wheel. It
switches the flow of oil from the steering pump to the left and right steering
cylinders to determine the direction of travel of the machine.
STRUCTURE
Spool (9) is directly connected to the drive shaft of the steering wheel, and
is connected to sleeve (8) by center pin (7) (it does not contact the spool
when steering wheel is at neutral) and centering spring (2).
The top of drive shaft (3) is meshed with center pin (7), and forms one unit
with sleeve (8), while the bottom of the drive shaft is meshed with the
spline of rotor (5) of the Girotor.
There are four ports in valve body (4), and they are connected to the pump
circuit, tank circuit, and the circuits at the head end and bottom end of the
steering cylinders. The pump port and tank port are connected by the check
valve inside the body. If the pump or engine fail, the oil can be sucked in
directly from the tank by the check valve.
WA500-3H 10-73
STRUCTURE AND FUNCTION STEERING VALVE
12
CONNECTION BETWEEN HAND PUMP AND SLEEVE
The diagrams above show the connections with the sleeve ports used to
connect the suction and discharge ports of the Girotor.
If the steering wheel has been turned to the right, ports a, c, e, g, i, and k
are connected by the vertical grooves in the spool to the pump side. At the
same time, ports b, d, f, h, j, and l are connected to the head end of the left
steering cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3 are the discharge ports of the
Girotor set. They are connected to ports l, b, and d, so oil is sent to the
cylinder. Ports 5, 6, and 7 are connected and the oil flows in from the
pump.
If the steering wheel is turned 90°, changes to the condition shown in Fig. 2. In this case ports 1, 2, and 3 are the suction ports,
and are connected to ports i, k, and c. Ports 5, 6, and 7 are the discharge ports, and are connected to ports d, f, and h.
10-74 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
In this way the ports of the Girotor acting as delivery ports are connected to
ports which are connected to the end of the steering valve spool. The ports
acting as suction ports are connected to the pump circuit Adjusting delivery
in accordance with angle of the steering wheel:
For every 1/7 turn of the steering wheel, the inner teeth of the Girotor
gear advances one position so the oil flow from the pump is adjusted
by this movement. In this way, the oil delivered from the pump is
directly proportional to the amount the steering wheel is turned.
Centering spring (2) consists of four layers of leaf springs crossed to form
an X shape. The springs are assembled in spool (9) and sleeve (8) as shown
in the diagram on the right. When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle variation) arises between the
spool and the sleeve. Because of this, the ports in the spool and sleeve are
connected and oil is sent to the cylinder. When the turning of the steering
wheel is stopped, the Girotor also stops turning, so no more oil is sent to
the cylinder and the oil pressure rises.
To prevent this, when the turning of the steering wheel is stopped, the
action of the centering spring only allows it to turn by an amount equal to
the difference in angle of rotation (angle variation) of the sleeve and spool,
so the steering wheel returns to the NEUTRAL position.
WA500-3H 10-75
STRUCTURE AND FUNCTION STOP VALVE
12
STOP VALVE
4. Poppet
10-76 WA500-3H
STRUCTURE AND FUNCTION DIVERTER VALVE
12
DIVERTER VALVE
FUNCTION
If the engine stops or the pump seizes while the machine is traveling, it becomes impossible to steer, the rotation of the
transmission is used to turn the ground driven steering pump to make steering possible.
WA500-3H 10-77
STRUCTURE AND FUNCTION DIVERTER VALVE
12
OPERATION
When the steering pump and engine are working normally, the hydraulic
pump, steering pump, and switch pump are rotated by the engine.
Therefore, oil is sent to the steering valve, and the machine can be steered.
In addition, the ground driven steering pump is rotated by the transmission,
so oil from port A of the diverter valve (1) pushes open check valve (2) and
enters port B.
Pressure oil from steering pump is flowing to port D, so it pushes spool (3)
in the direction of the arrow. As a result, the oil from port B flows to port C
and is drained to the hydraulic tank.
10-78 WA500-3H
STRUCTURE AND FUNCTION DIVERTER VALVE
12
2. Failure in pump or engine when machine is traveling.
If there is a failure in the pump or engine when the machine is traveling, the
rotation of the wheels is transmitted through the transfer to rotate the
ground driven steering pump. The steering pump is not rotating, so no oil
pressure is formed at port D.
As a result, spool (3) is pushed in the direction of the arrow by spring (4).
The oil from the ground driven steering pump passes from port A through
port B and flows to the steering valve to make steering possible.
The ground driven steering pump is designed so that it can rotate both
directions.
WA500-3H 10-79
STRUCTURE AND FUNCTION DIVERTER VALVE
12
MEMORANDUM
10-80 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
BRAKE
BRAKE PIPING
3. Parking brake switch 9. Parking brake valve 15. Brake valve (left)
5. Rear brake (right) 11. Rear brake (left) 17. Slack adjuster (front)
6. Charge valve 12. PPC pump (also for brake) 18. Front brake (right)
WA500-3H 10-81
STRUCTURE AND FUNCTION BRAKE
12
MEMORANDUM
10-82 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
BRAKE CIRCUIT DIAGRAM
3. Charge valve 9. Front slack adjuster 15. Torque converter charging pump
WA500-3H 10-83
STRUCTURE AND FUNCTION BRAKE
12
BRAKE VALVE
RIGHT BRAKE VALVE
1. Brake pedal (left, right brake) 6. Spool (right brake) A. Pilot port (right brake)
2. Rod (right brake) 7. Lower cylinder (right brake) B. To rear brake (right brake)
3. Pilot piston (right brake) 8. Rod (left brake) C. To front brake (right brake)
4. Spool (right brake) 9. Spool (left brake) D. Drain (left, right brake)
5. Upper cylinder (right brake) 10. Cylinder (left brake) E. To pilot port (left brake)
10-84 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
LEFT BRAKE VALVE
Remark
Legend is at left.
OUTLINE
There are two brake valves installed in parallel under the front of the operator’s cab, and these are actuated by depressing the
pedal.
When the right pedal is depressed, oil is sent to the brake cylinders to apply the brakes.
When the left pedal is depressed, oil is sent to the right pedal to apply the brakes in the same way as when the right pedal is
depressed.
In addition, the left brake pedal operates the transmission cut-off switch to actuate the transmission solenoid valve electrically
and set the transmission to neutral.
WA500-3H 10-85
STRUCTURE AND FUNCTION BRAKE
12
OPERATION
Upper portion
When brake pedal (1) is depressed, the operating force is transmitted to
spool (3) through rod (2) and spring (4). When spool (3) goes down, drain
port a is closed, and the oil from the pump and accumulator flows from
port A to port C and actuates the rear brake cylinder.
Lower portion
When brake pedal (1) is depressed, the operating force is transmitted to
spool (3) through rod (2) and spring (4). When spool (3) goes down, spool
(5) is also pushed by plunger (6). When this happens, drain port b is closed,
and the oil from the pump and accumulator flows from port B to port C and
actuates the rear brake cylinder.
When pedal (7) is depressed, spool (10) is pushed up by rod (8) and spring
(9), and drain port c is closed. The oil from the pump and the accumulator
flows from port E to port F.
Port F of the left brake valve and port PP of the right brake valve are
connected by a hose, so the oil flowing to port F flows to pilot port PP of
the right brake valve.
The oil entering pilot PP enters port G from orifice d, and pushes pilot
piston (11). The spring pushes spool (3) down, so the operation is the same
as when the right brake valve is depressed.
10-86 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
Applying brake when upper valve fails (right brake valve)
Even if there is leakage of oil in the upper piping, spool (5) is moved down
mechanically when pedal (1) is depressed, and the lower portion is actuated
normally. The upper brake is not actuated.
Lower portion
When spool (3) in the upper portion moves up and the circuit between port
A and port C is shut off, oil also fills the front brake cylinder at the same
time, so the pressure in the circuit between port B and port D rises. The oil
entering port J from orifice f of spool (5) pushes up spool (5) by the same
amount that spool (3) moves, and shuts off port B and port D. Drain port b
is closed, so the oil entering the brake cylinder is held, and the brake is
applied.
The pressure in the space in the upper portion is balanced with the operat-
ing force of the pedal, and the pressure in the space in the lower portion is
balanced with the pressure in the space in the upper portion. When spools
(3) and (5) move to the end of their stroke, the circuits between ports A and
C and between ports B and D are fully opened, so the pressure in the space
in the upper and lower portions and the pressure in the left and right brake
cylinders is the same as the pressure from the pump. Therefore, up to the
point where the piston moves to the end of its stroke, the effect of the brake
can be adjusted by the amount that the pedal is depressed.
WA500-3H 10-87
STRUCTURE AND FUNCTION BRAKE
12
Brake released (right brake valve)
Upper portion
When brake pedal (1) is released and the operating force is removed from
the top of the spool, the back pressure from the brake cylinder and the force
of the spool return spring move spool (3) up. Drain port a is opened and the
oil from the brake cylinder flows to the hydraulic tank return circuit to
release the rear brake.
Lower portion
When the pedal is released, spool (3) in the upper portion moves up. At the
same time, the back pressure from the brake cylinder and the force of the
spool return spring move spool (5) up. Drain port b is opened and the oil
from the brake cylinder flows to the hydraulic tank return circuit to release
the front brake.
10-88 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
CHARGE VALVE
A. To PPC valve
ACC. To brake valve
PP. To brake valve
P. From pump
T. Drain
FUNCTION
The charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and store it in the
accumulator.
When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load
on the pump.
WA500-3H 10-89
STRUCTURE AND FUNCTION BRAKE
12Operation
10-90 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
OPERATION
The spring chamber at the right end of spool (15) is connected to port
C of the relief valve (R1), so the pressure becomes the tank pressure.
The oil from the pump enters port P, pushes spool (15) to the right at a
low pressure equivalent to the load on spring (14), and flows from port
A to the PPC valve. At the same time, it also passes through orifices
(17), (18), and (16), and flows to the tank.
A. Cut-in condition
When the pressure at port B is lower than the set pressure of the
relief valve (R1), piston (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought into tight contact, and
port C and port T are shut off.
The spring chamber at the right end of spool (15) is also shut off
from port T, so the pressure rises, and the pressure at port P also
rises in the same way.
WA500-3H 10-91
STRUCTURE AND FUNCTION BRAKE
12
B. When cut-out pressure is reached
When the pressure at port B (accumulator pressure) reaches the
set pressure of the relief valve (R1), poppet (6) separates from
valve seat (7), so an oil flow is generated and the circuit is
relieved.
10-92 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
ACCUMULATOR (FOR BRAKE)
FUNCTION
The accumulator is installed between the charge valve and the brake valve.
It is charged with nitrogen gas between cylinder (3) and free
piston (4), and uses the compressibility of the gas to absorb the pulse of the
hydraulic pump or to maintain the braking force and to make it possible to
operate the brake if the engine should stop.
1. Valve
2. Top cover
3. Cylinder
4. Piston
SPECIFICATIONS:
WA500-3H 10-93
STRUCTURE AND FUNCTION BRAKE
12
SLACK ADJUSTER
FUNCTION
The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. It acts to provide a fixed time lag
when the brake is applied.
SPECIFICATIONS
10-94 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
OPERATION
If the brake pedal is depressed further, and the oil pressure discharged
from the brake valve goes above the set pressure, check valve (3)
opens and the pressure is applied to port C to act as the braking force.
Therefore, when the brake is applied, the time lag is a fixed value.
WA500-3H 10-95
STRUCTURE AND FUNCTION BRAKE
12
BRAKE
3. Cylinder 7. Plate
FUNCTION
The brakes are wet-type multiple disc brakes, and are fitted to all four wheels.
10-96 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
OPERATION
When the brake pedal is depressed, the pressure oil from the brake valve
moves brake piston (4) to the right in the direction of the arrow. This brings
disc (8) and plate (7) into contact, and friction is generated between the
disc and plate. The wheel is rotating together with the disc, so the machine
speed is reduced, and the machine is stopped by this friction.
When the brake pedal is released, the pressure at the back face of brake
piston (4) is released, so the piston is moved to the left in the direction of
the arrow by the force of return spring (2), and the brake is released.
WA500-3H 10-97
STRUCTURE AND FUNCTION PARKING BRAKE
12
PARKING BRAKE
OUTLINE
The parking brake is a wet-type multiple-disc brake built into the transmission. It is installed to the output shaft bearing, and
uses the pushing force of a spring to apply the brake mechanically and hydraulic power to release the brake.
When parking brake switch (1) installed in the operator’s compartment is switched ON, parking brake solenoid valve (4)
installed to the transmission control valve (3) shuts off the oil pressure and applies the parking brake. When the parking brake
switch is turned OFF, the oil pressure in the cylinder releases the parking brake.
When the parking brake is applied, the neutralizer relay shuts off the electric current to the transmission solenoid valve and
keeps the transmission at neutral.
10-98 WA500-3H
STRUCTURE AND FUNCTION PARKING BRAKE
Emergency release switch (2) for the parking brake is installed for use when moving the machine, if the machine has stopped
(the parking brake is automatically applied) because of trouble in the engine or drive system.
PARKING BRAKE
2. Piston 5. Spring
3. Disc
OUTLINE
The parking brake is a wet-type multiple-disc brake. It is actuated mechanically by a spring and applies the braking force to
output shaft (1) of the transmission.
The pushing force of spring (5) pushes piston (2), plate (4), and disc (3) into contact and applies the braking force to stop
output shaft (1).
WA500-3H 10-99
STRUCTURE AND FUNCTION PARKING BRAKE
12
PARKING BRAKE SOLENOID VALVE
OPERATION
At the same time, the pressure oil from the parking brake flows from port A
to port T and is drained. As a result, the disc inside the parking brake is
pushed by the spring and the parking brake is applied.
When the parking brake switch is turned OFF, the solenoid is turned ON
and spool (6) is moved to the right. As a result, the pressure oil from the
pump passes from port P through the inside of spool (6), flows to port A
and then flows to the parking brake. At the same time, port T is closed, so
the oil is not drained. As a result, the spring inside the parking brake is
pushed back by the oil pressure and the parking brake is released.
10-100 WA500-3H
STRUCTURE AND FUNCTION PARKING BRAKE
12
PARKINGBRAKE EMERGENCY RELEASE
SOLENOID VALVE
1. Valve assembly
2. Solenoid valve
A: To parking brake
B: From parking brake valve
C: From pilot circuit
T: Drain
P: From brake (accumulator circuit)
FUNCTION
The emergency release solenoid valve is installed between the transmission and the transmission control valve. If the engine
breaks down and no oil pressure is supplied from the transmission pump, it is possible to actuate the solenoid for the parking
brake release switch in the operator’s compartment. This allows the accumulator charge pressure in the brake circuit to flow to
the parking brake cylinder.
OPERATION
WA500-3H 10-101
STRUCTURE AND FUNCTION HYDRAULIC
12
HYDRAULIC
HYDRAULIC PIPING
1. Main control valve 6. PPC valve 11. Radiator 16. Steering cylinder
2. Bucket cylinder 7. Solenoid valve 12. Oil cooler 17. Boom cylinder
See Section 90 for illustration, Hudraulic Line Assembly, FOLDOUT 10-100-1 thru 10-100-3.
10-102 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
OUTLINE
The hydraulic system consists of the work equipment circuit and the steering circuit. The work equipment circuit controls the
movement of the bucket and attachment.
The oil in hydraulic tank (5) is sent to the main control valve (1) by hydraulic pump (13). When the bucket and boom spools of
the main control valve are at HOLD, the oil passes through the drain circuit of the main control valve, is filtered by the filter
inside the hydraulic tank, and then returns to the tank.
When the work equipment control levers are operated, the bucket or boom spool of the PPC valve (6) moves, and the spools of
the main control valve are actuated by hydraulic pressure, so oil flows from the main control valve to boom cylinder (17) or
bucket cylinder (2) to move the boom or bucket.
Control of the maximum pressure in the hydraulic circuit is carried out by the relief valve inside the main control valve. A
safety-suction valve is installed to the bucket cylinder circuit to protect the circuit.
Accumulator (10) is installed in the PPC pilot circuit, so this makes it possible to lower the boom to the ground even when the
engine is stopped.
Hydraulic tank (5) is a pressurized sealed type and is equipped with a breather with relief valve. This compresses the inside of
the tank and also prevents negative pressure, so this prevents cavitation of the pump.
WA500-3H 10-103
STRUCTURE AND FUNCTION HYDRAULIC
12
HYDRAULIC CIRCUIT DIAGRAM
MACHINES WITH STANDARD SPECIFICATIONS
10-104 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
5. Torque converter charging pump 13C. Safety valve with suction 18A. Demand spool
7. Steering pump 13E. Float selector valve 18C. Steering relief valve
10. Check valve 13H. Slow return valve 20. Cut-off valve
WA500-3H 10-105
STRUCTURE AND FUNCTION HYDRAULIC
12
MEMORANDUM
10-106 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
HYDRAULIC CIRCUIT DIAGRAM
WA500-3H 10-107
STRUCTURE AND FUNCTION HYDRAULIC
12
MEMORANDUM
10-108 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
WORK EQUIPMENT LEVER LINKAGE
WA500-3H 10-109
STRUCTURE AND FUNCTION HYDRAULIC
12
HYDRAULIC TANK
10-110 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
OIL FILTER BY-PASS VALVE
OPERATION
BREATHER
FUNCTION
WA500-3H 10-111
STRUCTURE AND FUNCTION HYDRAULIC
12
ACCUMULATOR (FOR PPC VALVE)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas: Nitrogen gas
Gas amount: 500 cc
Actuation Pressure:
Maximum: 35 kg/cm2 (497.8 lbf/in2)
Minimum: 12 kg/cm2 (170.6 lbf/in2)
FUNCTION
The accumulator is installed between the accumulator charge valve and the PPC valve. Even if the engine stops when the
boom is raised, it is possible to lower the boom and bucket under their own weight by using the pressure of the nitrogen gas
compressed inside the accumulator to send the pilot oil pressure to the main control valve to actuate it.
OPERATION
After the engine stops, if the PPC valve is at hold, chamber A inside the
bladder is compressed by the oil pressure in chamber B.
When the PPC valve is operated, the oil pressure in chamber B goes below
30 kg/cm2 (426.7 lbf/in2). When this happens, the bladder is expanded by
the pressure of the nitrogen gas in chamber A, and the oil inside chamber B
is used as the pilot pressure to actuate the main control valve.
10-112 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
PPC VALVE
FOR BUCKET / BOOM
P = From PPC pump P3 = To RAISE end of main control valve boom spool
P1 = To TILT end of main control valve bucket spool P4 = To DUMP end of main control valve bucket
WA500-3H 10-113
STRUCTURE AND FUNCTION HYDRAULIC
10-114 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
FOR OPTIONAL ATTACHMENT
WA500-3H 10-115
STRUCTURE AND FUNCTION HYDRAULIC
12
10-116 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
PPC VALVE NEUTRAL POSITION
The oil from the PPC pump enters port P of the PPC valve, but the circuit is closed by spool (8), so the oil is drained from the
relief valve (1). At the same time, the oil at port PA1 of the main control valve is drained from port f of spool (8). In addition,
the oil at port PB1 is drained from port g of spool (10).
WA500-3H 10-117
STRUCTURE AND FUNCTION HYDRAULIC
12
PPC VALVE POSITIONS FUNCTIONS
The PPC valve supplies pressure oil from the charging pump to the side
face of the spool of each control valve according to the amount of travel of
the control lever. This pressure oil actuates the spool.
OPERATION
10-118 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
3. Control lever moved back from slightly operated position to hold (Fine
control) (Fig. 3)
When plate (10) starts to be pushed back, piston (2) is pushed up by a
force corresponding to the force of centering spring (6) and the pres-
sure at port P4. At the same time, fine control hole (f) of valve (8) is
connected to drain chamber D, so the oil at port P4 escapes. If the
pressure at port P4 drops too far, valve (8) is pushed down by spring
(7). Fine control hole (f) is shut off from drain chamber D, and at
almost the same time it is connected to pump pressure chamber PP.
The pump pressure is supplied until the pressure at port PA1 returns to
a pressure equivalent to the position of the lever. When the spool of the
control valve returns, the oil in drain camber D flows in from fine
control hole (f1) of the valve which has not moved. The extra oil then
flows through port P1 to chamber PB1.
WA500-3H 10-119
STRUCTURE AND FUNCTION HYDRAULIC
12
PPC RELIEF VALVE
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
FUNCTION
The PPC relief valve is between the PPC brake pump and the PPC valve.
When the PPC pump is not being actuated, or when abnormal pressure is
generated, the oil sent from the pump is relieved through this valve to
protect the pump and circuit from damage.
OPERATION
The relief valve is installed to the charge valve. Port A is connected to the
pump circuit, and port C is connected to the drain circuit.
The oil passes through the orifice of main valve (1) and fills port B. In
addition, pilot poppet (4) is seated in valve seat (3).
When the pressure at port A and B reaches the set pressure, pilot poppet (4)
opens and the oil pressure at port B escapes from port D to port C to lower
the pressure at port B.
10-120 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
CUT-OFF VALVE
FUNCTION
The cut-off valve is installed between the switch pump and the main control valve. Depending on the operating condition, it
switches the oil from the switch pump to the main control valve or to the drain circuit.
WA500-3H 10-121
STRUCTURE AND FUNCTION HYDRAULIC
12
OPERATION
O X X
A. When the work equipment pump pressure is lower than the cut-off
pressure.
As when the work equipment valve is held, the oil at the switch
pump (the oil from the steering valve) pushes up check valve (1),
merges with the oil from the work equipment pump and flows to
the work equipment valve.
10-122 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
MEMORANDUM
WA500-3H 10-123
STRUCTURE AND FUNCTION HYDRAULIC
12
MAIN CONTROL VALVE
2-SPOOL
10-124 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
WA500-3H 10-125
STRUCTURE AND FUNCTION HYDRAULIC
12
3-SPOOL
A1. To attachment cylinder D1. Drain port PA2. From PPC valve P4
A2. To bucket cylinder bottom D2. Drain port PA3. From PPC valve P2
A3. To boom cylinder bottom P. From pump PB1. From option PPC valve
B1. To attachment cylinder P1. From PPC valve P2 PB2. From PPC valve P1
B2. To bucket cylinder head P2. From PPC valve P3 PB3. From PPC valve P3
B3. To boom cylinder head PA1. From option PPC valve T. Drain port
10-126 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
WA500-3H 10-127
STRUCTURE AND FUNCTION HYDRAULIC
12
OUTLINE
The main control valve controls the actuation of the boom attachments and the bucket in the hydraulic system. It has a tandem
circuit which gives priority to the bucket circuit.
The oil from the pump enters port P. The maximum pressure is set by the main relief valve. The oil passes through the by-pass
circuit of dump spool (5) and lift spool (4). It then flows from port T to the drain circuit, passes through the filter and returns to
the tank. If the dump and lift spools are actuated, the oil flows to the dump and lift cylinders.
However, the circuit gives priority to the bucket, so when the dump spool is being operated, even if the lift spool is operated,
the lift arm will not move.
There are two safety valves (with suction valves) (10) to protect the circuit if abnormal pressure is generated in the bucket
circuit. If one of the two safety valves is acting as a relief valve, the other valve acts as a suction valve to make up for any lack
of oil.
10-128 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
6. Lock nut
FUNCTION
The relief valve is installed to the inlet portion of the main control valve. If
the oil goes above the set pressure, the relief valve drains the oil to the tank
to set the maximum pressure for the work equipment circuit, and to protect
the circuit.
OPERATION
Port A is connected to the pump circuit and port B is connected to the drain
circuit. The oil passes through the orifice of the main valve (1) and fills
port B. Pilot poppet (3) is seated in valve seat (2).
If the pressure port A and port B reaches the set pressure of pilot poppet
spring (4), pilot poppet (3) opens, and the oil pressure at port B escapes
from port D to port C, so the pressure at port B drops.
The set pressure can be varied by changing the tension of pilot poppet
spring (4). To change the set pressure, remove cap nut, loosen lock nut (6)
and turn adjustment screw (5), to adjust the set pressure as follows:
WA500-3H 10-129
STRUCTURE AND FUNCTION HYDRAULIC
12
SAFETY VALVE (WITH SUCTION)
1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
FUNCTION
The safety valve is in the bucket cylinder circuit inside the main control
valve. If any abnormal pressure is generated by any shock to the cylinder
when the main control valve is at the neutral position, this valve relieves
the abnormal pressure to prevent damage to the cylinder.
OPERATION
10-130 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
OPERATION AS SUCTION VALVE
When the pressure at port A drops (and comes close to negative pressure),
it becomes lower than hydraulic pressure e. The relationship becomes oil
pressure e > oil pressure a + force of valve spring (5), and suction valve
(1) opens to let the oil from port B flow into port A and prevent any negative
pressure from forming at port A.
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
FUNCTION
This valve acts to prevent any negative pressure from forming in the
circuit.
OPERATION
WA500-3H 10-131
STRUCTURE AND FUNCTION HYDRAULIC
12
FLOAT SELECTOR VALVE AND UNLOAD VALVE
FUNCTION
The float selector valve and unload valve are inside the main control valve.
When the boom lever is operated to the FLOAT position, the float selector
valve detects this, and it acts to actuate the unload valve and set the boom
to the FLOAT position.
OPERATION
If the boom lever is pushed further from the LOWER position, it is set to
the FLOAT position and the PPC valve is set to the same condition as for
the LOWER position. The pressure at port A becomes high pressure and
the pressure at port B becomes low pressure.
The oil from the setting valve fills chamber F and chamber E.
When port C opened, the oil pressure in chamber E drops, unload valve (4)
is moved up in the direction of the arrow, and the oil from the pump flows
to the drain circuit, and also flows to the rod end of the boom cylinders.
The oil at the bottom end of the boom cylinders is connected to the drain
circuit and forms the FLOAT position.
10-132 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
BOOM AND DUMP SPOOLS AT HOLD POSITION
OPERATION
The oil from the pump enters port A and the maximum pressure is set by the relief valve (11).
Bucket spool (1) is at HOLD, so the by-pass circuit is open. The oil at port A passes around the spool and flows to port B.
Boom spool (2) is also at HOLD, so the by-pass circuit is open. The oil at port B passes around the spool and flows to port C
in the drain circuit. From here it passes through the filter and returns to the tank.
The oil from the PPC pump passes through check valve (13) and enters port L of the PPC valve. However, the boom and
bucket levers are at the HOLD position, so the oil returns from PPC relief valve (12) to the hydraulic tank.
WA500-3H 10-133
STRUCTURE AND FUNCTION HYDRAULIC
12
BOOM SPOOL AT RAISE POSITION
OPERATION
When boom lever (3) is pulled, pressure oil from port L of the PPC valve flows to port N and port S. The oil in port T passes
through port M and flows to the drain circuit. The pressure oil in port S pushes the piston against the force of the spring and
moves boom spool (2) to the RAISE position.
The oil flows from the pump through the by-pass circuit of the bucket spool, and then flows to the by-pass circuit of boom
spool (2). The by-pass circuit is closed by the spool, so the oil pushes open check valve (10). The oil then flows from port H to
port I, and goes to the bottom end of the cylinder.
At the same time, the oil at the rod end of the cylinder flows from port K to drain port C, and returns to the tank. Therefore, the
boom rises.
10-134 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
BOOM SPOOL AT LOWER POSITION
OPERATION
When boom lever (3) is pushed, pressure oil from port L of the PPC valve flows to port M and port T. In addition the oil at
port S is connected to the drain circuit. The pressure oil at port T pushes the piston against the force of the spring and moves
boom spool (2) to the LOWER position
The oil from the pump passes through the by-pass circuit of the bucket spool and flows to the by-pass circuit of boom spool
(2). The by-pass circuit is closed by the spool, so the oil pushes open check valve (10). The oil then flows from port J to port
K, and goes to the rod end of the cylinder.
At the same time, the oil at the bottom end of the cylinder flows from port I to drain port C, and returns to the tank. Therefore,
the boom goes down.
WA500-3H 10-135
STRUCTURE AND FUNCTION HYDRAULIC
12
BOOM SPOOL AT FLOAT POSITION
OPERATION
When boom lever (3) is pushed to the FLOAT position, the spool of the PPC valve moves further from the LOWER position to
the FLOAT position. Pressure oil at port L flows to port M, and at the same time, it also flows to port T and port W.
In addition, the pressurized oil at port S flows to port N.
The pressure oil at port T pushes the piston against the force of the spring and moves boom spool (2) to the LOWER position.
If the pressure difference between port W and port X goes above the specified level, valve (7) moves to the right and opens
ports C1 and C to connect them to the drain circuit. When port C1 is connected to the drain circuit, unload valve (8) moves up,
and the oil from the pump flows to the drain circuit.
Therefore, the oil at the rod end of the cylinder flows from port K, and then flows from unload valves (8) to the drain circuit.
At the same time, the oil at the bottom end of the cylinder flows from port I to port C, and then flows to the drain circuit.
Therefore, the boom is set to the FLOAT condition.
10-136 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
BUCKET SPOOL AT DUMP POSITION
OPERATION
When bucket lever (4) is pushed, pressure oil from port L of the PPC valve flows to port V via port Q. In addition, the oil at
port R is connected to the drain circuit. The pressure oil at port V pushes the piston against the force of the spring and moves
bucket spool (1) to the DUMP position.
The by-pass circuit is closed by bucket spool (1), so the oil from port A pushes open check valve (9). The oil from check valve
(9) then flows from port F and enters port G, and goes to the rod end of the cylinder.
At the same time, the oil at the bottom end of the cylinder flows from port D to drain port C, and returns to the tank. Therefore,
the bucket is dumped.
WA500-3H 10-137
STRUCTURE AND FUNCTION HYDRAULIC
12
BUCKET SPOOL AT TILT POSITION
OPERATION
When bucket lever (4) is pulled, the pressure oil at port L of the PPC valve flows to port R via port P. The oil in port V is
connected to the drain circuit. The pressure oil at port R pushes the piston against the force of the spring and moves bucket
spool (1) to the TILT position.
The by-pass circuit is closed by bucket spool (1), so the oil from port A pushes open check valve (9). The oil from check valve
(9) flows from port D to port E, and goes to the bottom end of the cylinder.
At the same time, the oil at the rod end of the cylinder flows from port G to drain port C, and returns to the tank. Therefore, the
bucket is tilted.
10-138 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
MEMORANDUM
WA500-3H 10-139
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
WORK EQUIPMENT
5. Boom
10-140 WA500-3H
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
WA500-3H 10-141
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
BUCKET
1. Bucket
2. Tooth
3. Corner tooth
10-142 WA500-3H
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
MEMORANDUM
WA500-3H 10-143
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
BUCKET POSITIONER AND BOOM KICK-OUT
10-144 WA500-3H
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
BUCKET POSITIONER
The bucket positioner is electrically actuated and is used to automatically
obtain the optimum digging angle for the bucket.
When the bucket is moved from the DUMP position to the TILT position,
and it reaches the desired angle, the dump lever is automatically moved
from the TILT position to the neutral.
Lever (4) is secured by bolts to dump cylinder rod (3). A proximity switch
(1) is fixed by bolts to the cylinder.
When the bucket is moved from the DUMP position to the TILT position,
the dump cylinder rod moves to the left. At the same time, lever (4) also
moves to the left. When it reaches the desired position, lever (4) separates
from proximity switch, and the bucket lever returns to neutral.
BOOM KICK-OUT
The boom kick-out is electrically operated and acts to stop the lift arm.
When the lift arm reaches the desired position before the maximum height,
the lift arm lever is returned to neutral.
Plate (5) is secured to the lift arm. A proximity switch (2) is fixed to the
frame. When the lift arm is moved from the LOWER position to the
RAISE position, the lift arm rises. When it reaches the desired position, the
proximity switch and plate come into contact and the lift arm lever is
returned to neutral.
WA500-3H 10-145
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
PROXIMITY SWITCH
FUNCTION
Proximity switches are installed by a support to the boom and bucket cylinders. The lift arm RAISE position and the TILT
BACK position can be selected to match the operating conditions. When these positions are reached, a pulse is generated from
the switch, the electric current flows to a magnet and the lift or dump lever is returned to the hold position. When this happens,
the main control valve is also returned to hold and the movement of the lift arm or bucket stops.
BOOM RAISE
When the boom is lower than the set position for the boom kick-out, the detection unit (steel plate) is on the sensing surface of
the proximity switch. Electricity flows through the proximity switch. The relay switch is at OFF and the electric current of the
magnet switch coil is shut off.
When the boom lever is moved to the RAISE position, the lever cam and the cam follower keep the lift spool in the RAISE
position, so the boom arm goes up.
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KICK-OUT
When the boom goes up and reaches the set position for the kick-out (that is, the detection unit (steel plate) is separated from
the sensing surface of the proximity switch), the proximity switch and relay circuit act to send electric current to the magnet
coil. This actuates the magnet, the cam is pulled out of the cam detent, and the lift spool is returned to the neutral position by
the return spring.
Position When detector is in position at detection When detector is separated from detection surface
surface of proximity switch of proximity switch
BUCKET TILT
HOLD
When the bucket is dumped beyond the set position for the bucket leveler, the sensor (steel plate) is above the detection surface
of the bucket proximity switch, so electric current flows in the proximity switch load circuit. The positioner relay is turned ON
and the current for the solenoid is shut off.
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TILT
When the bucket lever is moved to the TILT position, the bucket spool is held at the TILT position by the cam follower and
cam on the lever, and the bucket tilts.
POSITIONED
When the bucket tilts and reaches the set position for the bucket leveler (that is, the detection unit (steel plate) is separated
from the sensing surface of the proximity switch), the proximity switch and relay circuit act to send electric current to the
magnet coil. This actuates the magnet, the cam is pulled out of the cam detent, and the dump spool is returned to the neutral
position by the return spring.
Position When sensor is in position at detection When sensor is separated from detection surface of
surface of proximity switch proximity switch
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CAB
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ROPS CANOPY
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AIR CONDITIONER
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AIR CONDITIONING (GENERAL)
HEAT
The kinetic energy of the molecular activity of a substance takes the form of heat. If a substance is given heat by any other
substance, its temperature will rise. If heat is taken away by another body, the temperature will decrease.
1. Quantity of heat.
If the heat is transferred from one substance to another, the temperatures of both substances will change. The amount of
change in temperature will depend on the quantity of heat transferred. The quantity of heat is indicated in units of calories
(cal) or kilocalories (Kcal). One cal denotes the quantity of heat required to raise the temperature of 1g of water by 1
degree. One Kcal denotes the quantity of heat required to raise the temperature of 1 kg of water by 1 degree.
2. Specific heat.
The quantity of heat required to raise or lower the temperature of substance varies depending on the type, weight, and
amount of change in temperature of the substance. The quantity of heat required to raise the temperature of one unit
weight of a substance by 1 degree is called the "specific heat" of the substance. The unit of the specific heat is "kcal/kg C”.
The specific heat is often indicated with a numerical value without the unit.
The larger the specific heat of a substance, the more difficult it is for the substance to warm up and cool down. The
specific heat of water is 1, the largest value of any solid or liquid.
Water 1.0
Alcohol 0.57
Ice 0.49
Iron 0.11
Copper 0.09
Aluminum 0.21
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TEMPERATURE
When cooling or warming a substance, the units of warmth or coolness measurement are expressed as degrees C (Centigrade)
or F (Fahrenheit).
1. Scales of temperature.
The temperature at which water freezes at the standard barometric pressure
(1 barometric pressure) (the "freezing point"):
Centigrade . . . . . . . . . . . . . . . . 0 degrees ( C)
Fahrenheit . . . . . . . . . . . . . . . 32 degrees ( F)
On the Centigrade scale, the scale is equally divided into 100 graduations
ranging from 0 to 100 degrees. One graduation is 1° C. A temperature
below the freezing point (a subzero temperature) is indicated by a negative number, such as -a° C.
On the Fahrenheit scale, the scale is divided into 180 graduations ranging from 32 to 212 degrees. One graduation is 1° F. A
temperature below 0° F is called subzero temperature and indicated by a negative number, such as -B F.
Relationships between the absolute temperature scale and the Centigrade and Fahrenheit temperature scales:
0° C is 273° K (on the Kelvin scale) in the absolute temperature system. One degree in the Kelvin scale equals one degree
in the Centigrade scale.
On the Fahrenheit temperature scale, 0° F is equivalent to 460° R (on the Rankine scale). One degree in the Rankine scale
is equivalent to one degree on the Fahrenheit scale.
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PRESSURE
The force acting on a unit area is called "pressure". Normally, the force
acting on a unit area of 1 cm2 is indicated in unit of kg.
Unit of pressure: kg/cm2.
1. Absolute pressure.
The pressure actually imposed on the wall of a vessel by the gas inside
is called “absolute pressure”. The “complete vacuum pressure”, in
which no molecular activity occurs, is defined as the zero pressure.
The absolute pressure is used in the same manner as the absolute
temperature when treating problems theoretically. The unit of absolute
pressure is kg/cm2 abs.
2. Gauge pressure.
The pressure measured with a pressure gauge at zero barometric pressure is called the gauge pressure. This pressure
indicates the difference between the absolute pressure and the atmospheric pressure. For a theoretical calculation, the
gauge pressure must be converted into the absolute pressure. In most cases, pressure refers to the gauge pressure. The unit
gauge pressure is kg/cm2 g, which distinguishes it from ordinary pressure.
3. Atmospheric pressure.
This is the pressure of the air. The standard atmospheric pressure is 1.03 kg/cm2 abs. at sea level, equivalent to a mercury
column of 760 mm (Hg) or to a water column of 10.3 m. The relationship between the absolute pressure and the gauge
pressure is simple:
Even if the gauge pressure of a gas in a container is zero, the gas is actually subject to a pressure of 1.03 kg/cm2 abs.
The term "vacuum" refers to a given space filled with gas at a pressure
below the atmospheric pressure. A “perfect vacuum” refers to a space
completely empty of gas pressure (an absolute pressure of 0 kg/cm2
abs).
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HUMIDITY
The amount of water contained in the air is called the humidity. Humidity is generally classified into absolute humidity and
relative humidity.
1. Absolute humidity.
The absolute humidity is the weight of moisture per kg of dry air contained in the wet air, expressed in units of x kg/kg.
Practically, an air diagram is used to indicate the weight of moisture contained in 1 kg of wet air. For example, if 30 g of
moisture is contained in 1 kg of wet air, the absolute humidity on the air diagram is indicated as follows:
2. Relative humidity.
The ratio between the water partial pressure P (kg/cm2) of the wet air and the max. partial pressure Ps contained in the
water at that humidity (the water partial pressure of the saturated air) is called the "relative humidity".
Generally, when we speak of humidity, we mean relative humidity. This is the humidity obtained from a home hygrometer
or a weather forecast.
PRINCIPLE OF COOLING
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3. Refrigeration method (Vapor compression)
The refrigerant gas is compressed by a compressor (adiabatic
compression) and changes to high temperature and high compression.
It is then sent to the condenser and undergoes forced cooling in the
condenser to be turned to liquid. If this liquefied refrigerant is
expanded suddenly at the expansion valve, it changes into a low
temperature and low pressure mist and flows inside the evaporator.
4. Refrigerating cycle
The refrigerating cycle of an air conditioner consists of the
compressor, condenser, expansion valve, and evaporator as shown in
the diagram. Refrigerant is circulated in this sealed circuit
(refrigeration cycle), and heat is transferred from the low temperature
source (air inside the operator’s compartment) to the high temperature
source (outside air) to give the cooling. This is called the evaporation
compression refrigeration system, the most widely used form of
cooling used for bus coolers, room air conditioners, and small
refrigerators.
A. Flow of refrigerant
i. The liquid refrigerant which leaves the receiver is expanded suddenly at the expansion valve. It becomes a low
temperature, low pressure mist and flows to the evaporator.
ii. The refrigerant mist which flows into the evaporator takes heat from the air (air inside the operator’s
compartment) at the surface of the evaporator. It evaporates and is further heated, and is then sucked into the
compressor as a gaseous refrigerant.
The air inside the operator’s compartment is sucked into the cooling unit by a fan, is cooled on the evaporator
surface, and is then sent out into the operator’s compartment again.
iii. The gaseous refrigerant evaporated in the evaporator is sucked into the compressor.
iv. The gaseous refrigerant is compressed in the compressor, and is then sent to the condenser at high temperature
and high pressure.
v. In the condenser, the gaseous refrigerant is cooled. It becomes a liquid refrigerant again and flows to the receiver.
By repeating the above steps (1) to (5), the heat is taken from the air at the surface of the evaporator, and heat is
dissipated to the air at the surface of the condenser to produce cooling inside the operator’s compartment.
Remark
The temperature and pressure of the refrigerant vary according to the air flow and temperature of the front
surface of the condenser.
In this way, the refrigerant circulates during the refrigeration cycle to carry out the refrigeration action.
In refrigerators using the evaporation latent heat of the refrigerant at present used, if the gaseous refrigerant is not
liquefied at near normal temperature, it cannot take evaporation latent heat from the surrounding material to
carry out refrigeration (cooling).
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Generally speaking, for a gas to be liquefied, it must be
pressurized. However, if it is cooled at the same time as being
pressurized, it can be liquefied easily.
B. Properties of R-134a
Using R-134a as an example, let us explain how the refrigerant
can be liquefied.
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C. Temperature and pressure in the refrigeration cycle
1. Receiver 4. Compressor
2. Evaporator 5. Blower
In the refrigeration cycle, the refrigerant transforms from a liquid to a gas (evaporation) and from a gas to a liquid
(condensation). Both the temperature and pressure of the refrigerant vary throughout the refrigeration cycle.
The figure above indicates variations of the temperature and pressure in the refrigeration cycle. (The numbers in the
diagram are taken from the design values of a standard air conditioner, and are given only for reference. These values
vary depending on the conditions for the actual cycle).
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5. Heating cycle
The heating cycle uses cooling water taken from the engine cooling system.
A. The cooling water absorbs the heat from the engine, and its flow is controlled by the water valve to enter the heater
core.
B. In the heater core, the heat of the cooling water is transferred to the air at the surface of the core.
D. The cooling water which has given up its heat in the heater core returns to the engine.
By repeating the above steps (A) to (B), the inside of the operator’s compartment is heated.
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REFRIGERANTS
The refrigerant plays the most important role in the refrigeration cycle. Various kinds of refrigerants are available for various
types of applications. The most critical characteristic of a refrigerant is the ease with it liquefies and vaporizes at normal or low
temperatures. However, only a few kinds of refrigerants are used in air conditioners, depending on various conditions, such as
the type of compressor, evaporation temperature (pressure), and condensation temperature (pressure).
Ammonia and freon type gases, which satisfy the requirements, are widely used. Air conditioners usually use "freon type"
gases because of their safety and the small size required for a refrigeration system.
FREON-TYPE GASES
Components in this system are compatible with Refrigerant 134a (CCL2F2 - Dichlorodifluoromethane). Use of other
refrigerants would not achieve performance characteristics, and more importantly, would, in most cases, chemically
deteriorate components.
SAFETY PRECAUTIONS
WARNING! The refrigerant R-134a can be a fire and health hazard if handled incorrectly. Avoid
contact with the substance and never expose it to extreme heat, sparks or open flame.
WARNING! The substance used in the air conditioning system, called R-134a is basically a safe,
nontoxic refrigerant. However, when it is exposed to an open flame, it changes to a very
highly poisonous and deadly phosgene gas. This phosgene gas will tarnish bright metal
surfaces.
WARNING! The liquid refrigerant will boil (or vaporize at -29.8° C (-21.7° F) at atmospheric pressure
(or when it is exposed to the air). It also evaporates so rapidly that the gas may displace
the oxygen in the area, if it happens to be a small enclosed area. Therefore, whenever
the system is worked on, a safe practice would be to work on it in a well ventilated area.
WARNING! The refrigerant, when exposed to the air, is approximately -29 C (-21 F). Upon contact
with the skin, the effect is just like frostbite. Treat the same as you would for frostbite.
WARNING! If the refrigerant contacts the eyes, immediately flush the eyes with water and continue to
do so until the temperature is above the freezing point. Consult an eye specialist
immediately. Blindness could result from an injury of this sort and it is highly
recommended that safety goggles be worn whenever servicing the system. If the air
conditioning system must be discharged, do it out of doors or in a well ventilated area
where no extreme heat or open flame is present. Release the refrigerant slowly as it will
suck the oil from the compressor if the system is opened too fast.
WARNING! Always use the correct type of hoses for the air conditioning system. Do not use any hose
which is not specified for refrigeration use. Never apply heat of any sort on any of the air
conditioning hoses or components of the system while it is charged. The extra heat could
cause the pressure of the refrigerant in the system to become excessive and cause a
dangerous rupture.
WARNING! Be sure the pressurized refrigerant containers are never exposed to or stored in an area
where the temperature could exceed 52° C (125° F).
WARNING! Do not discard empty refrigerant containers where they might be subjected to a tempera-
ture of 52° C (125° F) or higher.
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WARNING! Do not add alcohol or other liquid driers to the system to prevent freeze up. The
desiccant in the dryer prefers alcohol to water and will discharge moisture to absorb
alcohol.
WARNING! Refrigerant oil is the exception to the rule that water and oil do not mix. If left in an open
container it will absorb moisture and Refrigerant oil is the exception to the rule that water
and oil do not mix. If left in an open container it will absorb moisture and may cause
freeze-ups at the expansion valve or sludge build up.
REMEMBER:
Freon type refrigerant dissolves in oil better than ammonia does. When the freon is dissolved in oil, the freezing point of the
oil goes down, which causes no hindrance to the use of the oil at low temperatures. The flash point and the ignition point of the
refrigerant oil are ordinarily 160° C to 170° C and 200° C to 220° C, respectively.
The lube oil for air conditioners will contact refrigerant. Thus, the viscosity of the oil when mixed with refrigerant is an
important factor in the selection of the refrigerant oil. The lube oil used in air conditioners is a mineral oil refined from
petroleum, and various types are available. The refrigerant has a large effect on the durability of the compressor and therefore,
the oil must conform to that specified for each compressor.
1. Chemical stability
The oil is resistant to chemical reactions with the refrigerant or any other substance in the system.
2. Thermal stability
No carbon deposits are formed at high temperatures in the valve and delivery (discharge) portion of the compressor.
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6. Proper viscosity
Excessive wear of the compressor is prevented because the proper viscosity is maintained even at high temperatures. Suf-
ficient fluidity of the oil is maintained at low temperatures and a satisfactory oil film is formed at all times.
7. Cleanliness of oil
No dust, or foreign matter that accelerate the deterioration of oil are mixed in the oil. Thus, the cylinder liners and bear-
ings will not get flawed and oil grooves will not get clogged.
GENERAL DESCRIPTION
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1. 2-Stage control of condenser fan motor
The electric fan of the condenser is controlled to two speeds by the
pressure of the refrigerant on the pressure side.
If the pressure of the refrigerant on the high pressure side rises above
18 kg/cm2, the pressure switch is turned ON and the fan motor runs at
high speed.
When the pressure of the refrigerant on the high pressure side drops
below 14 kg/cm2, the pressure switch is turned OFF and a resistor
reduces the voltage to make the fan motor run at low speed.
This extends the life of the fan motor, and also avoids the unnecessary
use of electricity.
2. Pressure switch
This switches ON and OFF according to the pressure of the
refrigerant.
ON: 14 kg/cm2 (199 psi)
OFF: 18 kg/cm2 (266 psi)
3. Defrosting device
Frost can build up on the evaporator fins if their temperature drops below freezing. Efficiency will suffer, so a thermistor
has been provided, attached to the evaporator fins, to signal when the fins are too cold. If so, the controller will turn off the
magnetic clutch, stopping the compressor.
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4. Magnetic clutch
The compressor pulley incorporates a magnetic clutch to connect and
disconnect from the engine. The clutch engages whenever current is
supplied to its magnet stator coil (air conditioning is switched on). The
drive belt then can power the compressor.
Fan (1)
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AIR CONDITIONER COMPRESSOR
The compressor is a pump to raise the pressure of the refrigerant. As the
refrigerant pressure increases, so does its temperature, and the high
temperature refrigerant gas then will condense rapidly in the condenser by
releasing heat to the surroundings.
The compressor illustrated here, a swash plate type, operates paired pistons
on the swash plate. Rotation of the shaft and attached swash plate operates
the pistons in their bores. The swash plate and shoes convert rotary motion
of the shaft to reciprocating motion of the pistons.
Intake stroke: When the piston moves to the left, the right side of the piston
draws the refrigerant through the suction valve while the discharge valve is
held closed against the valve plate.
Discharge stroke: When the piston moves to the left, the left side of the pis-
ton forces out the refrigerant through the discharge valve while the suction
valve is held closed against the valve plate.
A shaft seal and seal plate seal the compressor shaft. The cutaway drawing
illustrates a typical arrangement.
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RECEIVER WITH SIGHT GLASS (LIQUID TANK)
The refrigerant liquefied in the condenser is temporarily stored in this tank so that the refrigerant can be supplied to the
evaporator according to the cooling load.
A strainer is provided in the tank and the silica-gel is sealed on the external surface of the strainer. A sight glass and a fusible
plug are provided in the top. The purpose of the strainer and silica-gel is to remove dust and water content from inside the
refrigeration cycle.
If water gets into the refrigeration cycle, functional parts will corrode and/or water can freeze in the small port of the
expansion valve, and obstruct refrigerant flow.
1. Body 3. Drier
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1. Fusible plug
A fusible plug, also called a melt bolt, has a hole through its center
which is filled with special solder that melts at 103° to 110° C. If the
condenser cannot ventilate properly, and thoroughly dissipate the heat,
the special solder in the fusible plug will melt. The refrigerant escapes
to the open air before the pressure in the condenser and receiver can
increase enough to damage them.
When the special solder melts at 103° to 110° C, the pressure of the
refrigerant is approximately 30 kg/cm2.
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AIR CONDITIONER UNIT
OUTLINE
1. BLOWER SWITCH
Acts as the main switch and is used for controlling the air flow when
cooling or heating.
If the button is pushed to the OFF position, the air conditioner will
stop.
When the button is pressed, the switch is turned on and the pilot lamp lights up.
When the button is pressed again, the switch is turned off and the pilot lamp goes out.
If the air conditioner switch is turned on but the blower switch is still off, the air conditioner will not work (the pilot lamp
does not light up).
Turn the air conditioner switch on after turning the blower switch on.
3. TEMPERATURE CONTROL
These buttons (arrow up or arrow down) control the temperature during cooling or heating.
Move the lever towards (left) the Cool position to lower the temperature; move the lever towards (right) the WARM
position to raise the temperature.
If the air conditioner switch and blower switch are turned on, and the lever is moved to the WARM position, the air
conditioner will give dehumidifying and heating.
FRESH (right - outside air is brought in) This is used for normal cooling and heating. Fresh air from the outside is used in
addition to the air inside the operator’s compartment.
RECIRC (left - inside air is recirculated) This is used for quick cooling and heating.
In this position, only the air inside the operator’s compartment is used.
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MONITOR SYSTEMS
OUTLINE
The machine monitor system uses the sensors and other devices installed to various parts of the machine to observe the
condition of the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator of
the condition of the machine.
The machine monitor system consists of the main monitor, maintenance monitor, sensors, switches, relays, alarm buzzer, and
power source.
The displays can be broadly divided into the following: Cautions displayed on the monitors (abnormalities in the machine
where an alarm is given), and normal conditions which are always displayed on the instrument panel (pilot lamps, readings for
the gauges, speedometer, and service meter).
There are also various switches built into the monitor panel which function to operate the machine. The main monitor uses the
network wiring to send signals to the controller and functions to display the following information:
Shift indicator: 1st - 4th, N, F, R (F and R are optional).
HOLD
Failure action code, failure code, time elapsed since failure (failure data display mode).
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MAIN MONITOR
3. Caution items 4F. Shift hold 5C. Working lamp (front) switch
4A. Turn signal (left) 4I. Not used 5F. Auto shift, manual selector switch
OUTLINE
The main monitor has a display function for the speedometer and other gauges, and a switching function to control the electric
components and controllers.
There is one CPU (Central Processing Unit) installed internally, and this processes the signals from the sensors and outputs the
display.
A liquid crystal display and LEDs are used for the display. The switches are embossed sheet switches.
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MAIN MONITOR DISPLAY FUCTION
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MAIN MONITOR SWITCH FUNCTION
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TROUBLE DATA DISPLAY MODE
Method of switching to With engine stopped and starting switch turned ON, All switch displays (LEDs) go out, and failure
trouble data display mode press 2nd switch from top on left side of main monitor code is displayed on speedometer display and
(switch below ground driven steering display) and time elapsed since failure is displayed on fail-
work lamp (front switch simultaneously for at least 5 ure action code display.
seconds 1. Failure code is two-digit display given in
numbers or letters. The display for the fail-
ure now occurring flashes and the display
for past failures lights up.
2. The time elapsed since failure is displayed as
a three-digit number to show how long ago
the failure occurred (the oldest failure time
is displayed. Any time greater than 999H is
displayed as 999H).
3. A maximum of 9 times are stored in memory
for the failure codes.
Method of sending failure Press working lamp (front) switch Failure code and time elapsed since failure
code change to next item.
Clearing failure code Press working lamp (rear) switch for at least 2 seconds Failure code and time lapsed since failure
being displayed are cleared.
Failure code for problem now occurring
(flashing display cannot be cleared.
Resetting from travel data Press 2nd switch from top on left side of main monitor Changes to normal display
display mode (switch below ground driven steering display) and
front working lamp switch simultaneously for at least
5 seconds, or start the engine.
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MAINTENANCE MONITOR
OUTLINE
The maintenance monitor has a display function for the caution items and gauges, and switch functions to control the work
equipment controller.
The maintenance monitor consists of the monitor module, switch module, service meter, case, and other mechanisms.
The monitor module has a built-in CPU (Central Processing Unit). It processes the signal from the sensors, and carries out the
display and output.
A liquid crystal display and LEDs are used for the display portions. The switches are embossed sheet switches.
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MAINTENANCE MONITOR DISPLAY FUNCTION
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MAINTENANCE MONITOR SWITCH FUNCTION
Sets stopping position in LOWER Flashes (2.5 sec) Sets stopping position
Remote boom
direction for remote boom positioner
positioner LOWER
(boom position when switch is pressed is Goes out ---
position setting
recorded)
Sets stopping position in RAISE direction Flashes (2.5 sec) Sets stopping position
Remote boom
for remote boom positioner (boom
positioner RAISE
position when switch is pressed is Goes out ---
position setting
recorded)
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ALL-RANGE ELECTRONIC CONTROL AUTOMATIC
TRANSMISSION SYSTEM
OUTLINE OF SYSTEM
The all-range electronic control automatic transmission system consist of the transmission controller, directional and speed
levers, engine speed sensor, speed sensor, and all-speed-range ECMV (transmission clutch modulation valve).
The transmission controller controls the shifting to the appropriate speed range according to the lever position and travel speed
signal.
To reduce shock when shifting gear (engaging the clutch), all-speed-range ECMV carries out modulation control.
A travel damper function and joystick steering control function are available as options, and these controls are possible if the
function is installed to the machine.
To improve durability, there is a safety function which prevents the machine from moving suddenly when the engine is started,
and a transmission protection function which protects the clutch when the direction of travel is changed.
The self-diagnostic function always observes the input and output condition, and displays the output condition on the two
7-segment LED displays on the transmission controller. There is also a failure detection function, and if any abnormality
occurs, it displays a failure code. Depending on the condition, it also displays a failure action code on the main monitor and
flashes the caution lamp to improve safety.
The transmission controller has a communications function, and it sends the speed range (N, 1st-4th) data to the main monitor,
which displays the speed range. (If the joystick mode is used, it also displays F and R.)
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SYSTEM STRUCTURE DIAGRAM
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FUNCTION
1. Auto-shift function.
Shifting the transmission up or down is carried out when the engine speed is above 1450 rpm. Shifting is decided by sig-
nals from the directional lever, speed lever, and travel speed sensor according to (Table 1 Automatic gear shift change
point table) recorded in the memory of the transmission controller.
i. Shift up (when speed lever is at 4th) When the accelerator pedal is depressed to increase the engine speed and the
travel speed rises, when the travel speed reaches approximately 9.3 km/h, the ECMV 3rd is turned ON, and at the
same time, 2nd is turned OFF. (Shifting to F3)
When the travel speed rises further to approximately 17.6 km/h, the ECMV 4th is turned ON, and at the same
time, 3rd is turned OFF. (Shift to F4)
When the travel speed goes down to approximately 9.8 km/h, the ECMV 2nd is turned ON, and 3rd is turned
OFF. (Switches to F2)
E. Skip shift
When coasting (in engine speed OFF mode) in 3rd or 4th speed with the accelerator pedal depressed, if the travel
speed is less than 8 km/h, the gear shifts down to 2nd to make it easier to accelerate. If the travel speed is more than 8
km/h, the speed range is maintained, and when the engine speed goes above 1450 rpm, the gear is shifted to a range
that matches the travel speed.
2. Modulation control.
The modulation control acts to reduce the shock when shifting gear (when engaging the clutch). It uses the data for the
engine speed, transmission oil temperature, and gear shift pattern to control the clutch oil pressure (including the charac-
teristics when starting) to match the condition of the hydraulic circuit to control all speed ranges to the optimum according
to the data in the transmission modulation table stored in the transmission controller memory. In addition, to reduce the
torque cut, it carries out modulation control of the ECMV at the side which switches OFF also.
The transmission modulation data table is set for each transmission oil temperature. In addition, it has a learning function
(transmission clutch piston data) to prevent any abnormal time lag when shifting gear.
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3. HOLD function.
When the HOLD switch is pressed, the speed range is held at the optimum speed range, and even if the travel speed goes
down, the transmission does not shift down. However, when switching between forward and reverse, the transmission
normally shifts down to 2nd according to the travel speed, and then shifts up to the HOLD shift range according to the
travel speed and gear shifting conditions. (This prevents any unnecessary shift down when leveling ground, or when
traveling downhill.)
4. Kickdown function.
When operator turns the kick down switch ON, it overrides the auto shift and switches down forcibly to 1st if the
conditions (speed range, travel speed) in [Table 1 Automatic gear shift change point table, 5. Kickdown] are fulfilled.
5. Travel mode.
i. If the machine is equipped with the joystick steering function, the operator can switch between steering wheel
and joystick steering mode as desired.
ii. The transmission controller controls the signals from the travel system. (The steering system is controlled by the
work equipment controller.)
iii. When switching the steering between steering wheel and joystick steering, always stop the machine first, return
the speed lever to the N position, then switch the steering. When this is done, the transmission controller is set to
the neutral safety condition to prevent the machine from suddenly moving.
6. Safety function.
A. Neutral safety.
When the engine is started, if the directional lever is at any position other than N, the transmission controller keeps
the transmission in neutral and prevents the machine from moving. If the N signal is input after the engine is started,
the neutral safety is canceled.
C. Transmission protection.
When traveling in 3rd or 4th speed, the travel speed is controlled and a warning buzzer sounds to protect the
transmission when shifting between forward and reverse.
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D. Manual shift.
If the travel speed sensor is abnormal and it is impossible to detect the travel speed data, the transmission is set to
manual (shift) mode.
2➞3 8.7 0
3➞4 16.5 0
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7. Self-diagnostic function
The transmission controller always observes the input and output signals of the automatic gear shifting system. It carries
out self diagnosis and displays the results on the LEDs of the transmission controller. In addition, it sends the following
data to the main monitor.
A. Normal display:
Transmission controller LEDs display output range.
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Table 2: Failure code table.
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8. Communications function
The transmission controller is equipped with a communications function using S-NET. It always maintains
communications with the main monitor, and when the engine is started, it receives model, travel damper availability, and
tire compensation data.
When any abnormality occurs, it displays an action code on the main monitor according to the condition of the problem to
warn the operator in order to increase safety.
The failure code can recognize the codes recorded in the main monitor memory using the main monitor problem history
mode. For details of operating the main monitor, see the section on the main monitor.
When the engine is started, the availability of the travel damper function is transmitted from the main monitor, and the
troubleshooting function can also be actuated for the travel damper system.
If the supply voltage is less than 19V, all outputs are turned OFF and the solenoids cannot carry out control (travel is
impossible).
INPUT SIGNALS
1. Directional lever (F,N,R) signal
This signal is a +24V/OPEN digital signal, and when it is normal, one of F, N, or R signals (+24V) is input.
3. Kickdown switch
This signal is a +24V/OPEN digital signal and +24V is input when the kick down switch on the work equipment control
lever is pressed. The switch operation is judged from the +24V starting signal from the OPEN condition at that point. 4.
4. FORWARD switch
This signal is a +24V/OPEN digital signal and +24V is input when the HOLD switch on the work equipment control lever
is pressed. The switch operation is judged from the +24V starting signal from the OPEN condition at that point.
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8. Fill switch (F, R, 1st - 4th signals)
This signal is a GND/OPEN digital signal, and is installed to each ECMV. The switch is operated by oil pressure.
When the ECMV is on, GND is input.
GND Komatsu 6
A. Model selection
It selects the automatic gear shift change point data table for each model to use for shifting gear.
C. Travel damper function selection This is a function selection signal and judges if the travel damper function exists. It
controls the travel damper system, including troubleshooting.
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OUTPUT SIGNALS
1. Transmission modulation valve (ECMV command current)
This signal is an electrical output (0 - 1A). There are six types of ECMV: R and F for direction, and 1st, 2nd, 3rd, and 4th for
each speed range. This valve is a pressure control valve and converts to a pressure matching the value of the current flowing to
the solenoid. Therefore, it controls the oil pressure for the clutch selected for each speed range and controls the engagement of
each independent clutch. In addition, only the 2nd clutch is actuated when the transmission is at neutral.
ECMV/
F R 1st 2nd 3rd 4th
Speed range
F1 O O
F2 O O
F3 O O
F4 O
R1 O O
R2 O O
R3 O O
R4 O O
O = ON
3. F1 (cut-off) signal
This signal is a +24V digital (ON/OFF) output. This signal is output when the kick down is operated and sets the machine
to Fl.
A. Speed range
1st speed range output: [1]
2nd speed range output: [2]
3rd speed range output: [3]
4th speed range output: [4]
Neutral: [N]
B. F / R display
F / R are displayed in the joystick steering mode (option).
C. HOLD display
The pilot display is given on the main monitor when the HOLD function is ON.
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LED DISPLAY
When the engine is started, the display goes first to 1. “Program quality display mode”, and next to 2. “Output speed range
display mode”. However, if any abnormality is detected, it goes immediately to the troubleshooting mode.
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B. When there are two abnormal items.
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ECSS SYSTEM
1. Main monitor 6. ECSS valve assembly 7. Charge control solenoid valve (Sol 2)
3. Combination switch 6B. Solenoid valve (Sol 1) 9. Work equipment control valve
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2. System
ECSS consists of the following electronic devices.
ECSS is turned on and off with the ECSS switch on the main monitor.
If this system (switch) is turned ON, the ECSS LED on the main
monitor lights up
ECSS circuit
OPERATION
If the ECSS switch is turned on, the solenoid valve (Sol 1) is excited and the valve is changed, then the main spool is pushed
and the circuits between the lift cylinder bottom and accumulator and between the lift cylinder head and tank are connected.
A. Operating condition
This system operates when the speed range is 2nd through 4th and the travel speed is 5 km/h or higher.
B. Stopping of operation
When the travel speed is lowered to 3 km/h or the transmission is shifted into 1st or the ECSS switch is turned off, the
main spool is returned by the spring, and the circuits between the lift cylinder bottom and accumulator and between
the lift cylinder head and tank are disconnected.
D. Charging of accumulator
The accumulator is charged by utilizing the oil pressure in the between the pump and work equipment valve when the
lift arm or bucket is operated. The charge pressure of the accumulators is 75 kgf/cm2 (1066.7 lbf/in2), which is
regulated with the charge valve in the ECSS valve.
E. No charging of accumulator
While ECSS is working, the accumulator cannot be charged since the charge control solenoid valve (Sol 2) is turned
off. The reason for this setting is to prevent the lift arm from rising when the accumulator is charged while the bucket
is operated.
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3. Contents of control
The controller receives the inputs in the left columns of the following table and gives the outputs in the right columns to
control the system.
Inputs Outputs
4 ON 1 --- X O
Max. 5 km/h
5 2nd or higher X O
Remark 2
Remark 1
ECSS is turned on and off with the ECSS switch on the main monitor. If this system is turned ON, the red
ECSS LED on the main monitor lights up.
The ON-OFF condition of the system is kept even after the engine is stopped and the starter switch is
turned OFF. When the starter switch is turned on the next time, the system is set in the previous condition.
Remark 2
When the output is turned off, and if the travel speed exceeds 5 km/h, the output is turned on.
When the output is turned on, it is kept turned on until the travel speed lowers to 3 km/h.
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4. Self diagnosis function
This system always observes the condition of the system and displays the condition of the system (see LED code in the
table below) of the controller self diagnostic display.
If any abnormality occurs in either the controller itself or in the input or output devices, the controller diagnoses this, turns
all outputs OFF and displays the error code (failure code) on the self diagnostic display and main monitor.
LED Code
LED display Content System condition
A. Display on controller
See the section on the transmission controller (controller LED).
5. Controller
The new travel damper controller is included inside the transmission controller.
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MEMORANDUM
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STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
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TRANSMISSION CONTROLLER
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CONNECTOR SIGNALS
CNC1 CNC3A CNC4
1 Joystick N output 1 NC 1 NC
2 Buzzer signal 2 NC 2 Engine speed
3 Relief solenoid 3 NC 3 NC
4 Engine speed output 4 NC 4 NC
5 Low pressure solenoid 5 NC 5 NC
6 GND 6 Pressure sensor power supply (+24v) 6 NC
7 Power supply (+24 V) 7 Potentio power supply 7 NC
8 F1 output 8 NC 8 NC
9 Damper solenoid 5 9 NC 9 GND (for rotate sensor)
10 High pressure solenoid 10 ENC select 10 NC
11 Back lamp relay 11 T/M oil temp. Sensor 11 Network (-)
12 GND 12 NC 12 Network (-)
13 Power supply (+24 V) 13 NC CNC5
CNC2 14 NC 1 GND (for plus)
1 Sol. power supply (+24V) 15 NC 2 Speed
2 ECMV 3 (+) 16 GND (for pressure sensor) 3 GND
3 NC 17 GND (for potentio) 4 GND
4 ECMV 4 (+) 18 NC 5 Kick down SW
5 NC 19 Joystick ON/OFF SW 6 T/M cut-off SW
6 NC 20 Pressure SW 7 Joystick N (NC)
7 ECMV F (+) CNC3B 8 Joystick F (NC)
8 ECMV R (+) 1 Pressure SW B 9 Joystick R (NC)
9 ECMV 1 (+) 2 Fill SW F 10 GND (for plus)
10 ECMV 2 (+) 3 Fill SW 1 11 Fill SW 3
11 P GND 4 NC 12 Fill SW 4
12 Sol. power supply (+24V) 5 Direction F 13 Hold SW
13 ECMV 3 (-) 6 Direction R 14 Manual SW
14 NC 7 Range SW 1 15 Joystick N (NO)
15 ECMV 4 (-) 8 Range SW 3 16 Joystick F (NO)
16 NC 9 Damper SW 17 Joystick R (NO)
17 ECMV F (-) 10 Fill SW R
18 ECMV R (-) 11 Fill SW 2
19 ECMV 1 (-) 12 NC
20 ECMV 2 (-) 13 Direction N
21 P GND 14 Neutralizer relay
15 Range SW 2
16 Range SW 4
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STRUCTURE AND FUNCTION SENSORS
12
SENSORS
FUNCTION
The sensors are a contact type sensor with one end grounded to the chassis. The signal from the sensor is input directly to the
monitor panel, and when the contacts are closed, the panel judges the signal to be normal. However, the engine oil pressure
uses a relay to reverse the sensor signal.
SPEEDOMETER SENSOR
FUNCTION
The speedometer sensor is installed to the transmission output gear. A pulse voltage is generated by the rotation of the gear
teeth, and signal is sent to the machine monitor to display the travel speed.
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ENGINE SPEED SENSOR
FUNCTION
The engine speed sensor is installed to the ring gear portion of the flywheel housing. A pulse voltage is generated by the
rotation of the gear teeth, and a signal is sent to the controller and monitor panel.
2. Terminal 4. Boot
This sensor is installed to the engine block and the diaphragm detects the oil pressure. If the pressure goes below the specified
pressure, the switch is turned ON, and a relay is actuated to turn the output OFF. This makes the maintenance monitor flash to
warn of the abnormality. The caution lamp and alarm buzzer are also actuated at the same time to warn of the abnormality.
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RADIATOR WATER LEVEL SENSOR
FUNCTION
The sensor is installed to the top of the radiator. If the coolant goes below the specified level, the float goes down and the
switch is turned OFF. The caution lamp and alarm buzzer are also actuated at the same time to warn of the abnormality.
This sensor is installed to the side face of the oil pan. When the oil goes below the specified level, the float goes down and the
switch is turned OFF. This makes the maintenance monitor flash, and the check lamp to also light up at the same time to warn
of the abnormality.
1. Connector 3. Float
2. Bracket 4. Switch
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FUEL LEVEL SENSOR
FUNCTION
The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down as the level of the fuel changes.
As the float moves up and down, the arm actuates a variable resistance, and this sends a signal to the maintenance monitor to
display the fuel level. When the display the maintenance monitor reaches the specified level, the warning lamp flashes.
2. Float 5. Spring
3. Arm 6. Contact
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ENGINE WATER TEMPERATURE SENSOR
These sensors are installed to the engine cylinder block and transmission case. The change in the temperature changes the
resistance of the thermistor, and a signal is sent to the maintenance monitor to display the temperature. If the display on the
maintenance monitor reaches the specified position, the lamp flashes and the buzzer sounds to warn of the abnormality.
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MEMORANDUM
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ELECTRICAL
FUNCTION
To ensure safety when starting the engine, the system is equipped with a neutral safety circuit. This makes it impossible for the
engine to start if the directional lever is not at the N (Neutral) position.
OPERATION
When the directional lever is placed at the N (Neutral) position contacts of the directional lever switch are closed. In this
condition, if the starting switch is turned to the START position, current flows in the following circuit.
[1] Battery (+) ➞ starting switch terminal B ➞ starting switch terminal C ➞ safety relay terminal S ➞ safety relay
terminal B ➞ directional lever switch terminal N ➞ ground, so the safety relay is closed.
In addition, current flows from starting switch terminal BR ➞ battery relay coil ➞ ground, so the battery relay switch is
closed. This forms the following circuit.
[2] Battery (+) ➞ battery relay ➞ starting motor terminal B ➞ safety relay terminal B ➞ safety relay terminal C ➞
starting motor terminal C, and the engine starts.
If the directional lever is at any position other than N (Neutral), circuit [1] is not formed, and the engine does not start.
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SAFETY RELAY
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ENGINE STOP CIRCUIT
OPERATION
When the starting is turned ON, electric current flows in the following circuit.
[1] Battery (+) ➞ starting switch terminal B ➞ starting switch terminal BR ➞ fuel cut solenoid ➞ ground connection.
When electric current flows to the fuel cut solenoid, the fuel governor is put in the FREE position by the fuel control linkage.
Fuel flows to the fuel injection pump and the engine starts.
When the starting switch is turned OFF, circuit [1] is shut off, but the engine is rotating, so there is still voltage at terminal R of
the alternator. For this reason, the following circuit is formed.
The battery relay is maintained, but because of the diode inserted into the circuit, no electric current flows to the fuel cut
solenoid, so the engine stops.
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ELECTRICAL TRANSMISSION CONTROL
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STRUCTURE AND FUNCTION ELECTRICAL
COMBINATION SWITCH
OUTLINE
The directional lever has three positions and the speed lever switch has four positions. As an individual part, the switch does
not have a detent mechanism; the detent mechanism is in the combination switch. Each switch is positioned by two pins, and is
secured to the body by three screws.
When each lever is operated to the desired position, the switch, which is interconnected by a shaft, acts to allow electric
current to flow to that circuit only.
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OPERATION
Directional lever (1) and shaft (2) of the speed lever of the combination
switch form one unit with magnet (3), and magnet (3) also moves together
with lever (1).
Control switch (5) with built-in hole IC (4) is installed at the bottom of
magnet (3), and hole IC (4) is positioned on the board to match each posi-
tion.
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KICK-DOWN / HOLD SWITCH
1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness
KICK-DOWN SWITCH
OPERATION
The kick-down (shifting down from 2nd ➞ 1st) is actuated only when
traveling in F2.
After this, even if the kick-down switch is pressed, the transmission is kept
at F1.
HOLD SWITCH
The hold switch is installed to the boom lever, and when the hold switch is pressed, the speed range displayed on the main
monitor transmission indicator is held.
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KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS
NORMAL OPERATION
(When directional lever is at F and speed lever is at 2nd)
If the parking brake is placed at the RELEASED position, electricity flows from battery (+) ➞ parking brake safety relay
terminals 5 - 3 ➞ parking brake switch terminals 3 - 2 ➞ neutralizer relay terminals 1 - 2 ➞ ground, and terminals 3 - 5 of
the neutralizer relay are connected.
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STRUCTURE AND FUNCTION ELECTRICAL
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WHEN KICK-DOWN SWITCH IS OPERATED
(Operation with speed lever at F2 position)
(When kick down switch is pressed ON)
When the kick-down switch is pressed, the main monitor network signal (-) enters from CNL08 terminal 2 to controller CNC5
terminal 5. The kick-down circuit is formed inside the controller and the solenoid output signal flows from CNC2 terminal 7
and terminal 9 to the F solenoid and 1st solenoid, the solenoid valves are actuated, and the speed range is set to F1.
This kick-down circuit continues to be actuated even if the kick-down switch is returned. (Self-hold circuit)
In this way, if the kick-down switch is pressed when the speed lever is at F2, the transmission is automatically shifted to F1. At
the same time, the self-hold function of the kick-down circuit keeps the condition at F1 even if the switch is released or is
pressed several times.
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KICK-DOWN SWITCH OPERATION CANCELED
(When directional lever is set to N or R)
If the directional lever is operated to the R position, the contact of terminal F of the lever is turned off, so the electricity stops
flowing from battery (+) ➞ speed lever switch terminals 1 - 2 ➞ transmission controller.
The FORWARD circuit inside the transmission controller is opened, so electricity stops flowing to the kick-down circuit. As a
result, the kick-down self-hold circuit is canceled and the 1st solenoid stops actuating. (Even if the directional lever is set to
the N position, the same operation as above is carried out and the kick-down circuit is canceled.)
The FORWARD circuit is also opened, so the F solenoid also stops actuating.
When the directional lever is set to the R position, current flows from battery speed lever terminals 1 - 4 ➞ transmission
controller CNC3B terminal 6 ➞ CNC 2-8 terminal (Reverse circuit formations R (+) signal inside controller) ➞ R solenoid ➞
controller (-) CNC2 terminal 18, and the REVERSE solenoid valve is actuated.
At the same time, electricity flows from transmission controller 2nd signal (+) CNC2 terminal 10 ➞ 2nd solenoid ➞ CNC2
terminal 20, and the 2nd solenoid valve is actuated to set to R2.
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MEMORANDUM
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ELECTRIC PARKING BRAKE CONTROL
OUTLINE
The parking brake is a wet type multiple disc brake built into the transmission. When electricity flows to the parking brake
solenoid valve, the oil pressure from the transmission pump is applied to the parking brake cylinder and releases the parking
brake.
When the flow of electricity is stopped, the hydraulic pressure from the transmission pump is shut off. The hydraulic pressure
inside the parking brake cylinder passes through the parking brake solenoid valve and is drained. The force of the brake spring
then applies the parking brake.
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STRUCTURE AND FUNCTION ELECTRICAL
12
FUNCTION
3. Emergency brake
If the pressure in the oil pump should drop because of damage to the hydraulic circuit and the braking force can not be
ensured, the parking brake is applied automatically to act as an emergency brake.
5. Neutralizer
The parking brake may seize if the machine is driven with the parking brake still applied. To prevent this problem, the
caution lamp lights up and the alarm buzzer sounds to warn the operator of the mistaken operation. In addition to this,
when the parking brake is applied, the transmission is forcibly shifted to neutral to make it impossible to drive the
machine.
However, the braking distance will become longer if the transmission is shifted to neutral when the emergency brake is
applied. It may also be necessary to move the machine if it stops in places where it is prohibited to stop (such as on
railway crossings). To overcome this, the circuit is designed so that the transmission is not shifted to neutral when the
emergency brake is applied.
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PARKING BRAKE EMERGENCY RELEASE SWITCH
WA500-3H 10-215
STRUCTURE AND FUNCTION ELECTRICAL
12
PARKING SAFETY RELAY
NEUTRALIZER RELAY
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STRUCTURE AND FUNCTION ELECTRICAL
12
OPERATION
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STRUCTURE AND FUNCTION ELECTRICAL
12
2. Starting switch ON
A. When parking brake switch is ON (actuated) before starting switch is turned ON.
The electric current flows in circuit ➀ from the battery + ➞ starting switch ➞ battery relay coil ➞ ground, so the
battery relay is closed. When this happens, electric current flows in circuit ➁ from the battery + ➞ battery relay ➞
parking brake switch terminal 1 - 3 ➞ parking brake safety relay terminal 1 - 2 ➞ ground. In this way, the parking
safety relay is actuated and safety relay terminals 3 - 5 are closed.
When this happens, circuit ➂ is formed from the battery + ➞ battery relay ➞ parking safety relay terminal 5 - 3 ➞
parking safety relay terminal 1 - 2 ➞ ground. From this point, the parking safety relay is in the condition of circuit ➂
until the starting switch is turned OFF.
In this condition, electric current does not flow to the parking brake solenoid valve, so the parking brake is actuated.
In addition, in this condition, neutralizer relay terminals 3 and 5 are open, so electric current does not flow to the
transmission directional circuit, and the transmission is shifted to neutral.
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B. When parking brake switch is OFF (actuated) before starting switch is turned ON
Electric current flows in circuit ➀ from the battery + ➞ starting switch ➞ battery relay coil ➞ ground, so the battery
relay is closed. However, in this case, the parking brake switch is OFF (released), so the parking safety relay is not
actuated. For this reason, the electric current does not flow to the parking brake solenoid valve, so after the automatic
parking brake is applied, the parking brake is not released automatically even when the starting switch is turned ON.
In addition, the electric current does not flow to the transmission directional circuit, so the machine does not move.
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STRUCTURE AND FUNCTION ELECTRICAL
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3. Parking brake switch OFF (released)
When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
If the parking brake switch is turned from ON (actuated) to OFF (released), the circuit for terminals 2 and 3 of the parking
brake switch is connected, and the parking brake safety relay is also actuated. For this reason, electric current flows in
circuit ➀ from the battery + ➞ battery relay ➞ parking brake safety relay ➞ parking brake switch, and then flows to
circuits ➁ and ➂ given below.
➁ This circuit is formed from the emergency brake switch ➞ parking brake solenoid valve ➞ ground, and the parking
brake is released.
➂ This circuit is formed from the battery + ➞ battery relay ➞ neutralizer relay terminal 3 - 5 ➞ transmission directional
circuit, so when the directional lever is operated, the machine will move.
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4. Parking brake switch ON (actuated)
If the parking brake switch is turned ON (applied) after carrying out operations with the parking brake switch OFF
(released), the circuit in the diagram above is formed.
Electric current does not flow to the parking brake solenoid valve, so the oil pressure from the transmission pump to the
parking brake cylinder is shut off. At the same time, the oil pressure inside the parking brake cylinder passes through the
parking brake valve and is drained, so the parking brake is applied by the force of the spring.
In addition, at the same time, the neutralizer relay is reset, so the circuit between terminals 3 and 5 is opened, and no
electricity flows to the transmission directional circuit, so the transmission is shifted to neutral. This kind of neutralizer
relay shuts off the electric current going to the transmission solenoid valve when the parking brake is applied and shifts
the transmission to neutral to prevent seizure of the parking brake if the operator should drive the machine with the
parking brake still applied.
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5. When main brake oil pressure drops (emergency brake actuated)
OPERATION
If the oil pressure in the main brake line drops, the emergency brake switch installed to the accumulator is opened.
For this reason, the electric current stops flowing to the parking brake solenoid valve, so the oil pressure inside the parking
brake cylinder is drained and the parking brake is applied.
However, in this case, the condition is different from the case where the parking brake switch is ON (applied), because
there is electric current flowing to the neutralizer relay coil.
For this reason, electric current flows to the transmission directional circuit, and it is possible to engage the transmission
clutch. In this way, it is possible to use the engine brake when the emergency brake is applied, so the braking distance
becomes shorter. At the same time, if the emergency brake has been applied and it is necessary to move the machine (for
example, if the emergency brake is applied when the machine is on a railway crossing), it is possible to move the machine
by operating the transmission lever.
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6. Parking brake emergency release
OPERATION
If the machine should stop because of engine trouble, the oil pressure from the transmission pump to the parking brake
cylinder is shut off and the parking brake is applied. When this happens, the oil pressure in the main brake line is stored
in the accumulator. When the emergency release switch is turned on (released), the buzzer sounds, and at the same time,
electric current flows to the emergency parking brake release solenoid valve.
The oil pressure stored in the accumulator in the main brake line then flows to the parking brake cylinder to release the
parking brake.
The emergency release switch should normally be kept at the OFF position and should be returned to the OFF position
after the emergency release.
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7. Function of parking brake neutralizer relay
OUTLINE
When the parking brake is being actuated, the transmission is held at neutral to prevent the parking brakes from dragging
if the machine is operated by mistake.
OPERATION
A. When the parking brake is actuated (ON), electricity flows from the battery relay ➞ parking brake switch terminals
1 - 3 ➞ parking brake safety relay terminal 1 ➞ ground. As a result, the safety relay coil is actuated, and safety relay
terminals 3 and 5 are connected to form the circuit.
B. When the parking brake switch is OFF (released) and the engine is started, the circuit in Item A is not formed, so the
parking brake switch must be turned ON.
C. When the parking brake is being actuated, electricity does not flow to the neutralizer relay coil, so neutralizer relay
terminal 3 and terminal 5 are separated and no electricity flows to the transmission directional circuit. In this way,
when the parking brake is applied, the transmission is held at neutral.
10-224 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
ELECTRICAL DIAGRAM
See Section 90 for;
WA500-3H 10-225
STRUCTURE AND FUNCTION ELECTRICAL
12
ENGINE HARNESS DIAGRAM
10-226 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
ENGINE - FRAME - FLOOR HARNESS DIAGRAM
WA500-3H 10-227
STRUCTURE AND FUNCTION ELECTRICAL
12
MEMORANDUM
10-228 WA500-3H
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
12-+
STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
HANDLING EQUIPMENT IN FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
RELEASING REMAINING PRESSURE IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
REDUCED CYLINDER MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
BLEEDING AIR FROM FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
CHECK FOR LEAKAGE IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
ADJUSTING SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TESTING AND ADJUSTING ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TESTING AND ADJUSTING FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
RUN-IN STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
PERFORMANCE TEST STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TORQUE CONVERTER STALL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
AIR CONDITIONER BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
SHIFT LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
OPERATING FORCE OF SPEED LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
TRAVEL OF SPEED LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
OPERATING ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
TORQUE CONVERTER OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
TRANSMISSION OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
TORQUE CONVVERTER AND TRANSMISSION HYDRAULIC CIRCUIT FLUSHING . . . . . . . . . . . . . . . 20-34
TRANSMISSION VALVE FAILS - MOVING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
MEASURING PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
MEASURING OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
MEASURING OPERATING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
STEERING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
STEERING STOP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
WA500-3H 20-1
TESTING AND ADJUSTING
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
PEDAL PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
MEASUREMENT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
BRAKE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
INSPECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
MEASUREMENT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
CALCULATING PISTON STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
MEASURING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
MANUAL RELEASE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
ADJUSTING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
RELEASING REMAINING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
LEVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
BOOM POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
TROUBLESHOOTING - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
ELECTRICAL CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
(ELECTRIC CONTROL MECHANISM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
TROUBLESHOOTING SYSTEMS OF:
D MODE - ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM). . . . . . . . . . . . . . . . 20-401
E MODE - CHASSIS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
J MODE - JOYSTICK STEERING CONTROLLER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701
M MODE - MAIN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-901
T MODE - TRANSMISSION CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1201
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1301
20-2 WA500-3H
TESTING AND ADJUSTING
12
★ For further detail information, refer to Engine Shop Manual.
★ Heed the following precautions when referring to the Standard Value Tables for testing, adjusting and troubleshooting:
A. The standard values in tables are those established for a new machine and are given as reference values for the point
at which the machine is shipped from the factory. These values should be used only as a guide when estimating wear
after the machine is operated and when carrying out repairs.
B. Permissible values shown in the tables are estimations based on the results of test performed on the machines shipped
from the factory, so they should be used together with the information on the repair condition and other information
such as the operating history of the machine itself when judging the condition of the machine.
WARNING! Before testing, adjusting, or troubleshooting, park the machine on level ground,
install the safety bar, and use blocks to prevent the machine from moving.
WARNING! When working with others, always use signals and keep unauthorized people
away from the machine.
WARNING! Wait for the engine coolant water to cool before checking the coolant level. If the
radiator cap is removed while the coolant is still hot, the coolant will spurt out and
cause burns. Be careful to stay away from the fan, fan belt and other moving
parts
WA500-3H 20-3
TESTING AND ADJUSTING
12
MEMORANDUM
20-4 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE - IN
12
STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS
Engine cold:
Valve clearance Intake valves mm 0.35 0.35
Exhaust valves 0.57 0.57
Deflection when pressed with finger force
Alternator belt of approximately 98 N (22 lbf) mm 13 - 16 13 - 16
WA500-3H 20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS
20-6 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Item Measurement condition Unit Standard value for Service limit value
new machine
• Torque converter inlet port oil pressure 0.83 ±0.1 0.83 ±0.1
(8.5 ±1) (8.5 ±1)
• ECMV output (clutch) oil pressure
1st • Torque converter oil
temperature: 60 - 80° C
2nd, 3rd, 4th, F-R kgf/cm2 33.5 ±2 33.5 ±2
• Engine speed: High idling (lbf/in2) 476.4 ±28.4) 476.4 ±28.4)
• Main relief valve 35.5 ±1.5 35.5 ±1.5
Low idling • Manual switch ON (476.4 ±21.3) (476.4 ±21.3)
2 - 10 -
WA500-3H 20-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Standard value for
Testing and measuring item Measurement condition Unit new machine Service limit value
• Play mm 15 +1/-0 -
Accumulator
• Charge cut-in pressure 60 +5/-0 60 +5/-0
Point where brake oil pressure warn- 853.4 +71.1/-0 853.4 +71.1/-0
ing lamp goes out • Engine speed: Low idle kgf/cm2
• Hydraulic temperature: 45-55°C (lbf/in2)
• Charge cut-out pressure
Point where oil pressure is going up 100 +10/-0 100 +10/-0
and then starts to go down (1422.3 +142.2/-0) (1422.3 +142.2/-0)
Warning buzzer pressure
• Actuating starting • Coolant temperature: kgf/cm2 6.0 ±0.1 6.0 ±0.1
• Actuating stopping Inside operating range (lbf/in2) (85.3 ±1.4) (85.3 ±1.4)
• Road surface: Flat, horizontal, dry,
paved surface
• Speed when applying brakes: 20
km/h
• Time lag when pressing the pedal:
Brake performance 0.1 sec. mm Max. 5 Max. 5
• Brake pedal operating force: 294
±29.4 N (30 ±3 kg)
• Tire inflation pressure:
Specified pressure
• Coolant temperature:
Inside operating range kgf/cm2 Max. 5 Max. 5
Drop in brake oil pressure • Test pressure: (71.1) (71.1)
(lbf/in2)
53 kg/cm2/5 min.
Wear of brake disc • Piston stroke mm 2.2 - 5.5 Max. 8.5
• Tire inflation pressure:
Specified pressure
No
• Road surface: No
machine
Parking brake performance Flat, dry, paved surface with 1/5 machine
movement
(11°20') gradient movement
• Machine:
In operating condition
• Thickness of pad • With back plate 31.7 12.7
• Clearance between mm
• Total of both side 1.06 ±0.18 Max. 2.3
disc and pad
20-8 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Testing and measuring item Unit Standard value for Service limit value
Measurement condition new machine
WA500-3H 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, it is
normal
Between C1 (7), (13) - chassis 1. Turn starting switch
OFF
Power source C1 Measure voltage
Between C2 (1), (12) - chassis 2. Insert T-adapter
20 - 30 V 3. Turn starting switch ON
Between C1 (7), (13) - (6), (12)
Between C2 (1), (12) - (11), (21)
If the condition is as shown in the table below, it is 1. Turn starting switch
normal OFF
Power source
C3A Measure voltage 2. Insert T-adapter
(signal) Between (6) - (17)
20 - 30 V 3. Turn starting switch ON
Between (6) - chassis 4. Apply parking brake
If the condition is as shown in table below, the sen-
sor is normal 1. Turn starting switch
Parking brake OFF
L01 Measure voltage
switch Parking brake ON, Between (1) - (3), 20 - 30 V 2. Insert T-adapter
3. Turn starting switch ON
Parking brake OFF, Between (1) - (3), Max. 1 V
Transmission & Travel Damper Controller
20-10 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
ECMV fill switch If the condition is as shown in the table below, it is 1. Turn starting switch
Transmission & Travel Damper Controller
normal OFF
2. Disconnect connector
Directional lever at measurement 3. Connect T-adapter
position: 4. Start engine
Max. 1 Ω 5. Place directional lever
Between (1) - chassis at N
F - CN17 6. Turn manual switch ON
(male) Measure 1. Turn starting switch
R - CN15 resistance OFF
(male) Directional lever not at
measurement position: 2. Disconnect connector
3. Connect T-adapter
4. Start engine
Min. 1 Ω
5. Turn transmission cut-
off (lamp OFF)
Between (1) - chassis 6. Turn parking brake
switch OFF
7. Depress brake
If condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Transmission oil CN11 Measure OFF
temperature sensor (male) resistance Normal temperature (25° C) 3.8 - 4.8 Ω 2. Disconnect connector
3. Connect T-adapter
100° C Between (1) - chassis 3.6 - 3.9 Ω
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
Transmission oil
C2 Measure Normal temperature (25° C) OFF
temperature 4.4 - 4.6 Ω
resistance Between (11) - (17) 2. Disconnect connector
(controller)
3. Connect T-adapter
100° C Between (11) - (17) 2.1 - 2.3 Ω
WA500-3H 20-11
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Measure voltage
(controller) (male) Measure with AC range 2. Disconnect connector
Max. 0.5 V 3. Start engine
Between (2) - (9)
If the condition is as shown in the table below, the
sensor is normal
1. Screw in until speed sensor contacts ring gear,
Engine speed - Adjust -
then turn back 3/4 - 1 turn
2. Sensor should work normally when adjusted as
above.
If condition is as shown in the table below, it is
normal 1. Turn starting switch
CN3 Measure OFF
(male) resistance Between (1) - (2) 500 - 1000 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1) - (2 - chassis) Min. 1 MΩ
Speed If the condition is as shown in the table below, the
sensor is normal
1. Screw in until speed sensor contacts ring gear,
- Adjust -
then turn back 3/4 - 1 turn
2. Sensor should work normally when adjusted as
above.
20-12 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
Speed lever Speed lever at 1st.
20 - 30 V
(1st) Between (7) - chassis
Speed lever not at 1st.
Max. 1 V
Between (7) - chassis
If the condition is as shown in the table below, it is
normal
Speed lever Speed lever at 2nd.
20 - 30 V
(2nd) Between (15) - chassis
Speed lever not at 2nd.
Max. 1 V
Between (15) - chassis
If the condition is as shown in the table below, the
sensor is normal
Speed lever Speed lever at 3rd.
20 - 30 V
(3rd) Between (8) - chassis
Speed lever not at 3rd.
Transmission & Travel Damper Controller
Max. 1 V
Between (8) - chassis
If the condition is as shown in the table below, it is
normal
Speed lever Speed lever at 4th.
20 - 30 V
(4th) Between (16) - chassis
Controller
WA500-3H 20-13
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, it is
normal
1. Turn starting switch
Kick-down switch ON OFF
Kick-down Switch
Between (1) - (2) Max. 1 Ω 2. Insert T-adapter
3. Turn starting switch ON
Kick-down switch OFF
Between (1) - (2) Min. 1 MΩ
L15 Measure
Transmission & Travel Damper Controller
20-14 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
1. Turn starting switch
Directional switch Measure Directional lever at N OFF
L05 20 - 30 V
(N) voltage Between (8) - (3) 2. Insert T-adapter
3. Turn starting switch ON
Directional lever not at N Max. 1 V
Between (8) - (3)
If the condition is as shown in the table below, it is
normal
Starting switch 1. Turn starting switch
L09 Measure Starting switch at start 20 - 30 V OFF
terminal C (male) voltage Between (3) - chassis 2. Insert T-adapter
Starting switch at OFF or ON Max. 1 V
Between (3) - chassis
If the condition is as shown in the table below, the
sensor is normal
Starting switch 1. Turn starting switch
L04 Measure Engine started 20 - 30 V OFF
terminal C voltage Between (4) - (3) 2. Insert T-adapter
Maintenance Monitor Related
WA500-3H 20-15
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
1. Turn starting switch
Directional switch Measure Directional lever at R OFF
(R) L08 20 - 30 V
voltage Between (8) - chassis 2. Insert T-adapter
3. Turn starting switch ON
Directional lever not at R
Max. 1 V
Between (8) - chassis
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
Power source Measure OFF
L18
voltage Between (1), (2) - chassis 2. Insert T-adapter
20 - 30 V 3. Turn starting switch ON
Between (1), (2) - (3)
If the condition is as shown in the table below, the
sensor is normal
1. Turn starting switch
Engine water tem- E06 Measure 50° C Approxiately OFF
perature sensor (male) resistance Between (A) - (B) 19 Ω 2. Disconnect connector
3. Connect T-adapter
100°C Approxiately
Between (A) - (B) 3.6 Ω
Maintenance Monitor Related
20-16 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
Accumulator pressure:
Brake B08 1. Turn starting switch
Min. 55 ±5 kgf/cm2 (782.2 +71.1 Max. 1 Ω
accumulator low (male) Measure OFF
lbf/in2) Between (1) - (2)
pressure switch B13 resistance 2. Disconnect connector
(male) Depress brake and lower accumula- 3. Connect T-adapter
tor pressure to below 45 ±5 kg/cm2
(640.0 ±71.1 lbf/in2) Between (1) - Min. 1 MΩ
(2)
If the condition is as shown in the table below, it is
normal
Engine running (at above 1/2
Maintenance Monitor Related
WA500-3H 20-17
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
WARNING! Check carefully that there is no one in the surrounding area before starting inspection.
★ When carrying out operations during inspection, raise the work equipment control lever stand for operations, and
lower it when traveling.
★ Turn the starting switch OFF before inserting the T-adapter, or making any connections.
Measurement
Name of component Judgement table
conditions
If the condition is as shown in Table 1, the monitor panel is normal
20-18 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Measurement
Name of component Judgement table
conditions
Table 2 (Gauge portion)
Maintenance Monitor Related
WA500-3H 20-19
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
Parking brake emergency cancel 1. Turn starting switch
Parking brake
Measure switch ON 20 - 30 V OFF
emergency cancel L90
voltage Between (1) - (2) and (3) - (4) 2. Insert T-adapter
switch
3. Turn starting switch ON
Parking brake emergency cancel
switch OFF Max. 1 V
Between (1) - (2) and (3) - (4)
If the condition is as shown in the table below, it is
normal
Parking brake Parking brake emergency cancel 1. Turn starting switch
emergency cancel Measure switch ON 20 - 30 V OFF
B14
solenoid voltage Between (1) - (2) 2. Insert T-adapter
3. Turn starting switch ON
Parking brake emergency cancel
switch ON Max. 1 V
Between (1) - (2)
If the condition is as shown in the table below, the
sensor is normal
Accumulator pressure: Min. 40
1. Turn starting switch
Emergency brake B09, B10 Measure
±5 kg/cm2 (568.9 ±71.1 lbf/in2) Max. 1 Ω OFF
Between B09 (1) - B10 (2)
Others
20-20 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
When
When
screwdriver is 1. Turn starting switch
Between screwdriver is
Boom kick-out Measure not brought OFF
F06 brought close
proximity switch voltage close 2. Insert T-adapter
3. Turn starting switch ON
(1) - (2) 20 - 30 V Max. 3 V
(1) - (3) 20 - 30 V 20 - 30 V
(2) - (3) Max. 3 V 20 - 30 V
Others
WA500-3H 20-21
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Power source Measure OFF
L28 Between (8), (17), (18) - (9), (18)
voltage voltage 2. Insert T-adapter
When actuated 20 - 30 V 3. Turn starting switch ON
When not actuated Max. 1 V
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
Joystick R CNR Measure OFF
(right) solenoid (male) resistance Between (1) - (2) 10 - 20 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1) - chassis Min. 1 MΩ
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Joystick L CNL Measure OFF
(left) solenoid (male) resistance Between (1) - (2) 10 - 20 Ω 2. Disconnect connector
Joystick Controller
3. Connect T-adapter
Between (1) - chassis Min. 1 MΩ
If the condition is as shown in the table below, it is
normal
Joystick neutral switch between (1) - (3) 1. Turn starting switch
Joystick neutral Measure OFF
NEUTRAL
switch resistance Not at N Max 1 Ω 2. Disconnect connector
3. Connect T-adapter
At N
Min. 1 MΩ
Between (1) - chassis
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
Joystick Measure OFF
L27
potentiometer voltage Between (20) - (9) 2. Insert T-adapter
3. Turn starting switch ON
When actuated 0.5 - 4.5 V
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Between (1) - (2) 0-5Ω OFF
Joystick JS7 Measure
2. Disconnect connector
potentiometer (male) resistance
Between (2) - (3) 4-5Ω 3. Connect T-adapter
4. Start engine
Between (3) - (1) 0-5Ω
20-22 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
WA500-3H 20-23
TESTING AND ADJUSTING SKETCHES OF SPECIAL TOOLS
12
SKETCHES OF SPECIAL TOOLS
TOOL N
Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
20-24 WA500-3H
TESTING AND ADJUSTING ENGINE
ENGINE
Remark
To tune, test and troubleshoot the following procedures you must refer to ENGINE SHOP MANUAL
Section 12 for tools and proper procedure.
RUN-IN STANDARD
WA500-3H 20-25
TESTING AND ADJUSTING TORQUE CONVERTER STALL SPEEDS
12
TORQUE CONVERTER STALL SPEEDS
★ Measurement conditions
• Coolant temperature: Inside operating range
• Hydraulic oil temperature: 45 - 55°C (113 - 131°F)
• Torque converter oil temperature: 70 - 90°C (158 - 194°F)
★ Check that the low and high idle speeds are at the standard value.
★ Before measuring at each stall speed, install tachometer (A), using the
instructions that came with it.
C. Using the brake, stop the machine and measure the engine speed
when the accelerator pedal is fully depressed.
★ Turn the transmission cut-off selector switch (1) to the OFF
position and use the left brake. (Check that the pilot lamp is
OFF).
★ Do not run at the stall speed for more than 20 seconds and do
not let the torque converter oil temperature raise above 120°C
(248°F).
★ Turn the parking brake switch OFF (release).
2. Adjusting
A. Loosen mount bolt and nut, and the adjustment plate bolt and nut.
D. After adjusting the belt tension, repeat the testing procedure above
to check that the tension is adjusted within the standard value.
20-26 WA500-3H
TESTING AND ADJUSTING SHIFT LEVERS
12
SHIFT LEVERS
★ Measurement conditions:
• Engine stopped
• Torque converter oil temperature: 60 - 80° C (140 - 176° F)
• Measure at center of lever knob
WA500-3H 20-27
TESTING AND ADJUSTING ACCELERATOR PEDAL
12
ACCELERATOR PEDAL
OPERATING FORCE
1. Measuring procedure
B. Start the engine, push the pedal in the direction of operation and
measure the maximum value when pushing from low idle to the end of the pedal travel (high idling).
Remark
There is no testing and adjustment (unit is electronically controlled).
20-28 WA500-3H
TESTING AND ADJUSTING ACCELERATOR PEDAL
12
OPERATING ANGLE
1. Measuring procedure
B. Put angle gauge "A" in contact with the accelerator pedal, then
measure the operating angle from low idle to high idle, and
calculate operating angle a = a1 - a2.
2. Adjusting procedure
A. Remove the cover under the cab, and open the inspection cover on
the right side of the engine.
B. Loosen nut (1) and adjust bolt (2) so that pedal stroke angle is 13°.
Remark
See drawing on previous page.
WA500-3H 20-29
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
TORQUE CONVERTER AND TRANSMISSION
OIL PRESSURE
★ Measurement conditions
• Coolant temperature: Inside operating range.
• Torque converter oil temperature: 60 - 80°C
• Engine speed: High idle
• Manual switch ON
A. Remove the cover at the front of the engine and the cover at the
rear of the operator’s compartment.
C. Start the engine and measure the oil pressure with the engine at
low idling and high idling.
If the main relief pressure is not within the standard value, adjust as
follows:
20-30 WA500-3H
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
3. Measuring torque converter relief (inlet port) pressure
A. Remove the cover at the front of the engine and the cover at the
rear of the operator’s compartment.
C. Start the engine and measure the oil pressure with the engine at
high idling. (If the pressure is not affected by any adjustments, it
may indicate possible need for repair.)
C. Start the engine and measure the oil pressure with the engine at
high idling. (If the pressure is not affected by any adjustments, it
may indicate possible need for repair.)
WA500-3H 20-31
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
5. Measuring ECMV output (clutch) pressure
A. Remove the cover at the front of the engine and the cover at the
rear of the operator’s compartment.
D. Start engine and measure the 1st, 2nd, 3rd, and 4th clutch
pressures under the following conditions at high idling.
iii. Place the gear shift lever at the speed range to be measured.
E. Start the engine and measure the forward and reverse clutch
pressures under the following conditions at high idling.
iii. Turn the main monitor manual switch ON and place the
gearshift lever in 4th.
iv. Keep the brake depressed and place the directional lever at
F or R.
ii. Remove the oil pressure measurement plug (1), then, install
oil pressure gauge C1 60 kg/cm2 (853.4 lbf/in2).
20-32 WA500-3H
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
iii. Start the engine and measure the oil pressure with the engine at high idling. (If the pressure is not affected by any
adjustments, it may indicate possible need for repair.)
WA500-3H 20-33
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
HYDRAULIC CIRCUIT FLUSHING
★ Metal particles and other dirt in the torque converter and transmission hydraulic circuit will reduce the life of the torque
converter and transmission, and will cause internal damage. To prevent this, flush the system to remove the dirt or metal
particles in the hydraulic circuit.
A. If there has been any breakage of the torque converter, transmission, or hydraulic equipment, and metal particles are
circulating in the hydraulic circuit.
B. When the torque converter and transmission have been overhauled or repaired.
B. Remove the two transmission oil filters, then install two flushing elements (561-15-55670).
★ After flushing the system, assemble the parts that were removed, and the parts inside the case.
A. After starting the engine, run the engine for approximately 20 minutes at low idling without operating the speed lever
or directional lever.
★ From time to time, raise the engine speed to approximately 1500 rpm.
★ If the ambient temperature is low and the engine coolant temperature gauge does not enter the green range,
continue the warming-up operation longer.
C. Repeat the procedure in 4-A, and run the engine at low idling for approximately 20 minutes.
20-34 WA500-3H
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
5. Replace the flushing element.
A. Using the procedure in step 2-A, replace the flushing element with the standard element (424-16-11140).
WARNING! If the flushing element is used for a long time, there will be premature clogging, so always
replace the flushing element with the standard element.
A. Use a wrench to turn portion (A) of fail safe filter case (1) to
remove it.
★ If there is any dirt inside the filter case, wash the case.
WA500-3H 20-35
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
TRANSMISSION VALVE FAILS - MOVING MACHINE
★ If the machine cannot be moved because of a failure in any part of the
transmission valve system (electrical system, solenoid valves, spools,
etc.), it is possible to move the machine by installing plate N.
1. Remove the cover at the bottom of the operator’s cab, and the cab at
the bottom of the step on the left side.
20-36 WA500-3H
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
4. Depending on the direction for moving the machine (forward or
reverse), remove the following 2 ECMV solenoids (14) and install
plate N.
• FORWARD: F solenoid and 2nd solenoid
• REVERSE: R solenoid and 2nd solenoid
★ If there is any mistake in the selection of the solenoid to
remove, there is danger that the transmission may be
damaged.
★ Install plate N with the protruding surface facing the ECMV.
Check also that there is an O-ring installed to the mating
surface.
★ Be careful not to let any dirt or mud get inside the removed
solenoid or valve
6. Start the engine, release the parking brake, then release the brake pedal
gradually to allow the machine to start, then move the machine.
WA500-3H 20-37
TESTING AND ADJUSTING STEERING WHEEL
12
STEERING WHEEL
MEASURING PLAY
★ Measurement conditions
• Engine speed: Stopped
• Machine posture: Facing straight forward
Method of measurement
A. Move the steering wheel 2 or 3 times lightly to the left and right,
check that the steering mechanism is at the neutral position, then
make a mark on the outside frame of the machine monitor.
B. Turn the steering wheel to the right, and make a mark at the
position where the operating force starts to become heavy (when
the steering valve lever starts to move).
C. Turn the steering wheel to the left in the opposite direction from
Step 2, and make a mark at the point where the operating force
becomes heavy (when the steering valve lever starts to move).
Then measure the distance in a straight line between the marks
made in Step 2 and Step 3.
Measurement method
C. Pull push-pull scale l2 in the tangential direction and measure the value when the steering wheel moves smoothly.
★ Avoid measuring when the steering wheel starts to move.
20-38 WA500-3H
TESTING AND ADJUSTING STEERING WHEEL
12
MEASURING OPERATING TIME
★ Measurement conditions
• Road surface: Flat, horizontal, dry paved surface
• Engine water temperature: Within green range on engine water
temperature gauge
• Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
• Tire inflation pressure: Specified pressure
• Engine speed: Low and high idling
Measurement method
B. Operate the steering wheel to the end of its stroke to turn the machine to the left or right.
C. Measure the time taken to operate the steering wheel to the end of the stroke to the right (left).
★ Operate the steering wheel as quickly as possible without using force.
★ Carry out the measurements both at low idling and high idling, and to both the left and right.
WA500-3H 20-39
TESTING AND ADJUSTING STEERING OIL PRESSURE
12
STEERING OIL PRESSURE
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
MEASURING
1. Measuring steering relief pressure
B. Start the engine, run the engine at high idling, then turn the
steering wheel to the right and measure the pressure when the
relief valve is actuated.
★ When removing the oil pressure measurement plug on the left
steering cylinder, turn the steering wheel to the left.
C. Start the engine and measure the oil pressure when the steering
wheel is turned with the engine running at high idling.
20-40 WA500-3H
TESTING AND ADJUSTING STEERING OIL PRESSURE
12
3. Measuring Orbit-roll output pressure
C. Start the engine and measure the oil pressure when the steering
wheel is turned with the engine running at high idling.
★ Hose (1): Turn steering to right
Hose (2): Turn steering to left
ADJUSTING
WA500-3H 20-41
TESTING AND ADJUSTING STEERING STOP VALVE
12
STEERING STOP VALVE
TESTING
1. Set the front and rear frames facing straight.
3. Start the engine, and check that there is a clearance between the front
frame stopper and rear frame stopper when the steering is turned to the
right or left.
★ Measure the clearance between the front frame and rear frame
when steering stop valve contact surface (3) and stopper bolt (1)
coming into contact and the turning stops. - Standard clearance a:
40 ±5 mm
ADJUSTING
If the clearance between the front frame and rear frame is not within the
standard value, adjust as follows.
1. Loosen locknut (2), tighten stopper bolt (1), and make sure that there is no contact with the steering stop valve.
2. Start the engine, run at low idling, then turn the steering wheel slowly to bring the front and rear frames into contact.
When turning, be extremely careful not to get your arm or any other part of your body caught between the front and rear
frames.
3. Stop the engine, then loosen the stopper bolt until it contacts the steering stop valve contact surface.
5. Loosen stopper bolt (1) 8.5 turns, then tighten locknut (2).
★ Carry out the procedure in Steps 1 - 5 to adjust both the left and right sides.
6. Start the engine, turn the machine, and check that clearance a between the front and rear frames is within the standard
value for both the left and right and that the steering stopper valve and stopper bolt come into contact and the steering is
stopped.
20-42 WA500-3H
TESTING AND ADJUSTING BRAKE PEDAL
12
BRAKE PEDAL
★ Measurement conditions
• Engine water temperature: Within green range on engine water
temperature gauge
• Engine speed: Low idling
OPERATING FORCE
1. Install push gauge (1) to the operator’s foot.
★ Align the center of the push gauge with the center of the pedal.
2. Start the engine, run at low idling, and measure the operating force
when the pedal is depressed.
TRAVEL
1. Install push gauge (1) to the operator’s foot.
★ Align the center of the push gauge with the center of the pedal.
2. Start the engine, and measure pedal angle a1 when running at low
idling, and pedal angel a2 when the pedal is depressed with a force of
294 N (66 lbf)
★ Install angle gauge (2) to the brake pedal when measuring.
PEDAL PLAY
1. Start the engine.
2. Push the brake pedal lightly by hand, and measure pedal angle a3 when
the pedal starts to become heavy.
WA500-3H 20-43
TESTING AND ADJUSTING BRAKE PERFORMANCE
12
BRAKE PERFORMANCE
★ Measurement conditions
• Road surface: Flat, horizontal, dry paved surface
• Travel speed: 20 km/h when brakes are applied
• Delay in applying brakes: 0.1 sec.
• Tire inflation pressure: Specified pressure
MEASUREMENT METHOD
2. Set the speed lever to the highest speed position and drive the machine.
3. When the travel speed reaches 20 km/h, depress the left brake pedal with the specified operating force.
★ Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the
brakes when the machine reaches that point.
★ Switch the transmission cut-off switch ON when carrying out this operation.
4. Measure the distance from the point where the brakes were applied to the point where the machine stopped.
★ Repeat this measurement three times and take the average.
20-44 WA500-3H
TESTING AND ADJUSTING TESTING BRAKE OIL PRESSURE
12
TESTING BRAKE OIL PRESSURE
1. Inspecting
A. Remove bleeder screw (1), then install oil pressure gauge tool 1
400 kgf/cm2 (2942 lbf/in2), the joint, bleeder screw, and nipple.
B. Connect hose (2) to the bleeder screw and bleed the air from the
brake circuit. For details, see BLEEDING AIR.
C. Depress the left brake and measure the brake oil pressure.
A. Remove bleeder screw (1), then install oil pressure gauge tool l
400 kgf/cm2 (2942 lbf/in2), the joint, bleeder screw, and nipple.
B. Connect hose (2) to the bleeder screw and bleed the air from the
brake circuit. For details, see BLEEDING AIR.
C. Stop engine, depress the left brake pedal, leave for 5 min. with the
oil pressure at 50 kgf/cm2 (711 lbf/in2), and measure the drop in
★ Be careful not to move the brake pedal for 5 minutes.
★ After completing the operation, bleed the air from the brake
circuit again.
WA500-3H 20-45
TESTING AND ADJUSTING BRAKE DISC WEAR
12
BRAKE DISC WEAR
★ Brake oil pressure: 50 ±5 kg/cm2 (711 ±71 lbf/in2)
Measurement Method
3. Use calipers M to measure depth a from the end face of the housing to
the spring guide.
★ When measuring, keep the brake pedal depressed.
4. Install a vinyl hose (3) to bleeder (2), then loosen the bleeder and drain
the brake oil.
★ After draining the brake oil, check that the brake piston has
returned to the end of its stroke.
5. Measure depth b from the end face of the housing to the spring guide
pin.
20-46 WA500-3H
TESTING AND ADJUSTING PARKING BRAKE
12
PARKING BRAKE
Performance
★ Measurement conditions
• Tire inflation pressure: Specified pressure
• Road surface: Flat, dry, paved surface with 1/5 (11°20') gradient.
• Machine: In operation condition
Measuring Procedure
1. Start the engine, set the machine facing in a straight line, then drive the
machine up a 1/5 grade slope with the bucket empty.
2. Depress the brake, stop the machine, set the directional lever to the
neutral position, then stop the engine.
3. Turn the parking brake switch ON, then slowly release the brake pedal,
and the machine must not move at all.
★ Carry out the measurement in two ways. Once with the machine
facing uphill, and once more with the machine facing downhill.
WA500-3H 20-47
TESTING AND ADJUSTING PARKING BRAKE
12
OIL PRESSURE
1. Measuring parking brake inlet port
★ Torque converter oil temperature: 60 - 80° C (140 - 176° F)
D. Start the engine and measure with the engine running at low idling
and high idling.
A. Remove the cover at the front of the engine and the cover at the
top of the transmission.
B. Disconnect hose (1), then install adapter and oil pressure gauge in
tool C1 60 kgf/cm2 (853 lbf/in2).
20-48 WA500-3H
TESTING AND ADJUSTING PARKING BRAKE
12
3. Measuring parking brake solenoid valve output pressure
★ Torque converter oil temperature: 60 - 80° C (140 - 176° F)
A. Remove the cover at the front of the engine and the cover at the
top of the transmission.
B. Disconnect hose (1), then install adapter and oil pressure gauge in
tool C1 60 kgf/cm2 (853 lbf/in2).
WA500-3H 20-49
TESTING AND ADJUSTING PARKING BRAKE
12
DISC WEAR
★ If the parking brake effect becomes weak, measure the wear of the
parking brake disc as follows.
3. Using calipers M, measure depth a from the end face of cage (2) to
piston (3).
• Standard depth a: Max. 40.3 mm
20-50 WA500-3H
TESTING AND ADJUSTING PARKING BRAKE
12
MANUAL RELEASE METHOD
★ The parking brake is controlled by hydraulic pressure, so if there
should be any failure in the transmission and it becomes impossible to
release the parking brake, it is possible to release it manually to move
the machine.
2. Remove two cage mounting bolts (2), then screw them into the plug
mount gradually in turn.
★ When bolts (2) are screwed in, piston (3) is pulled and the parking
brake is released.
WA500-3H 20-51
TESTING AND ADJUSTING PPC VALVE
12
PPC VALVE
OIL PRESSURE
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° f)
MEASURING
C. Start the engine and measure the oil pressure at high idling.
A. Disconnect hose (1), then install the adapter and oil pressure
gauge 60 kgf/cm2 (853 lbf/in2) in tool C1.
B. Start the engine, run the engine at high idling, then operate the
work equipment control lever and measure the oil pressure.
20-52 WA500-3H
TESTING AND ADJUSTING PPC VALVE
12
3. Measuring PPC valve output pressure
C. Start the engine, run the engine at high idling, then operate the
work equipment control lever and measure the oil pressure.
ADJUSTING
WA500-3H 20-53
TESTING AND ADJUSTING PPC VALVE
12PPC
ADJUSTING LINKAGE
1. Remove cover (1) at the bottom of the work equipment control lever.
2. Adjust dimension a from nut (1) of the PPC valve linkage to the top
surface of the floor.
• Dimension a (target value): 54 mm
3. Loosen nuts (2) and (3), then adjust the installed height of trunnion (5)
so that there is no play in lever (4).
20-54 WA500-3H
TESTING AND ADJUSTING ACCUMULATOR
12
ACCUMULATOR
CHARGE PRESSURE
MEASURING
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
1. Disconnect accumulator inlet port hose (1), then install the adapter and
oil pressure gauge 400 kg/cm2 (2942 lbf/in2) in tool C1.
2. Measure the accumulator charge cut-in pressure. Start the engine, run
at low idling, and measure the oil pressure when the brake oil pressure
warning pilot lamp on the maintenance monitor goes out.
ADJUSTING
★ When the accumulator charge cut-out pressure is adjusted, the cut-in
pressure also changes because of the valve area ratio. For this reason,
there is no cut-in pressure adjustment nut.
1. Loosen locknut (2) of the accumulator charge cut-out valve (1), then
turn adjustment screw (3) to adjust.
★ Turn the adjustment screw to adjust as follows:
• To INCREASE the pressure, turn clockwise.
• To DECREASE the pressure, turn counter clockwise.
★ Amount of adjustment - for one turn of adjustment screw:
57 kg/cm2 (810 lbf/in2)
WA500-3H 20-55
TESTING AND ADJUSTING WORK EQUIPMENT
12
WORK EQUIPMENT
HYDRAULIC PRESSURE
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
B. Stop the engine, then operate the work equipment control lever
and check that the bottom surface of the bucket (both portion a
and portion b is in contact with the ground.
★ After lowering the bucket to the ground, operate the work
equipment control lever several times to release the
remaining pressure in the piping.
20-56 WA500-3H
TESTING AND ADJUSTING WORK EQUIPMENT
12
E. Start the engine, raise the lift arm approximately 400 mm, run the
engine at high idling, tilt the bucket back, then measure the oil
pressure when the relief valve is actuated.
ADJUSTING
1. Adjusting work equipment relief valve.
A. Loosen locknut (2) of work equipment relief valve (1), then turn
adjustment screw (3) to adjust.
★ Turn the adjustment screw to adjust as follows.
To INCREASE the pressure, turn clockwise.
To DECREASE the pressure, turn counter clockwise.
★ Amount of adjustment for one turn of adjustment screw:
52.9 kg/cm2 (752 lbf/in2)
WA500-3H 20-57
TESTING AND ADJUSTING WORK EQUIPMENT
12
RELEASING REMAINING PRESSURE
1. Releasing remaining pressure between each hydraulic cylinder and control valve.
★ If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining
pressure from the circuit as follows:
B. Release the oil filler cap slowly to release the pressure inside the tank.
20-58 WA500-3H
TESTING AND ADJUSTING WORK EQUIPMENT
12
LEVER LINKAGE
ADJUSTING
★ Always stop the engine before adjusting the work equipment lever
linkage.
★ Check that the operating effort of the work equipment control lever is
within the standard value.
3. Operate the boom lever and adjust distance c between the pins of rod
(8) so that clearance b between the notches at both ends of boom lever
cam (4) and boom lever cam follower (5) is 0 - 1 mm.
★ Distance c between pins of rod (8): 337 mm
4. Operate the bucket lever and adjust distance c between the pins of rod
(8) so that clearance d between the notches (1 place) bucket lever cam
(6) and bucket lever cam follower (7) is 0 - 1 mm.
★ Distance c between pins of rod (8): 337 mm
WA500-3H 20-59
TESTING AND ADJUSTING BLEEDING AIR
12
BLEEDING AIR
A. Remove cap (1) of the bleeder screw, insert a vinyl hose into the
screw, and insert the other end in a container.
C. Depress the brake pedal, then loosen the bleeder screw and bleed the air.
★ This operation is carried out with two workers. One worker operates the brake pedal while the other bleeds the
air from the bleeder screw.
★ When depressing the brake pedal, use the left pedal.
D. When no more air bubbles come out with the fluid from the hose, depress the pedal fully and tighten the bleeder
screw while the oil is still flowing.
★ Repeat the operation to bleed the air from the other cylinders, and after completing the operation, check the level
in the oil tank and add more oil if necessary.
★ To bleed the air completely, bleed the air first from the cylinder which is farthest from the brake pedal.
B. Run the engine at low idling, the raise and lower the boom 4 - 5 times in succession.
★ Operate the piston rod to a point approximately 100 mm before the end of its stroke. Do not relieve the circuit
under any circumstances.
C. Run the engine at full throttle and repeat step B. After that, run the engine at low idling, and operate the piston rod to
the end of its stroke to relieve the circuit.
D. Repeat steps B and C to bleed the air from the bucket cylinder.
★ When the cylinder has been replaced, bleed the air before connecting the piston rod.
20-60 WA500-3H
TESTING AND ADJUSTING BUCKET POSITIONER
12
BUCKET POSITIONER
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
TESTING
1. Start the engine, operate the bucket and actuate proximity switch (1),
then stop the engine and measure clearance a between the proximity
switch and angle (2).
★ Standard clearance a: 3 - 5 mm
2. Run the engine at mid-range speed (1500 rpm), actuate the proximity
switch, and check that the bucket angle is 0 - 1° facing down when the
bucket is lowered to the ground. Measure dimension b between the
center of the proximity switch to the tip of the angle.
★ Measure three times and take the average.
★ Standard dimension b: 15 mm
ADJUSTING
1. If dimension a is not within the standard value, adjust as follows:
A. Adjust mounting nut (4) so that clearance c between the tip of the
switch protector (3) and the sensing surface of proximity switch
(1) is the standard value.
★ Standard clearance c: 0.5 - 1.0 mm
B. Adjust with washer (5) and shim (6) so that clearance a between
the sensing surface of proximity switch (1) and angle (2) is the
standard value.
2. If the bucket angle and dimension b are not within the standard value,
move the switch protector (3) to adjust
WA500-3H 20-61
TESTING AND ADJUSTING BOOM POSITIONER
12
BOOM POSITIONER
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
TESTING
1. Start the engine, operate the boom lever to actuate proximity switch
(1), then stop the engine and measure dimension a between the center
of proximity switch (1) and the top of plate (2).
★ Standard clearance a: 0 - 5 mm
ADJUSTING
1. If the dimension a is not within the standard value, move the plate to
adjust.
★ After adjusting, operate the boom lever and check that the proximity switch is actuated normally.
20-62 WA500-3H
TESTING AND ADJUSTING BOOM POSITIONER
12
Proximity switch actuation pilot lamp (red)
The proximity switch is equipped with a pilot lamp which shows when it is
being actuated, so use this when adjusting.
Proximity switch
actuation Lights up Goes out
pilot lamp
When detector is positioned at detection surface When detector has moved away from detection surface of
Detector position
of proximity switch proximity switch
Bucket
positioner
Boom kick-out
WA500-3H 20-63
TESTING AND ADJUSTING TRANSMISSION CONTROLLER
12
TRANSMISSION CONTROLLER
★ The transmission controller is equipped with a learning function to self compensate so that it provides a constant gear
shifting feeling to match the changes in the transmission clutches occurring with the wear.
If the transmission is overhauled or replaced, the transmission controller keeps the control command values learned to
match the previous transmission. For this reason, transmission shock or abnormal noise may occur. After operating the
machine for a short time, the controller will learn to match the condition of the new transmission and will gradually return
to the normal condition, but if it is desired to reset the condition quickly and to carry out learning again, it is possible to
reset the learning data and to carry out initial learning as follows.
B. Remove the cover at the right side of the work equipment control
box.
E. Short circuit between terminals No. (1) to (16) for at least one second, then return them to free condition.
A. Stall the torque converter. For details, see ENGINE SHOP MANUAL.
20-64 WA500-3H
TESTING AND ADJUSTING TRANSMISSION CONTROLLER
12
C. When the torque converter oil temperature gauge rises to the 2nd level on the maintenance monitor, return engine
to low idling.
★ Target value for torque converter oil temperature: 40 - 50° C (104 - 122° F)
★ There is no problem if oil temperature gauge goes down to the lst level.
D. Operate the speed lever and directional lever twice in succession as follows:
N → F1 → F2 → F3 → F4 → F3 → F2 → F1 → N → R1 → N
★ Operate the levers with engine running at low idling, transmission cutoff selector switch at OFF, and the manual
switch at ON.
★ Hold for the following periods of time for each speed range.
• Speed range 4 only: 3 seconds
• Other speed ranges: 2 seconds
★ After carrying out gear shifting operation in Step B, if engine is stopped before carrying out the gear shifting
operation in Step D, repeat Step B again.
★ It is possible to carry out this operation with the left brake pedal depressed fully, so there is no need to travel.
WARNING! Check area around the machine to be sure it is safe and depress the left brake securely
when shifting gear.
WA500-3H 20-65
TESTING AND ADJUSTING MAIN MONITOR
12
MAIN MONITOR
ADJUSTMENT PROCEDURE
• The speedometer on the main monitor is a common part for all machines, the input signal for the travel speed differs
according to the machine, so it is necessary to adjust the monitor for use with a particular model.
• In addition, the tire diameter also differs according to the size of tires used, so it is necessary the monitor to give the
correct travel speed.
• It is also necessary to change the switches if the machine has E.C.S.S. (Electronically Controlled Suspension System)
installed.
2. When the rubber caps are removed, a rotary switch can be seen
inside. Using a flat-blade screwdriver, turn the dipswitch to adjust
the settings per the tables on the following pages.
20-66 WA500-3H
TESTING AND ADJUSTING MAIN MONITOR
3. DIP SW1, DIP SW2, and DIP SW3 are rotary switches.
Controls model and weather the monitor
DIP SW1 displays miles per hour (mph) or kilometers per
hour (Km/h).
29.5 x 25 km/h 5 4 0 1
29.5 x 25 mph D 4 0 1
★ The tachometer feature will only work on loaders equipped with the "Autoshift" transmission.
1 ON ON
2 ON ON
3 ON OFF
4 OFF OFF
WA500-3H 20-67
TESTING AND ADJUSTING MAIN MONITOR
12
MEMORANDUM
20-68 WA500-3H
TROUBLESHOOTING GENERAL
WA500-3H 20-101
TROUBLESHOOTING
12
MEMORANDUM
20-102 WA500-3H
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and
parking brake are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the
agreed signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out
and cause burns, so wait for the engine to cool down before starting
troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating
parts.
WARNING! When disconnecting wiring, always disconnect the negative (-) terminal of the
battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil,
water or air, always release the internal pressure first. When installing measuring
equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However, a
short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure
that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of the
user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investiga-
tion and to carry out troubleshooting in accordance with the fixed procedure.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
WA500-3H 20-103
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
3. Check before troubleshooting.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5. Troubleshooting
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
20-104 WA500-3H
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLE-
12
SEQUENCE OF EVENTS IN TROUBLESHOOTING
WA500-3H 20-105
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to pre-
vent failures or other troubles before they occur, correct operation, mainte-
nance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mecha-
tronics and is aimed at improving the quality of repairs. For this purpose, it
gives sections on ’Handling electric equipment’ and ’Handling hydraulic
equipment’ (particularly hydraulic oil).
20-106 WA500-3H
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
C. Disconnections in wiring
If the wiring is held and tugged 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
compression of the connectors to the wire may be loosened, or the
soldering may be damaged, or the wiring may be broken.
WA500-3H 20-107
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
3. Removing, installing, and drying connectors and wiring harnesses.
A. Disconnecting connectors
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up and
down, the housing may break.
20-108 WA500-3H
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
iv. Action to take after removing connectors.
After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.
B. Connecting connectors
WA500-3H 20-109
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and check
that there is no looseness of the clamp.
i. Disconnect the connector and wipe off the water with a dry
cloth.
★ If the connector is blown dry with air, there is the risk that
oil in the air may cause a faulty contact, so avoid
blowing with air.
20-110 WA500-3H
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
HANDLING CONTROL BOX
1. The control box contains a microcomputer and electronic control
circuits.
This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control box.
6. Do not place the control box on oil, water, or soil, or in any hot place,
even for a short time.
(Place it on a suitable dry stand)
WA500-3H 20-111
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
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.
20-112 WA500-3H
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
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 cir-
cuit 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. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary flushing is carried out
with flushing oil, 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 circuit.
The oil cleaning equipment is used to remove the ultra fine (about 3µ)
particles that the filter built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
WA500-3H 20-113
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item standard Remedy
Lubricating oil, cooling water
10. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring - Repair or replace
12. Check operation of instruments - Repair or replace
13. Check for abnormal noise, smell - Repair
mechanical
Hydraulic,
equipment
20-114 WA500-3H
TROUBLESHOOTING JUDGEMENT OF POWER TRAIN
12
JUDGEMENT OF POWER TRAIN
To judge if any abnormality in the power train is in the electrical system of the transmission or in the transmission itself, use
the following judgement flow chart. If the abnormality is in the electrical system, carry out troubleshooting for E-5, and if the
abnormality is in the transmission system, go to troubleshooting T-1 - T-4.
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower
the bucket to the ground and stop the engine. Then apply the parking brake and
put blocks under the wheels to prevent the machine from moving.
1. Install a T-adapter checker to connector CNFT1, and check the voltage between the connector pins and the chassis ground.
4. When using the foot brake, press the right brake so that the transmission cut-off is not turned off.
WA500-3H 20-115
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
12
PRECAUTIONS WHEN TROUBLESHOOTING
SAFETY
WARNING! Stop the machine on level ground, and check that the safety pins and parking brake are
correctly applied, and that the tires are blocked.
WARNING! When working in groups, use agreed upon signals and do not allow unauthorized per-
sons near machine.
WARNING! Be careful not to get burned by hot parts or get caught in rotating parts.
WARNING! Always disconnect the cable from the negative (-) terminals of the battery before discon-
necting any wiring.
WARNING! Always release the pressure before removing the plugs or caps of any place under
hydraulic or air pressure, and connect all measuring tools correctly.
As a result,
• The customer and operator will lose confidence in you.
• Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.
1. Ask the customer and operator the following questions about the breakdown.
B. Have there been any other problems apart from the one reported?
C. Did the breakdown occur suddenly, or had there been signs of trouble before?
E. Had the machine been repaired before the breakdown? If so, who carried out the repair, and when?
2. Check the following items which can be checked simply by visual checks etc.
20-116 WA500-3H
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
3. Reenact the failure and check the condition of the machine (particular conditions at the time of failure).
A. Ask the user or operator if the decision about the failure was made based on measured values, or by comparison, or
by feeling.
D. Did not make any check or measurement that will make the condition worse.
A. TROUBLESHOOTING TABLE
POWER TRAIN
STEERING SYSTEM
BRAKE AND AIR SYSTEM
WORK EQUIPMENT SYSTEM
Follow theses charts to carry out troubleshooting. At the same time, do not forget the following points.
• Check related items.
• Check that there are no other failures or breakdowns.
WA500-3H 20-117
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
12
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR
ASSEMBLING PARTS DURING TROUBLESHOOTING
Carry out the various testing and adjusting while observing the items on quality control given in "Testing and Adjusting".
When removing parts, check their condition of mounting, and distinguish between front and rear, left and right, and top and
bottom.
Check the match marks, or make match marks to prevent mistakes when installing.
If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it. Check the
part to see if there is any problem with it and remove the problem before trying to disassemble the part.
When installing or assembling, clean off all dust and dirt and repair any scratches or dents. Remove all grease or oil before
coating with gasket sealant.
20-118 WA500-3H
TROUBLESHOOTING PREVENTING RECURRENCE OF TROUBLE
12
PREVENTING RECURRENCE OF TROUBLE
• The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment.
However, it is not able to establish the root cause of the damage or failure.
• Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention
what action should be taken to prevent a recurrence of the root cause.
• In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while refer-
ring to the following items.
• Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting" in the
Shop Manual.
HYDRAULIC EQUIPMENT
OIL CHECKS
The fundamental cause of almost all faults occurring in hydraulic equipment is the inclusion of water, air or other foreign
matter in the oil. Accordingly, it is necessary to check the oil to see whether or not it contains any of the above substances, and
then take appropriate action.
1. Oil checks
• Check for water contamination.
Check the oil for possible water contamination by means of a diesel engine oil checker or a hot plate.
• Check for contamination of other foreign matter. Remove the drain plug and filter, then check the bottom of the tank
and also the filter to see if any foreign matter has collected there. Check the degree of contamination by means of a
contamination checker.
• Viscosity check
Check the viscosity of the oil using a viscometer in order to confirm whether or not the oil is satisfactory.
In addition, disassemble and wash such parts as valves and cylinders which are liable to collect metal fragments and other
foreign matter, thus helping to prevent a recurrence of faults due to such fragments becoming lodged in various parts of the
engine or hydraulic equipment.
WA500-3H 20-119
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING
12
METHOD OF USING TROUBLESHOOTING CHARTS
Remark
Troubleshooting code number E-00 Engine Electrical System are found in the ENGINE SHOP MANUAL.
2. Distinguishing conditions.
Even with the same failure mode (problem), the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small
letters (for example, (a)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start the troubleshooting from the first check item in the failure
mode. (See Example (2)).
20-120 WA500-3H
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING
12
4. General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all the items are given at the
top of the page and marked with a .(See Example (4)).
The precautions marked are not given in the condition box, but must always be followed when carrying out the
check inside the condition box.
5. Troubleshooting tools
When carrying out troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING,
ADJUSTING AND TROUBLESHOOTING.
(4)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
WA500-3H 20-121
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLE-
12
METHOD OF USING MATRIX TROUBLESHOOTING TABLES
The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of fail-
ures in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steer-
ing system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to locate
the problems accurately and swiftly.
Step 1. Questioning the operator 1. Steering does not work Symptom [Example]
The questions to ask the operator are given below the
failure symptom. If the answers to the questions match the Ask the operator about the following points.
information given, follow the arrow to reach the probable • Did the steering suddenly stop working? ➛ Breakage in
cause of the failure. steering equipment
Consider the contents of the questions and consult the table • Did the steering gradually become heavy? ➛ Internal wear
while proceeding to Steps 2 and 3 to grasp the true cause. of steering equipment, defective seal.
20-122 WA500-3H
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLE-
12
3) Operate the machine and check the troubleshooting items
other than those in 1).
Operate the machine and check the items in the same way
Causes
as in 1) and if the symptom appears, mark that item. (In
the chart on the right, the symptom appears again for item
a b c d e
5).
Remedy
X C X A X
Problems
4) Find the appropriate cause from the cause column. In the
1 O O O O
same way as in Step 2), if the symptom appears, the O
2 O ●
marks on that line indicate the possible causes. (For item
3 O O
No.5 in the table on the right, the possible causes are b or
4 O O
e.)
5 ● ●
5) Narrow down the possible causes.
There is one common cause among the causes located in Applicable troubleshooting item located in Step 3).
Applicable troubleshooting item located in Step 1).
Steps 2) and 4). (One cause marked O, appears on the line
for both items.) This cause is common to both the
symptoms in troubleshooting Steps 1) and 3).
Ignore these causes
★ The causes which are not common to both
troubleshooting items (items which are not marked O
for both symptoms) are unlikely causes, so ignore them.
Causes
Common causes
(In the example given on the right, the causes for
Troubleshooting Item 2 are c or e, and the causes for
a b c d e
Troubleshooting Item 5 are b or e, so cause e is Remedy
common to both.) X C X A X
Problems
1 O O O O
6) Repeat the operations in Steps 3), 4) and 5) until one 2 ● ●
cause (one common cause) remains. 3 O O
★ If the causes cannot be narrowed down to one cause, 4 O O
narrow the causes down as far as possible. 5 ● ●
7) Remedy
If the causes are narrowed down to one common cause,
take the action given in the remedy column.
Causes
WA500-3H 20-123
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12
METHOD OF USING ENGINE RELATED CHARTS
Using troubleshooting charts for engine-related failure
This troubleshooting chart is divided into three sections:
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 chart on the right corresponds to the
items where answers can be obtained from the user. The items
in (B) are items that can be obtained from the user, depending
on the user’ level.
[Check items]
The serviceman carries out simple inspection to narrow down
the causes. The items under (C) in the chart on the right
correspond to this.
The service man narrows down the causes from information
(A) that he has obtained from the user and the results of (C)
that he has obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in order of probability, starting
with the causes that have been marked with having the highest
probability from information gained from [Questions] and
[Check items]
Causes
(A) (a)
Ques-
tions
(b)
(c)
(B) (d) O
(e) O
Check items
(C)
i ●
Trouble-
shooting
ii ●
iii ●
20-124 WA500-3H
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12
The basic method of using the troubleshooting chart is as follows.
Items listed for [Questions] and [Check items] that have a
relationship with the Cause items are marked with O, and these,
causes that have high probability are marked with a .
Check each of the [Questions] and [Check items] in turn and mark
the O or the in the chart for items where the problem appeared.
The vertical column (Causes) that has the highest number of points
is the most probable cause, so start troubleshooting for that item to
ake final confirmation of the cause.
❇1. For [Confirm recent repair history] in the
[Questions Section, ask the user, and mark the Cause
column with to use as reference for locating the
cause of the failure. However, do not use this when
making calculations to narrow down the causes.
❇2. Use the in the Cause column as reference for
[Degree of use (operated for long period)] in the
[Questions] section as reference.As a rule do not use
it when calculating the points for locating the cause,
but it can be included if necessary to determine the
order for troubleshooting.
Causes
WA500-3H 20-125
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12• Example of troubleshooting when exhaust gas is black
Let assume that [Clogged air cleaner] is taken to be the cause of the black gas. Three symptoms have causal relationship
with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us
explain here the method of using this causal relationship to pin point the most probable cause.
Causes
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-126 WA500-3H
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12
Five causes
Step 1
Three symptoms
Step 2
Step 3
WA500-3H 20-127
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12
MEMORANDUM
20-128 WA500-3H
TROUBLESHOOTING CONNECTORS
12
CONNECTOR ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-153
CONNECTOR NUMBERS, TYPES AND PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-154
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-163
WA500-3H 20-151
TROUBLESHOOTING
12
MEMORANDUM
20-152 WA500-3H
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
12
CONNECTOR ARRANGEMENT DIAGRAM
See foldouts in Section 90.
WA500-3H 20-153
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
12
CONNECTOR NUMBERS, TYPES AND PINS
The address column in the table below shows the address in the connector arrangement diagram.
Connector
Type No. of pins Place of use
Number
A14 4 Relay
A14 X 2 Relay
A15 2 Hi / Lo switch
A5 M 2 Thermistor
B01 X 2 Condenser
B05 2 Diode
B06 2 Diode
20-154 WA500-3H
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
Connector
Type No. of pins Place of use
Number
C02 9 Radio
C13 1 Ground
WA500-3H 20-155
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
Connector
Type No. of pins Place of use
Number
CL4 M 6
D1 2 Diode (ECSS)
D2 2 Diode (ECSS)
20-156 WA500-3H
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
Connector
Type No. of pins Place of use
Number
WA500-3H 20-157
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
Connector
Type No. of pins Place of use
Number
F07 1 Horn
F08 1 Horn
F09 1 Horn
F10 1 Horn
FS2 S 12 Fuse
FS3 M 6 Fuse
FS5 M 6 Fuse
FS6 M 4 Fuse
JL57 DT2 6
JL58 DT2 6
20-158 WA500-3H
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
Connector
Type No. of pins Place of use
Number
JS7 3 Potentiometer
WA500-3H 20-159
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
Connector
Type No. of pins Place of use
Number
20-160 WA500-3H
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
Connector
Type No. of pins Place of use
Number
R01 2 Diode
R02 2 Diode
R03 2 Diode
WA500-3H 20-161
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
Connector
Type No. of pins Place of use
Number
R04 2 Diode
T02 2 Diode
TAC 1 Tachograph
20-162 WA500-3H
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
WA500-3H 20-163
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
20-164 WA500-3H
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
WA500-3H 20-165
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
20-166 WA500-3H
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
WA500-3H 20-167
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
20-168 WA500-3H
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
WA500-3H 20-169
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
20-170 WA500-3H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR
12
WA500-3H 20-171
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR
12
20-172 WA500-3H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR
12
WA500-3H 20-173
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR
12
MEMORANDUM
20-174 WA500-3H
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ECM
WA500-3H 20-201
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
EXPLANATION OF FUNCTIONS OF ECM (ELECTRIC CONTROL
MECHANISM)
20-202 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Function of equipment at input end.
A. F/R switch.
This detects the condition of operation of directional lever and inputs it to the controller as a digital (ON-OFF) signal.
(On machines equipped with joystick, the signal from the joystick switch is also input.)
E. Hold switch.
This detects the condition of operation of the hold switch or shift up switch (when using the joystick) and inputs it to
the controller as a digital (ON-OFF) signal.
F. Kick-down switch.
This detects the condition of operation of the kick-down switch or shift-down switch (when using the joystick) and
inputs it to the controller as a digital (ON-OFF) signal.
I. Speed sensor.
This detects the speed of the transmission output shaft as the travel speed and inputs it to the controller as a pulse
(rotation) signal. (The speed sensor is also used with the main monitor system.)
L. Neutralizer relay.
This detects the condition of actuation of the parking brake and inputs it to the controller as a digital (ON-OFF)
signal.
A. Auto-shift function:
This calculates the optimum speed range from the signals from the switches and sensors, and outputs it to the ECMV
as an analog (current) signal in order to shift up or down.
WA500-3H 20-203
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
B. Modulation control function:
This calculates the optimum modulation pattern from the signals from the switches and sensors in order to reduce the
shock when shifting up or down, and outputs it to the ECMV of both the clutch to be engaged and the clutch to be
disengaged as an analog (current) signal.
C. Hold function:
When the hold switch is turned ON, it outputs a signal to the ECMV to stop the auto-shift and hold it at the same
speed range.
D. Kick-down function:
When the kick-down switch is turned ON, if it matches the control conditions, the signal is output to the ECMV to
shift down to 1st.
H. Buzzer function:
The signal is sent through the main monitor to the alarm buzzer as a digital (ON-OFF) signal according to the
condition of the input signal.
I. Self-diagnostic function:
The controller always observes the directional switch, speed range switch, speed sensor, engine speed sensor,
transmission oil temperature sensor, the 6 ECMV fill switches at the input side, and the 8 ECMV solenoids at the
output side to check that no abnormality occurs in the back-up lamp relay systems.
i. The controller communicates the actuated speed range through the network.
ii. The controller communicates the actuated F/R position through the network. (Machines with joystick.)
iii. It communicates the condition of actuation of the hold mode through the network.
iv. If any abnormality is detected by the self-diagnostic function, it communicates the details of the abnormality
through the network.
20-204 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
4. Main monitor display.
For details, see MAIN MONITOR.
WA500-3H 20-205
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
MAIN MONITOR SYSTEM
20-206 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Functions of equipment at input end
C. Speed sensor.
This detects the speed of the transmission output shaft as the travel speed and inputs it to the main monitor as a pulse
(rotation) signal. (The speed sensor is also used with the transmission control system.)
H. Dimmer switch.
This detects the condition of operation of the dimmer switch and inputs it to the main monitor as a digital (ON-OFF)
signal.
J. Preheating relay.
Optional equipment, detects actuation of the relay from the secondary outlet voltage of the preheating relay, and
inputs it to the main monitor as a digital (ON-OFF) signal.
K. Maintenance monitor.
WA500-3H 20-207
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
L. Starting switch.
i. Terminal BR.
This detects the condition of operation of the starting switch to the ON position and inputs it to the main monitor
as a digital (ON-OFF) signal.
ii. Terminal C.
This detects the condition of operation of the starting switch to the START position and inputs it to the main
monitor through the neutral relay as a digital (ON-OFF) signal.
ii. The directional position (F, N, R) now being selected is communicated (machines with joystick).
iii. When the hold function is actuated, the actuation signal is communicated.
iv. If any abnormality occurs in the transmission control system or ECSS control system, the details of the
abnormality are communicated.
A. Self-check function:
When the starting switch is turned ON, all lamps and meters light up for 3 seconds and the alarm buzzer sounds for 1
second to carry out a self check. (If the starting switch is turned to the START position during the 3 seconds of the
self check, the self check stops.)
B. Speedometer function:
The speedometer is displayed on the meter portion by the signal from the speed sensor. (When the system is set to the
tachometer display specification, the tachometer is displayed on the meter portion by the signal from the engine speed
sensor.)
20-208 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
F. Turn signal pilot lamp function:
The left or right turn signal pilot lamps are made to flash (in the case of hazard the lamps on both sides flash) by the
signal from the turn signal and hazard switch.
A. Alarm buzzer:
This receives the signal from the main monitor and generates the alarm sound. (The alarm buzzer is also used for the
maintenance monitor system.)
WA500-3H 20-209
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
MAINTENANCE MONITOR SYSTEM
20-210 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Functions of equipment at input end.
A. Self-check function:
When the starting switch is turned ON, all lamps and meters light up for 3 seconds and the alarm buzzer sounds for 1
second to carry out a self check. (If the starting switch is turned to the START position during the 3 seconds of the
self check, the self check stops.)
B. Fuel gauge:
The fuel gauge is displayed and the pilot lamp flashes or goes out according to the signal from the fuel level sensor.
WA500-3H 20-211
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
D. Torque converter oil temperature gauge:
The torque converter oil temperature gauge is displayed and the pilot lamp flashes or goes out according to the signal
from the torque converter oil temperature sensor.
K. Service meter:
The service meter is driven by the signal from the engine oil pressure switch.
A. Main monitor:
This receives the signal from the maintenance monitor and makes the CHECK lamps or CAUTION lamps flash.
B. Alarm buzzer:
This receives the signal from the maintenance monitor and makes the buzzer sound. (The alarm buzzer is also used
for the main monitor system.)
20-212 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
MEMORANDUM
WA500-3H 20-213
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
ECSS(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)
CONTROL SYSTEM
This system has functions in the transmission controller, and judges the function by the select signal from the main monitor
when the engine is started.
20-214 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Functions of equipment at input end High.
C. Speed sensor:
This detects the speed of the transmission output shaft as the travel speed (speed) and inputs it to the controller as a
pulse (rotation) signal. (The ECSS system carries out control with the same controller as the transmission control
system, so the speed sensor signal is also used inside the controller.)
A. Damper function:
To prevent pitching and bouncing of the bucket, the input signals from the switches and sensors are output as a digital
(ON-OFF) signal to the relief solenoid (SOL1), High-1) pressure solenoid (SOL2), Low-pressure solenoid (SOL3),
and pressure release solenoid (SOL4).
D. Self-diagnostic function:
The controller always observes the system to check that no abnormality has occurred in the systems for the four
solenoids at the output end.
WA500-3H 20-215
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
3. Functions of equipment at output end.
20-216 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
MEMORANDUM
WA500-3H 20-217
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
JOYSTICK STEERING CONTROL SYSTEM
This section describes only the items related to steering in the joystick steering control system. For details of the transmission,
see TRANSMISSION CONTROL SYSTEM.
20-218 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Functions of equipment at input end.
D. Joystick potentiometer:
This detects the angle of operation of the steering lever and inputs it to the controller as an analog (current) signal.
B. Steering function:
This calculates the signal from the steering potentiometer and outputs an analog (current) signal corresponding to this
to the left and right steering solenoids.
E. Self-diagnostic function:
The controller always observes the condition to check that there is no abnormality in the joystick potentiometer and
joystick neutral switch systems at the input end and the left and right steering solenoids, solenoid cut relay, and
caution relay systems at the output end.
WA500-3H 20-219
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
C. Solenoid cut relay:
This receives the signal from the controller and drives the solenoid to switch the circuit at the return side of the
steering solenoid ON-OFF.
D. Caution relay:
This receives the signal from the controller and drives the relay to switch the alarm buzzer circuit ON-OFF.
20-220 WA500-3H
TROUBLESHOOTING METHOD OF DISPLAYING ACTION AND
12
METHOD OF DISPLAYING ACTION AND FAILURE CODE
1. Outline
The speedometer display on the main monitor is used to display the troubleshooting for each control system. The nature of
the troubleshooting is displayed as the failure action code, failure code, and the time elapsed since failure. The signals
between the main monitor and each controller are transmitted in serial through the network circuit. (Only the engine
controller uses a special parallel signal.)
i. Failure code
C. The failures are saved in the order that they occur. If a failure code
already exists in the memory, the repeat failure code is not saved.
D. If there are already 9 items in memory, and a 10th failure occurs, the oldest item is deleted and the new item is saved.
It is possible to display the failure code and time elapsed since failure for items saved in memory by operating the
main monitor set switch.
WA500-3H 20-221
TROUBLESHOOTING METHOD OF DISPLAYING ACTION AND
12
5. Switch operation procedure actuation
20-222 WA500-3H
TROUBLESHOOTING CHART OF ACTION CODES, FAILURE
12
CHART OF ACTION CODES, FAILURE CODES AND RE-ENACTION
• After an error occurs, turn starting switch OFF and if the display goes out, it is possible to re-enact the problem as follows.
• For details of the method of displaying the action codes and failure codes, see METHOD OF DISPLAYING SELF
DIAGNOSIS (ERROR CODE) AND SAVING TO MEMORY.
• Re-enaction marks:
★ Turn starting switch ON (with engine stopped)
❑ Start engine
■ Carry out operation to actuate actuator
TRANSMISSION CONTROLLER
TRANSMISSION CONTROL SYSTEM
12 F ECMV solenoid O O ❑ ■ O O
13 R ECMV solenoid O O ❑ ■ O O
E01+
25 Transmission oil temperature sensor O X ★ ★ O O
CALL
★ E23 (short circuit engine speed sensor) can only be detected if the machine is traveling at 4 km/h (3 mp/h) or more.
WA500-3H 20-223
TROUBLESHOOTING CHART OF ACTION CODES, FAILURE
12
ECSS CONTROL SYSTEM
Main Failed system Re-enaction
monitor Failure Alarm
Item Short Discon- Short Discon- Memory
action code buzzer
code circuit nection circuit nection
JOYSTICK CONTROLLER
62 Neutral switch O O ★ ★ O O
E00 63 Potentiometer O O ★ ★ O X
★ E59 and E60 cannot be distinguished, so they are issued at the same time.
★ Disconnection cannot be detected for E56. It is always ON and is called up when there is a failure warning.
ENGINE CONTROLLER
Remark
See ENGINE SHOP MANUAL for engine fault codes.
Main
monitor Failure
Item
action code
code
20-224 WA500-3H
TROUBLESHOOTING CHART OF ACTION CODES, FAILURE
12
ACTION CODE TABLE.
Transmission control system Joystick control system
Action Action
Action by operator
code buzzer
Problem system Action of machine Problem system Action of machine
Disconnection in travel Automatic gear shifting Disconnection, Shifts to neutral Normal manual
speed sensor system not carried out (changes to short circuit with (possible to switch to gear shifting
manual gear shifting) ground, or short manual) possible
circuit in joystick
FNR signal system
E01 + Short circuit in Suitable gear shifting data Travel under own
CALL transmission oil for transmission oil power possible,
temperature sensor temperature cannot be --- --- Yes move to safe place
selected (there is shock then call for service
when shifting gear)
WA500-3H 20-225
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DIS-
12
TRANSMISSION CONTROLLER LED DISPLAY
The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and input/output
errors. The display shows two characters at the same time, and changes these in turn to give the display.
When the engine is started, “Program part No. display mode" appears, followed by "Output speed range display mode". If
there is any abnormality in the controller, it changes to "Troubleshooting mode". The failure mode is saved to memory by the
main monitor.
20-226 WA500-3H
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DIS-
12
Table 1 (Output speed range display mode)
Display Content Display Content
WA500-3H 20-227
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DIS-
12
MEMORANDUM
20-228 WA500-3H
TROUBLESHOOTING OF ECSS (D MODE)
WA500-3H 20-401
TROUBLESHOOTING JUDGEMENT TABLE FOR CONTROLLER
12
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
ECSS Control System
1. ECSS relay.
2. Short circuit with power source, short circuit with ground, defective
contact, or disconnection in wiring harness between transmission
d0 ECSS relay controller C1 (female) (3) and ECSS relay L90 (1).
3. Defective contact or disconnection in wiring harness between ECSS relay
L90 (female) (2) and chassis ground.
4) Defective transmission controller.
20-402 WA500-3H
TROUBLESHOOTING JUDGEMENT TABLE FOR CONTROLLER
12
MEMORANDUM
WA500-3H 20-403
TROUBLESHOOTING D-1 ECSS DOES NOT WORK
12
D-1 ECSS DOES NOT WORK
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Carry out troubleshooting with the starting switch ON.
• Check that the ECSS switch on the main monitor is ON.
A. ERROR CODE (D0) IS DISPLAYED
Cause Remedy
4 Yes
Defective ECSS controller Replace
Yes Is resistance between
L90 (female) (2) and
chassis normal?
1) Max. 1Ω. Defective contact or
3 disconnection in wiring Repair or
2) Turn starting switch
OFF. No harness between L90 replace
Yes Is resistance between (female (2) and chassis.
L90 (female) (1) and 3) Disconnect L90.
chassis normal?
1) Max. 1Ω.
2) Turn starting switch
OFF. Short circuit with ground
2 in wiring harness between Repair or
3) Disconnect L90
and C1. No C1 (female) (3) and L90 replace
Is resistance between (female) (1) and chassis
L90 (female) (1) and
Yes chassis normal when
C1 (male) (3) is
1 grounded to chassis?
Is troubleshooting code 1) Max. 1Ω. Defective contact or
displayed when L90 is 2) Turn starting switch disconnection in wiring Repair or
replaced with another OFF. harness between C1 replace
No (female (3) and L90
relay of the same type? 3) Disconnect L90 (female (1)
and C1.
1) Turn starting switch
OFF.
2) Interchange with
another relay of same Defective ECSS relay Replace
type. No
3) ECSS switch: ON
20-404 WA500-3H
TROUBLESHOOTING D-1 ECSS DOES NOT WORK
D-1 A. Related electrical circuit diagram
WA500-3H 20-405
TROUBLESHOOTING D-1 ECSS DOES NOT WORK
12
B. NO ABNORMALITY DISPLAY IS GIVEN
1. DOES NOT WORK AT ALL
• Before starting troubleshooting, check that the main monitor dipswitch is set to ON for ECSS function.
Cause Remedy
2 Yes
Defective ECSS controller Replace
Yes Is voltage between C3B
(9) and chassis normal?
1 Go to troubleshooting
Defective main monitor of main monitor
Is resistance between 1) Max. 1Ω. No
L06 (female) (7) and 2) Turn starting switch
chassis normal when ON.
C3B (male) (9) is 3) Main monitor ECSS
switch: ON. Defective contact or
grounded to chassis? disconnection in wiring
1) Max. 1Ω. No harness between L06 Repair or replace
2) Turn starting switch (female (7) and C3B
(female (9)
OFF.
3) Disconnect L06.
20-406 WA500-3H
TROUBLESHOOTING D-2 ECSS CANNOT BE CANCELED
12
D-2 ECSS CANNOT BE CANCELED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes
Defective ECSS controller Replace
Yes Is voltage between C3B
(female) (9) and chassis
1 normal?
Defective main monitor Go to troubleshooting
1) 20 - 30 V No of main monitor
Is resistance between 2) Turn starting switch
C3B (female) (9) and ON.
chassis normal? 3) Main monitor ECSS
switch: OFF. Short circuit with ground
in wiring harness between Repair or replace
1) Max. 1Ω. No C3B (female) (9) and L06
2) Turn starting switch (female) (7)
OFF.
3) Disconnect L06.
WA500-3H 20-407
TROUBLESHOOTING D-2 ECSS CANNOT BE CANCELED
12
MEMORANDUM
20-408 WA500-3H
TROUBLESHOOTING OF CHASSIS
ELECTRICAL SYSTEM (E MODE)
Remark
Troubleshooting of the ENGINE electrical system (E MODE) is found in the ENGINE SHOP MANUAL.
WA500-3H 20-501
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
E-1 ENGINE DOES NOT START
• When connecting or disconnecting T-adapter (or socket adapter) or short connector to carry out checks, always turn the
starting switch OFF before starting.
• When connecting T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
A. STARTING MOTOR DOES NOT TURN
Yes
a
3
Yes Is voltage between
starting motor
terminal (B) and
chassis normal? Yes
b
1) 20 - 30 V
2) Turn starting
switch OFF. 5
Yes Is voltage between
battery relay terminals
and chassis normal?
1) 20 - 30 V.
2) Turn starting switch
ON.
3) Check voltage
2 between chassis and
both terminals c
Yes Is there continuity connected by thick No
cable.
between starting
motor terminal (E) 4
and chassis?
Does battery relay
make sound of
1) Turn starting No actuation?
switch OFF.
1) Starting switch
ON↔OFF.
Yes
d
6
Is voltage between
both connection
1 terminals of R12
No and R13 of
Is voltage between battery relay
E13 (female) (1) normal?
and chassis
normal? 1) 20 - 30 V
2) Turn starting
1) 20 - 30 V switch OFF.
2) Disconnect E13. e
3) Directional No
lever: Neutral
4) Turn starting
switch to
START.
f
No
g
No
20-502 WA500-3H
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
Cause Remedy
Defective contact or
b disconnection in cable Repair or
between battery relay and replace
starting motor
• If answer is NO for
both terminals:
Defective contact or
disconnection in
wiring harness
c between battery and Repair or
replace
battery relay
• If answer is NO for
one terminal:
Defective battery
relay
Defective contact or
disconnection in wiring
Yes harness between starting Replace
switch terminal BR - L09
8 (2) - LR4 (9) - R03 (diode)
(2), (1) - R12 female)
Yes Is resistance between
R13 (female) and
7 chassis normal?
Is voltage between 1) Max. 1Ω. Defective contact or
e starting switch 2) Turn starting switch disconnection in wiring Repair or
terminal BR and OFF. No harness between R13 and replace
chassis normal? 3) Disconnect R13. chassis ground
1) 20 - 30 V
2) Turn starting switch
ON.
Defective battery relay Replace
No
g Go to A on next page -
WA500-3H 20-503
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
Yes
a
Yes
b
11
Yes Is voltage between 13 Yes
L57 (female) (5) c
9 and chassis normal? Yes Is voltage between
starting switch
Does starting 1) 20 - 30 V. terminal C and
motor rotate 2) Disconnect 12 chassis normal?
A when neutral L57. d
relay is 3) Turn starting Is voltage between 1) 20 - 30 V. No
replaced? switch to starting switch 2) Turn starting
START. terminal B and switch to START.
1) Replace No chassis normal?
neutral relay
(L57) with 1) 20 - 30 V.
stop lamp 2) Turn starting e
relay (L53). switch OFF. No
2) FR lever:
Neutral
3) Turn starting
switch to
START. 16 Yes
f
10 Yes Is voltage between
L04 (3) and chassis
Is voltage between normal?
L57 (female) (1)
No and (2) normal? 1) 20 - 30 V.
2) Connect T- g
1) Disconnect L57. 15 adapter to L04. No
2) Directional 3) Directional lever:
lever: Neutral Yes Is voltage between N Yes
3) Turn starting 4) Turn starting
switch to L04 (female) (1) switch ON. h
START. and chassis normal? 18
1) 20 - 30 V. Yes Are both voltages
2) Disconnect L04. between battery
3) Turn starting relay terminals
switch ON. and chassis
normal?
1) 20 - 30 V.
2) Turn starting i
17 switch ON. No
3) Check voltage
Does battery relay of both lines
make sound of between
No actuation? chassis and 2
terminals
14 1) Starting switch where thick
Yes
ON↔OFF. cable is j
Is resistance connected.
between L57
No (female) (2) and
chassis normal? 19
1) Max. 1Ω. Are both voltages
2) Turn starting between battery
switch OFF. No relay R12 and
3) Disconnect L57. R13 connection
terminals normal?
1) 20 - 30 V.
2) Turn starting
switch OFF.
k
No
l
No
20-504 WA500-3H
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
Cause Remedy
Defective contact or
b disconnection in wiring
harness between L57 (female) Repair or
(3) - LR4 (8) - R01, R02 replace
(diode) - ER1 (10) - E13
(female) (1)
Defective contact or
disconnection in wiring
Repair or
harness between starting
replace
c switch terminal C - L09 (3) -
L57 (female) (5)
Defective contact or
disconnection in wiring
harness between starting
Repair or
e switch terminal B - L09 (1) -
replace
FS3 (4) - fuse I-12, FS3 (6) -
LR5 (1) - R17 - slow blow
fuse 30A - battery relay
f Defective contact or
disconnection in wiring Repair or
harness between L04 (female) replace
(3) and L57 (female) (1)
Defective contact or
h disconnection in wiring har-
ness between battery relay - Repair or
slow blow fuse 80A - R15 - replace
LR6 (1) - FS1 (2) fuse I-9 -
FS2 (8) - L04 (female) (1)
• If answer is NO for
both terminals:
Defective contact or
disconnection in
wiring harness
i between battery and Repair or
replace
battery relay
• If answer is NO for
one terminal:
Defective battery
relay
Defective contact or
disconnection in wiring
Yes harness between starting Repair or
switch terminal BR - L09 (2) - replace
21 LR4 (9) - R03 (diode) (2), (1)
- R12 (female)
Yes Is resistance between
R13 (female) and chassis
20 normal?
Defective contact or
disconnection in wiring Repair or
l harness between L57 (female) replace
(2) - LR5 (2) - chassis ground
WA500-3H 20-505
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
B. STARTING MOTOR TURNS
Yes
a
4 Yes
b
Yes
Is resistance between
E03 (female) (8) and
chassis normal?
c
1 1) Max. 1Ω. No
2) Turn starting
3 switch OFF.
Does engine stop 3) Disconnect E03.
motor work?
Yes Is voltage between Yes
E03 (7) and chassis d
1) Turn starting normal?
switch ON ↔
OFF and check 1) 20 - 30 V.
visually. 2) Connect T-
adapter to E03. Yes
3) Turn starting e
switch ON. 5
7
Does engine stop
No motor when engine Yes Is resistance
stop relay is between L62
replaced (female) (2) and
chassis normal?
2 1) Replace engine 6 1) Max. 1Ω.
stop relay (L62) 2) Turn starting
Is voltage between with stop lamp Is voltage between switch ON.
E03 (female) (4) relay (L53). L62 (female) (1) 3) Disconnect f
No and chassis normal? 2) Turn starting No and chassis normal? L62. No
switch ON ↔
1) 20 - 30 V. OFF and check 1) 20 - 30 V.
2) Disconnect E03. visually. 2) Disconnect L62.
3) Turn starting 3) Turn starting
switch OFF. switch ON.
g
No
h
No
20-506 WA500-3H
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
Cause Remedy
Defective adjustment of
a wire between engine stop Replace
solenoid and lever
Defective contact or
disconnection in wiring
c harness between E03 (female) Repair or
replace
(8) - ER2 (5) - ER1 (10) -
chassis ground
Defective contact or
disconnection in wiring Repair or
f harness between L62 (female) replace
(2) chassis ground
Defective contact or
disconnection in wiring Repair or
g harness between L62 (female) replace
(1) and L09 (female) (2)
WA500-3H 20-507
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
E-1 Related electrical circuit diagram
20-508 WA500-3H
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
MEMORANDUM
WA500-3H 20-509
TROUBLESHOOTING E-2 ENGINE DOES NOT STOP
12
E-2 ENGINE DOES NOT STOP
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
Cause Remedy
Yes Defective adjustment
between engine stop motor Adjust
1 and stop lever
20-510 WA500-3H
TROUBLESHOOTING E-2 ENGINE DOES NOT STOP
12
E-2 Related electrical circuit diagram
WA500-3H 20-511
TROUBLESHOOTING E-3 ENGINE STOPS WHEN MACHINE IS
12
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING
• Check if the starting motor turns. If it does not turn, check E-1, a) Starting motor does not turn.
Cause Remedy
1 Yes Defective adjustment
between engine stop motor Adjust
and stop lever
Does engine stop motor
work?
2 Yes Defective engine stop
motor Replace
1) Turn starting switch
ON ↔ OFF and Does voltage
between E03 (7) and
check visually. No 3 Yes
(8) switch between 0 Defective engine stop Replace
V and 20 - 30 V? Is voltage between L62 relay
(female) (2) and
1) Connect T- No (female) (1) normal?
adapter to E03. Defective contact or
2) Turn starting 1) 20 - 30 V. disconnection in wiring
switch ON ↔ 2) Disconnect L62 harness between starting
Repair or
OFF. (engine stop relay. No switch terminal BR - L09 (2) - replace
3) Turn starting switch L62 (female) (1)
ON.
20-512 WA500-3H
TROUBLESHOOTING E-3 ENGINE STOPS WHEN MACHINE IS
12
E-3 Related electrical circuit diagram
WA500-3H 20-513
TROUBLESHOOTING E-5 PARKING BRAKE DOES NOT HAVE EF-
12
E-5 PARKING BRAKE DOES NOT HAVE EFFECT
• When carrying out troubleshooting of the brake system, stop the machine on flat ground.
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA().
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
A. PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS
TURNED ON (ACTUATED)
Cause Remedy
Yes Defective parking brake
switch Replace
1
Does connection
become normal when
L01 is disconnected? Yes Contact of wiring harness Repair or
at L01 (female) (2) end replace
1) Start engine 2 and (3) end
(charge brake oil
pressure). Is resistance between
L01 (female) (2) and
No (3) normal? 3 Yes Defective parking brake Replace
1) Disconnect L01. Is voltage between solenoid
2) Turn starting CN10 (female) (1) and
switch OFF. No chassis normal?
3) Disconnect L58.
4) Disconnect L59. 1) Max. 1 V.
2) Start engine. Contact of wiring harness Repair or
(Charge brake oil No at L01 (female) (2) end replace
pressure).
3) Turn parking brake
switch ON.
20-514 WA500-3H
TROUBLESHOOTING E-5 PARKING BRAKE DOES NOT HAVE EF-
12
MEMORANDUM
WA500-3H 20-515
TROUBLESHOOTING E-6 PARKING BRAKE IS APPLIED WHEN
12
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING
• When carrying out troubleshooting of the brake system, stop the machine on flat ground.
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
2 Yes
a
Yes Is resistance between
CN10 (female) (2)
and chassis normal?
1) Max. 1Ω.
2) Turn starting b
switch OFF. No
3) Disconnect L59.
Yes
c
1 4
Yes Does connection Yes
Is voltage between become normal d
CN10 (female) (1) when parking brake
and chassis normal? safety relay is
replaced?
1) 20 - 30 V. 1) Replace parking
2) Start engine. brake safety relay
(Charge brake oil (L59) with stop
pressure). lamp relay (L53).
2) Start engine.
(Charge brake oil
3 pressure)
Is continuity of L01 5
(male) (1)(2)(3) as
No shown in Table 1. Does condition
become normal
1) Turn starting No when B09 and B10
switch OFF. are connected to
2) Operating parking short connector?
brake switch
ON/OFF. 1) Connect short
3) Disconnect L01. connector to B09
(female) and B10
(female).
2) Start engine.
(Charge brake oil
pressure) Yes
e
7
Yes Is resistance
between L59
(female) (1) and
(3) normal?
1) Max. 1Ω
2) Turn starting
6 switch OFF.
3) Disconnect L59.
Is voltage between
L59 (female) (5) f
No and chassis normal? No
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Disconnect L59.
g
No
h
No
20-516 WA500-3H
TROUBLESHOOTING E-6 PARKING BRAKE IS APPLIED WHEN
12
Table 1
Operation Between (2) - (3) Between (1) - (3)
Cause Remedy
Defective contact or
disconnection in wiring Repair or
harness between CN10 replace
b (female) (2) and chassis
Defective contact or
Yes disconnection in wiring
harness between B10 (female) Repair
or
11 (2) - BR1 (8) - LR4 (14) - TH2 replace
(11) - CN10 (female)
10 Yes Is voltage between
B10 (female) (1) and
Yes Is voltage between chassis normal?
B09 (female) (1) and Defective contact or
chassis normal? 1) 20 - 30 V.
2) Turn starting switch disconnection in wiring Repair or
1) 20 - 30 V. ON. No harness between B09 (female) replace
2) Turn starting 3) Turn parking brake (2) and B10 (female) (1)
9 switch ON. switch ON↔OFF.
3) Turn parking 4) Disconnect B10.
Yes Is resistance between brake switch
L59 (female) (2) and ON↔OFF. Defective contact or
chassis normal? 4) Disconnect B09. disconnection in wiring
harness between B09 (female) Repair
or
1) Max. 1Ω. No (1) - BR1 (7) - LR4 (13) - L01 replace
2) Turn starting switch (female) (2)
8 OFF.
3) Disconnect L59.
e Is voltage between
L59 (female) (1) Defective contact or
and chassis disconnection in wiring Repair or
normal? No harness between L59 (female) replace
(2) and chassis
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Turn parking Defective contact or
brake switch disconnection in wiring
ON. harness between L59 (female) Repair or
4) Disconnect No (1) and L01 (female) (3), or replace
L59. between FS2 (female) (7) and
L01 (female) (1)
Defective contact or
disconnection in wiring Repair or
f harness between L59 (female) replace
(1) and L59 (female) (3)
Defective contact or
disconnection in wiring Repair or
g harness between L59 (female) replace
(5) and FS2 (7) - fuse I-9
WA500-3H 20-517
TROUBLESHOOTING E-6 PARKING BRAKE IS APPLIED WHEN
12
E-6 Related electrical diagram
20-518 WA500-3H
TROUBLESHOOTING E-6 PARKING BRAKE IS APPLIED WHEN
12
MEMORANDUM
WA500-3H 20-519
TROUBLESHOOTING E-7 PARKING BRAKE IS RELEASED WHEN
12
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS
TURNED ON
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOL( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
Cause Remedy
Yes Defective parking brake
safety relay Replace
1
20-520 WA500-3H
TROUBLESHOOTING E-7 PARKING BRAKE IS RELEASED WHEN
12
E-7 Related electrical diagram
WA500-3H 20-521
TROUBLESHOOTING E-8 TRANSMISSION DOES NOT CHANGE TO
12
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN
PARKING BRAKE IS APPLIED (BUT PARKING BRAKE
WORKS NORMALLY)
Cause Remedy
1 Yes
Defective neutralizer relay Replace
Is voltage between
neutralizer relay L58
(female) (5) - chassis
normal? Short circuit with power
source in wiring harness Repair or
1) Max. 1 V. No between L58 (female) (5) replace
2) Disconnect neutralizer and C3A (female) (6)
relay L58.
3) Turn starting switch
ON.
4) Shift directional lever
between F, N, and R,
and check each
voltage.
20-522 WA500-3H
TROUBLESHOOTING E-8 TRANSMISSION DOES NOT CHANGE TO
12
E-8 Related electrical diagram
WA500-3H 20-523
TROUBLESHOOTING E-9 KICK-DOWN SWITCH DOES NOT WORK
12
E-9 KICK-DOWN SWITCH DOES NOT WORK
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to original
condition before going on to the next check.
20-524 WA500-3H
TROUBLESHOOTING E-9 KICK-DOWN SWITCH DOES NOT WORK
12
E-9 Related electrical diagram
WA500-3H 20-525
TROUBLESHOOTING E-10 BOOM KICK-OUT CANNOT BE USED
12
E-10 BOOM KICK-OUT CANNOT BE USED
• Before carrying out troubleshooting, check that all related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Check that fuse I (10) is normal. If it is blown, check for a short circuit with ground in the wiring harness between
fuse I (10) - FS2 (10) - L49 (3) - LR2 (1) - FR2 (1) - F06 (female) (1), or FS2 (10) - L32 (1) - L33 (1) - L40 (female) (1)
Yes
a
Yes
b
6
Yes Is voltage between
L49 (2) and
1 chassis ground
normal?
Does condition 5
become normal
when L49 is Yes Is voltage between 1) 20 - 30 V.
replaced with a F06 (1) and chassis 2) Turn starting c
relay of same type? ground normal? switch ON. No
3) Bring a screw-
1) Interchange with 1) 20 - 30 V. driver close to
a relay of same 2) Turn starting boom kick-out
type. 4 switch ON. proximity
switch.
Yes Is resistance
between F06
(female) (3) and
chassis ground d
normal? No
3 1) Max. 1Ω.
2) Turn starting
Yes Is resistance switch OFF.
between L16 3) Disconnect F06.
(female) (1) and (2)
normal?
2 1) 19 - 23 1Ω.
2) Disconnect L16. e
No
Is voltage between
No each pin of F06 as
shown in Table 1?
f
1) See Table 1. No
2) Turn starting
switch ON.
g
No
Table 1
20-526 WA500-3H
TROUBLESHOOTING E-10 BOOM KICK-OUT CANNOT BE USED
12
Cause Remedy
Defective contact or
Yes disconnection in wiring Repair or
harness between L49 (female) replace
7 (5) and L16 (female) (1)
b Is resistance between
L16 (female) (2) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or
1) Max. 1Ω. No harness between L16 (female) replace
(2) - LR5 (2) - chassis ground
2) Turn starting switch
OFF.
3) Disconnect L16.
Defective contact or
disconnection in wiring
harness between L49 (female) Repair or
c (2) - L32 (2) - L33 (2) - LR2 replace
(2) - FR2 (2) - FO6 (female)
(2)
Defective contact or
disconnection in wiring
harness between fuse I (10) -
FS2 (10) - L49 (female) (3), Repair or
d between FS2 (10) - LR2 (1) - replace
FR12 (1) - F06 (female) (1), or
between FS2 (10) - L32 (1) -
L33 (1) - L49 (female) (1)
Defective contact or
disconnection in wiring Repair or
e harness between F06 (female) replace
(3) and chassis ground
WA500-3H 20-527
TROUBLESHOOTING E-10 BOOM KICK-OUT CANNOT BE USED
12
E-10 Related electrical diagram
20-528 WA500-3H
TROUBLESHOOTING E-10 BOOM KICK-OUT CANNOT BE USED
12
MEMORANDUM
WA500-3H 20-529
TROUBLESHOOTING E-11 ABNORMALITY IN BUCKET POSITION-
12
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness between
fuse I (10) - FS2 (10) - L48 (1) (3), or FS2 (10) - LR2 (1) - FR2 (1) - F05 (female) (1).
Yes
a
Yes
b
6
Yes Is voltage between
L48 (2) and
1 chassis ground
normal?
Does condition 5
become normal
when L48 is Yes Is voltage between 1) 20 - 30 V.
replaced with a F05 (1) and chassis 2) Turn starting c
relay of same type? ground normal? switch ON. No
3) Bring a screw-
1) Interchange with 1) 20 - 30 V. driver close to
a relay of same 2) Turn starting bucket
type. 4 switch ON. positioner
proximity
switch.
Yes Is resistance
between F05
(female) (3) and
chassis ground d
normal? No
3 1) Max. 1Ω.
2) Turn starting
Yes Is resistance switch OFF.
between L17 3) Disconnect F05.
(female) (1) and (2)
normal?
2 1) 19 - 23 1Ω.
2) Disconnect L17. e
No
Is voltage between
No each pin of F05 as
shown in Table 1?
f
1) See Table 1. No
2) Turn starting
switch ON.
g
No
Table 1
20-530 WA500-3H
TROUBLESHOOTING E-11 ABNORMALITY IN BUCKET POSITION-
12
Cause Remedy
Defective contact or
Yes disconnection in wiring Repair or
harness between L48 (female) replace
7 (5) and L17 (female) (1)
b Is resistance between
L17 (female) (2) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or
1) Max. 1Ω. No harness between L17 (female) replace
(2) - LR5 (2) - chassis ground
2) Turn starting switch
OFF.
3) Disconnect L17.
Defective contact or
disconnection in wiring
harness between L48 (female) Repair or
c (2) - L32 (2) - L33 (2) - LR2 replace
(2) - FR2 (2) - FO5 (female)
(2)
Defective contact or
disconnection in wiring
harness between fuse I (10) -
FS2 (10) - L48 (female) (3), Repair or
d between FS2 (10) - LR2 (1) - replace
FR12 (1) - F05 (female) (1), or
between FS2 (10) - L32 (1) -
L33 (1) - L48 (female) (1)
Defective contact or
disconnection in wiring Repair or
e harness between F05 (female) replace
(3) and chassis ground
WA500-3H 20-531
TROUBLESHOOTING E-11 ABNORMALITY IN BUCKET POSITION-
12
E-11 Related electrical diagram
20-532 WA500-3H
TROUBLESHOOTING E-12 ABNORMALITY IN LIGHTING UP OF
12
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP
• Go to Troubleshooting M-10.
20-533 WA500-3H
TESTING AND ADJUSTING E-16 ABNORMALITY IN BUZZER
12
MEMORANDUM
20-534 WA500-3H
TROUBLESHOOTING OF JOYSTICK STEERING
CONTROLLER SYSTEM (J MODE)
WA500-3H 20-701
TROUBLESHOOTING
12
MEMORANDUM
20-702 WA500-3H
TROUBLESHOOTING JUDGEMENT TABLE FOR JOYSTICK CON-
12
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM
RELATED PARTS
WA500-3H 20-703
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR
Failure
Abnormal system Nature of abnormality
code
1. Defective R solenoid
2. Defective steering solenoid cut relay
3. Short circuit in wiring harness between work equipment controller L26 (female) (6)
and (16)
Steering (R) (right) solenoid Short circuit with ground, defective contact, or disconnection in the following wiring
57
system harness:
4. Wiring harness between work equipment controller L26 (female) (6) and R (2)
5. Wiring harness between work equipment controller L26 (female) (16) and JS9 (3)
6. Wiring harness between steering solenoid cut relay JS9 (5) and R (1)
7. Defective work equipment controller
1. Defective L solenoid
2. Defective steering solenoid cut relay
3. Short circuit in wiring harness between work equipment controller L26 (female) (7)
and (16)
Steering (L) (left) solenoid Short circuit with ground, defective contact, or disconnection in the following wiring har-
58
system ness:
4. Wiring harness between work equipment controller L26 (female) (7) and L (2)
5. Wiring harness between work equipment controller L26 (female) (16) and JS9 (3)
6. Wiring harness between steering solenoid cut relay JS9 (5) and L (1)
7. Defective work equipment controller
20-704 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
Steering R, L solenoid
Joystick lever at neutral output: OFF and steering Impossible to use
Voltage between work equipment controller L26 (female) (6) solenoid cut relay output: joystick and joystick J-4
and chassis ground: Less than 1 V OFF and caution relay: caution actuated
OFF
Steering R, L solenoid
Joystick lever at neutral output: OFF and steering Impossible to use
Voltage between work equipment controller L26 (female) (6) solenoid cut relay output: joystick and joystick J-5
and chassis ground: Less than 1 V OFF and caution relay: caution actuated
OFF
WA500-3H 20-705
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
Failure
Abnormal system Nature of abnormality
code
20-706 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
Voltage between work equipment controller L27 (female) (20) Steering R, L solenoid
and L27 (9): 0.5 - 4.5 V (voltage when joystick is at neutral: output: OFF and steering Impossible to use
Approx. 2.5 V) solenoid cut relay output: joystick and joystick J-7
OFF and caution relay: caution actuated
OFF
WA500-3H 20-707
TROUBLESHOOTING J-1 FAILURE CODE [56] (SHORT CIRCUIT,
12
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN
CAUTION RELAY OUTPUT) IS DISPLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting any connector
Cause Remedy
Yes
Defective joystick boom Replace
1 controller
3 Yes
Is resistance Defective contact or
between L28 Yes disconnection in wiring Repair or
(female) (18) and Is resistance between harness between JS8(1) replace
chassis normal? 2 JS8 (female) (2) and and JS1(15)
chassis normal?
1. Disconnect L28 Is resistance between Defective contact or
2. 200 - 400 Ω JS8 (male) (1) and disconnection in wiring
No (2) normal? 1. Disconnect JS8 No harness between JS8(2) - Repair or
2. Max. 1 Ω LGL(2) - L23 (female) replace
1. Disconnect JS8 (10)
2. 200 - 400 Ω
Defective caution lamp Replace
No relay
20-708 WA500-3H
TROUBLESHOOTING J-2 FAILURE CODE [57] (SHORT CIRCUIT IN
12
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT
SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick Replace
Yes Is resistance between controller
L26 (female) (6) and
(16) normal?
Short circuit in wiring
3 1. Min. 1 MΩ. harness between L26
2. Turn starting (female) (6) and CNR
Yes Is resistance between switch OFF. No (female) (2) and between Repair or
L26 (female) (16) 3. Disconnect L26. L26 (female) (16) and JS9 replace
and chassis normal? (female) (5) and CNR
(female) (1)
2 1. Min. 1 MΩ.
2. Turn starting
Yes Is resistance between switch OFF.
L26 (female) (6) and 3. Disconnect JS9 Short circuit with chassis
chassis normal? and L26 ground in writing harness Repair or
between L26 (female) (16) replace
1 1. Min. 1 MΩ. No and JS9 (female) (3)
2. Turn starting
is failure code switch OFF.
displayed when 3. Disconnect L26 Short circuit with chassis
JS9 is replaced and CNR No ground in writing harness Repair or
with other relay of between L26 (female) (6) replace
same type? and CNR (female) (2)
1. Turn starting
switch OFF. Defective steering Replace
2. Interchange No solenoid cut relay
with another relay
of same type.
3. Turn starting
switch ON.
WA500-3H 20-709
TROUBLESHOOTING J-3 FAILURE CODE [58] (SHORT CIRCUIT IN
12
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT
SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick Replace
Yes Is resistance between controller
L26 (female) (7) and
3 (16) normal? Short circuit in wiring
harness between L26
Yes Is resistance between 1. Min. 1 MΩ. (female) (7) and CNL
L26 (female) (16) 2. Turn starting (female) (2) and between Repair or
2 and chassis normal? switch) OFF. No L26 (female) (16) and JS9 replace
3. Disconnect L26. (female) (5) and CNL
Yes Is resistance between 1. Min. 1 MΩ. (female) (1)
L26 (female) (17) 2. Turn starting
1 and chassis normal? switch) OFF.
3. Disconnect JS9 Short circuit with chassis
Is failure code 1. Min. 1 MΩ. and L26. No ground in wiring harness Repair or
displayed when 2. Turn starting between L26 (female) (16) replace
JS9 is replaced switch) OFF. and JS9 (female) (30
with other relay of 3. Disconnect L26
same type? and CNL.
Short circuit with chassis
1. Turn starting No ground in wiring harness Repair or
switch OFF. between L26 (female) (7) replace
2. Interchange and CNL (female) (2)
with other relay of
same type.
3. Turn starting Defective steering Replace
switch ON. No solenoid cut relay
20-710 WA500-3H
TROUBLESHOOTING J-4 FAILURE CODE [59] (SHORT CIRCUIT IN
12
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT
SOLENOID (HOT END) IS DISPLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 Yes
Defective joystick steering Replace
controller
Is voltage between
L26 (female) (6)
and chassis Short circuit with power
normal? source in wiring power
source in wiring harness
between L26 (female) (6) - Repair or
1. Max. 1V. No CNR (female) (2) or CNR replace
2. Turn starting (female) (1) - JS9 (female)
switch ON. (5)
WA500-3H 20-711
TROUBLESHOOTING J-5 FAILURE CODE [60] (SHORT CIRCUIT IN
12
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT
SOLENOID (HOT END) IS DISPLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
Cause Remedy
1 Yes
Defective joystick steering Replace
controller
Is voltage between
L26 (female) (6)
and chassis Short circuit with power
normal? source in wiring power
source in wiring harness
between L26 (female) (7) - Repair or
1. Max. 1V. No CNL (female) (2) or CNL replace
2. Turn starting (female) (1) - JS9 (female)
switch ON. (5)
20-712 WA500-3H
TROUBLESHOOTING J-6 FAILURE CODE [61] (SHORT CIRCUIT,
12
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN
STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick steering Replace
3 Yes Is resistance between controller
JS9 (female) (2) and
Yes Is resistance between chassis normal?
L28 (female) (8) and Defective contact or
chassis normal? 1. Max. 1 Ω. disconnection in wiring
2. Turn starting harness between JS9 Repair or
2 1. Max. 1 MΩ. switch OFF. No (female) (2) - JS12 (2) - replace
2. Turn starting 3. Disconnect JS9. LR (3) - chassis ground
Yes Is resistance between switch OFF.
L28 (female) (8) and 3. Disconnect L26
chassis normal when and JS9.
JS9 (female) (1) is Short circuit with chassis
1 grounded to chassis? No ground in wiring harness Repair or
between L28 (female) (8) replace
1. Max. 1 Ω. and JS9 (female) (1)
Is failure code
displayed when 2. Turn starting
JS9 is replaced switch OFF. Defective contact or
with another relay 3. Disconnect L26 disconnection in wiring
of same type? and JS9. No harness between L28 Repair or
(female) (8) and JS9 replace
1. Turn starting (female) (1)
switch OFF.
2. Interchange
with another relay Defective steering Replace
of same type. No solenoid cut relay
3. Turn starting
switch ON.
WA500-3H 20-713
TROUBLESHOOTING J-7 FAILURE CODE [62] (SHORT CIRCUIT,
12
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN
JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
• Turn the starting switch ON.
Cause Remedy
2 Yes
Defective joystick Replace
Yes Is resistance between steering controller
L27 9female) (17)
and chassis normal? 4 Yes Defective contact or
disconnection in wiring Repair or
1. disconnect L27. 3 Yes Is resistance between harness between JS6
2. Operate joystick JS6 (female) (1) and (female) (3) - D01 - L27 replace
1 lever fully to left or Is resistance between chassis normal? (female) 917)
right. JS6 9male) (1) and
Is resistance 3. Max. 1Ω. No (3) normal? 1. Disconnect JS6.
between L27 2. Max. 1 Ω. Defective contact or
(female) (17) and 1. Disconnect JS6. No disconnection in wiring Repair or
chassis normal? 2. Operate joystick harness between JS6 replace
lever fully to left or (female) (1) - JS12 (2) -
1. Disconnect L27. right. LR5 (3) - chassis ground
2. Max. 1Ω. 3. Max. 1Ω.
Defective neutral switch Replace
No
5 Yes
Short circuit with chassis
Is resistance between ground in wiring harness Repair or
JS6 9male) (1) and between JS6 (female) (3) - replace
No (3) normal? D01 - L27 (female) (17)
1. Disconnect JS6.
2. Max. 1Ω. Defective neutral switch Replace
No
20-714 WA500-3H
TROUBLESHOOTING J-8 FAILURE CODE [63] (SHORT CIRCUIT,
12
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN
JOYSTICK STEERING LEVER POTENTIOMETER SYSTEM) IS DIS-
PLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
• After connecting the T-adapter, turn the starting switch ON.
Cause Remedy
Replace,
Defective joystick adjust
Yes potentiometer, neutral neutral
position misaligned position
2 again
Yes Does voltage Short circuit with power
between L27 (20) source, short circuit with
and (9) change? 3 Yes ground, defective contact Repair or
or disconnection in wiring replace
1 1. Operate joystick Does voltage harness between L27
lever to left or right. between JS7 (male) (female) (20) and JS7
Is voltage between 2. 0.5 - 4.5 V. No (1) and (3) change? (female) (1)
L27 (10) and (9)
normal? 1. Turn starting
switch OFF. Defective joystick Replace
1. 4.9 - 5.1 V. 2. Disconnect JS7. No potentiometer
3. Operate joystick
lever to left and
right.
4. 0.2 - 5 kΩ.
Defective remote boom & Replace
No joystick steering controller
WA500-3H 20-715
TROUBLESHOOTING J-9 ABNORMALITY IN POWER SOURCE,
12
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Check that fuse I (11) is normal.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 Yes
Defective joystick steering Replace
controller
Is voltage between
L26 (female) (8), Defective contact or
(18) and chassis disconnection in wiring
normal? No harness betwen L26 Repair or
(female) (8), (18) - L32 (1) replace
1. 20 - 30 V. - FS2 (10) - fuse I (11)
2. Turn starting
switch ON.
20-716 WA500-3H
TROUBLESHOOTING J-10 ABNORMALITY IN JOYSTICK STEER-
12
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL
SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Check that fuse I (11) is normal.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Yes
Defective joystick steering Replace
controller
1 3 Yes
Defective system cut-off Replace
Yes Is voltage between switch
Is voltage between JS3 (female) and
l27 (female) (14) 2 chassis normal? Defective contact or
and chassis disconnection in wiring
normal? 1. 20 - 30 V. No harness between fuse I Repair or
Is resistance between 2. Turn starting (11) - FS2 (10) - L32 91) - replace
1. 20 - 30 V. L27 (female) (14) switch ON. JS3 (female)
2. Turn starting and chassis normal
switch ON. No when S4 (male) is
grounded to chassis? Defective contact or
No disconnection in wiring
harness between L27 Repair or
1. Turn starting (female) (14) - JS5 (1), (2) replace
switch OFF. - S4 (male) or defective
2. disconnect S4 and joystick ON - OFF switch
L27.
3. Max. 1Ω
WA500-3H 20-717
TROUBLESHOOTING J-11 DISCONNECTION IN STEERING RIGHT
12
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick steering Replace
3 Yes Is resistance between controller
JS9 (female) (5) and
chassis normal when Defective contact or
Is resistance between CNR (female) (1) is disconnection in wiring
2 Yes L26 (female) (15) grounded to chassis? No harness between JS9 Repair or
and chassis normal (female) (5) and CNR replace
when JS9 (female) 1. Max. 1 Ω. (female) (1)
(3) is grounded to 2. Turn starting
Is resistance between chassis?
Yes L26 (female) (6) and switch OFF. Defective contact or
chassis normal when 3. Disconnect JS9. disconnection in wiring
1 CNR (female) (2) is 1. Max. 1 Ω. harness between L26 Repair or
grounded to chassis? 2. Turn starting (female) (16) and JS9 replace
switch OFF. No (female) (3)
Is resistance 3. Disconnect L26
between CNR 1. Max. 1 Ω. and JS9.
(male) (1) and (2) Defective contact or
2. Turn starting disconnection in wiring
normal? switch OFF. harness between L26 Repair or
3. Disconnect L26. 9female) (6) and CNR replace
1. Max. 1 Ω. No (female) (20
2. Turn starting
switch OFF.
3. Disconnect Defective joystick steering Replace
CNR. No right solenoid valve
20-718 WA500-3H
TESTING AND ADJUSTING J-12 DISCONNECTION IN STEERING LEFT
12
J-12 DISCONNECTION IN STEERING LEFT SOLENOID
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick steering Replace
3 Yes Is resistance between controller
JS9 (female) (5) and
chassis normal when Defective contact or
Is resistance between CNL (female) (1) is disconnection in wiring
2 Yes L26 (female) (16) grounded to chassis? No harness between JS9 Repair or
and chassis normal (female) (5) and CNL replace
when JS9 (female) 1. Max. 1 Ω. (female) (1)
(3) is grounded to 2. Turn starting
Is resistance between chassis?
Yes L26 (female) (7) and switch OFF. Defective contact or
chassis normal when 3. Disconnect JS9. disconnection in wiring
1 CNR (female) (2) is 1. Max. 1 Ω. harness between L26 Repair or
grounded to chassis? 2. Turn starting (female) (16) and JS9 replace
switch OFF. No (female) (3)
Is resistance 3. Disconnect L26
between CNL 1. Max. 1 Ω. and JS9.
(male) (1) and (2) Defective contact or
2. Turn starting disconnection in wiring
normal? switch OFF. harness between L26 Repair or
3. Disconnect L26. 9female) (7) and CNL replace
1. Max. 1 Ω. No (female) (20
2. Turn starting
switch OFF.
3. Disconnect Defective joystick steering Replace
CNL. No right solenoid valve
WA500-3H 20-719
TESTING AND ADJUSTING J-12 DISCONNECTION IN STEERING LEFT
12
MEMORANDUM
20-720 WA500-3H
TROUBLESHOOTING OF MAIN MONITOR
SYSTEM (M MODE)
WA500-3H 20-901
TROUBLESHOOTING
AT POSITION OTHER THAN N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION
LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED . . . . . . . . . . . . . . 20-922
A. ACTUATED CONTINOUSLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
B. NOT ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
M-15 ABNORMALITY IN BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-923
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON
(FOR 3 SECONDS) (DURING SELF-CHECK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-923
B. BUZZER ALWAYS SOUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-923
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY . . . . . . . . . . . . . . . . . . . . 20-924
M-17 ABNORMALITY IN FAILURE DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
A. DOES NOT ENTER FAILURE DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY
MODE DOES NOT ADVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . 20-926
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . 20-927
A. EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . 20-927
B. EMERGENCY STEERING NORMAL DISPLAY STAYS LIT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-927
M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY . . . . . . . . . . . . . . . . . . . . . 20-928
A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . 20-928
B. EMERGENCY STEERING DISPLAY STAYS LIT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-928
M-21 NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-929
M-22 ABNORMALITY IN ECSS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-930
A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-930
B. MONITOR DISPLAY LIGHTS UP, BUT ECSS FUNCTION DOES NOT WORK . . . . . . . . . . . . . . 20-930
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) . . . . . . . 20-931
20-902 WA500-3H
TROUBLESHOOTING M-1 MAIN MONITOR DOES NOT WORK
12
M-1 MAIN MONITOR DOES NOT WORK
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Yes
Defective main monitor Replace
1
Is voltage between
L05 (1), (2) - (3) Defective contact or
normal? 2 Yes disconnection in wiring
harness between L05 Repair or
1. 20 - 30 V. (female) (1), (2) and FS2 replace
2. Turn starting Is resistance between (female) (9)
switch ON. No L05 (female) (3) and
chassis ground
normal?
Defective contact or
disconnection in wiring Repair or
1. Turn starting No harness between L05
switch OFF. (female) (3) and LR5 replace
2. Disconnect L05. (male) (3)
3. Max. 1 Ω.
WA500-3H 20-903
TROUBLESHOOTING M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS
12
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS
STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (4) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or
harness between L05 replace
1. 20 - 30 V. No (female) (4) and L57
2. Turn starting (female) (3)
switch to START.
20-904 WA500-3H
TROUBLESHOOTING M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY
12
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Check that the gap between the speed sensor and gear is normal.
Cause Remedy
2 Yes
Defective main monitor Replace
Yes
Is resistance between
1 L07 (female) (1) and
(2) normal?
Defective contact or dis-
Is resistance connection L07 (female) Repair or
between CN3 1. 500 Ω - 1 kΩ. Yes (1), (2) - TM2 (9), (10) - replace
(male) (1) and (2) 2. Turn starting CN3 (female) (1), (2)
normal? switch OFF.
3. Disconnect L07.
1. 500 Ω - 1 kΩ.
2. Turn starting Defective speed sensor Replace
switch OFF. No
3. Disconnect
CN3.
WA500-3H 20-905
TROUBLESHOOTING M-4 ABNORMALITY IN SHIFT INDICATOR
12
M-4 ABNORMALITY IN SHIFT INDICATOR
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Check that the transmission shifts.
A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L08 (7) and
chassis ground Defective contact or dis-
normal? No connection in wiring har- Repair or
ness between L08 (female) replace
1. 20 - 30 V. (7) and L04 (female) (2)
2. Turn starting
switch ON.
3. Directional
lever: F
20-906 WA500-3H
TROUBLESHOOTING M-4 ABNORMALITY IN SHIFT INDICATOR
12
D.DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND
DISPLAY F WHEN DIRECTIONAL LEVER IS AT R
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L08 (7) and
chassis ground Short circuit with power
normal? No source in wiring harness
between L08 (female) (7) Repair or
1. 0 - 5 V. and L04 (female) (2) or replace
2. Turn starting defective transmission
switch ON. lever
3. Directional
lever: N
WA500-3H 20-907
TROUBLESHOOTING M-5 HIGH BEAM DOES NOT LIGHT UP
12
M-5 HIGH BEAM DOES NOT LIGHT UP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the lamp bulb is not blown.
Cause Remedy
2 Yes
Defective main monitor Replace
Yes
Is resistance between
1 L06 (female) (13)
and chassis ground Defective contact or dis-
normal? No connection in wiring har- Repair or
Is voltage L06 ness between L06 (female) replace
(12) and chassis 1. Max. 1 Ω. (13) and L02 (female) (3)
ground normal? 2. Turn starting switch OFF.
3. Disconnect L06.
4. Dimmer switch: HI beam Defective contact or dis-
1. 20 - 30 V. connection in wiring har- Repair or
2. Turn starting ness between L06 (female) replace
switch ON. No (12) and L02 (female) (2)
20-908 WA500-3H
TROUBLESHOOTING M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP
12
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown.
A. LH TURN SIGNAL DISPLAY DOES NOT LIGHT UP
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L06 (14) and Defective contact or
chassis ground disconnection in wiring
normal? No harness between L06 Repair or
(female) (14) and L03 replace
1. Repeats 0 V and 20 - 30 V. (female) (4)
2. Turn starting switch ON.
3. Turn LH turn signal ON.
WA500-3H 20-909
TROUBLESHOOTING M-7 ABNORMALITY IN PARKING DISPLAY
12
M-7 ABNORMALITY IN PARKING DISPLAY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. PARKING LAMP DISPLAY DOES NOT LIGHT UP
Cause Remedy
3 Yes
Defective main monitor Replace
Yes
Is resistance between
2 CN19 (female) (2)
and chassis ground Defective contact or
normal? disconnection in wiring Repair or
Yes No harness between CN19
Is voltage between (female) (1) and chassis replace
1 L06 (11) and chassis 1. Max. 1 Ω. ground
ground normal? 2. Turn starting switch OFF.
3. Disconnect CN19. Defective contact or
Is resistance disconnection in wiring
between CN19 1. 20 - 30 V. No harness between L06 Repair or
(male) (1) and (2) 2. Turn starting (female) (11) - TM2 (7) - replace
normal? switch ON. CN19 (female) (1)
3. Turn parking
1. Max. 1 Ω. switch ON.
2. Disconnect Defective parking brake Replace
CN19. No indicator switch
3. Turn starting
switch ON.
4. Turn parking
switch ON.
20-910 WA500-3H
TROUBLESHOOTING M-8 NOT USED
12
M-8 NOT USED
WA500-3H 20-911
TROUBLESHOOTING M-9 NIGHT LIGHTING DOES NOT LIGHT UP
12
M-9 NIGHT LIGHTING DOES NOT LIGHT UP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the lamp bulbs are not blown.
● Check that fuse I - 6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness
between FS2 (female) (5) and L05 (female) (16).
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (16) and
chassis ground Defective contact or
normal? No disconnection in wiring Repair or
harness between L05 replace
1. 20 - 30 V. (female) (16) and FS2 (5)
2. Turn starting switch ON.
3. Turn small lamp switch ON.
20-912 WA500-3H
TROUBLESHOOTING M-9 NIGHT LIGHTING DOES NOT LIGHT UP
12
MEMORANDUM
WA500-3H 20-913
TROUBLESHOOTING M-10 ABNORMALITY IN FRONT WORKING LAMP
12
M-10 ABNORMALITY IN FRONT WORKING LAMP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the monitor lighting is lighted up.
A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP
Cause Remedy
Yes Defective contact or
disconnection in wiring Repair or
1 harness between L60
(female) (1) - L05 (17) - replace
CL1 (female) (7)
Is voltage between
L60 (1) and Yes
chassis ground Defective front working Replace
normal? 3 lamp relay
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT
UP
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (17) and Defective contact or
chassis ground disconnection in wiring
normal? No harness between L05 Repair or
(female) (17) and L60 replace
1. 20 - 30 V. (female) (1)
2. Turn starting
switch ON.
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT
UP
Cause Remedy
Defective contact or
disconnection in wiring
harness between L60 (1) - Repair or
CL1 (7) - C03 (female) replace
(1), C04 (female) (1) or
blown working lamp bulb
20-914 WA500-3H
TROUBLESHOOTING M-10 ABNORMALITY IN FRONT WORKING LAMP
12
M-10 Related electrical circuit diagram
WA500-3H 20-915
TROUBLESHOOTING M-11 ABNORMALITY IN REAR WORKING LAMP
12
M-11 ABNORMALITY IN REAR WORKING LAMP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the monitor lighting is lighted up.
A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP
Cause Remedy
Yes Defective contact or
disconnection in wiring Repair or
1 harness between L61
(female) (1) - L05 (18) - replace
LR1 (female) (12)
Is voltage between
L61 (1) and Yes
chassis ground Defective rear working Replace
normal? 3 lamp relay
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT
UP
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (18) and Defective contact or
chassis ground disconnection in wiring
normal? No harness between L05 Repair or
(female) (18) and L61 replace
1. 20 - 30 V. (female) (1)
2. Turn starting
switch ON.
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT
UP
Cause Remedy
Defective contact or
disconnection in wiring
harness between L61 (1) - Repair or
LR1 (12) - G02 (female) replace
(1), G04 (female) (1) or
blown working lamp bulb
20-916 WA500-3H
TROUBLESHOOTING M-11 ABNORMALITY IN REAR WORKING LAMP
12
M-11 Related electrical circuit diagram
WA500-3H 20-917
TROUBLESHOOTING M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
12
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS
PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES
NOT CHANGE
Cause Remedy
20-918 WA500-3H
TROUBLESHOOTING M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
12
E.MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH
TURN ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED
Cause Remedy
1 Yes
Defective transmission Replace
cut-off switch
Does cut-off
function work 2 Yes
when L12 is Defective main monitor Replace
disconnected?
Does cut-off
1. Disconnect L06. No function work when 3 Yes
2. Turn starting L06 is disconnected? Defective transmission Replace
switch ON. Is voltage between controller
C5 (6) and chassis
1. Disconnect L06. No ground normal? Short circuit with power
2. Turn starting source in harness between Repair or
switch ON. 1. Disconnect L12. No L06 (female) (3) - C5
2. Turn starting (female) (6) - L12 replace
switch ON. (female) (10
3. 20 - 30 V.
WA500-3H 20-919
TROUBLESHOOTING M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
12
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS
(INTERMITTENTLY) AND CAUTION LAMP FLASHES WEVEN WHEN
DIRECTIONAL LEVER IS AT N.
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (8) and
chassis ground
normal? Defective contact or
disconnection in wiring
1. 20 - 30 V. No harness between L05 Repair or
2. Turn starting (female) (8) - JSA replace
switch ON. (female) (1) - L04
3. Directional (female) (3)
lever: N.
20-920 WA500-3H
TROUBLESHOOTING M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
12
M-13 Related electrical circuit diagram
WA500-3H 20-921
TROUBLESHOOTING M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,
12
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,
BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,
OR THEY ARE NOT ACTUATED
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. ACTUATED CONTINOUSLY
Cause Remedy
2 Yes
Defective maintenance Replace
Yes monitor
Does buzzer stop
1 and lamp go out?
Defective contact or
disconnection in wiring Repair or
1. Turn starting No harness between L07
Does buzzer stop switch ON. (female) (6) and L19 replace
and lamp go out? 2. Connect L19 (female) (5)
(female) (5) to
1. Turn starting chassis ground.
switch ON. Defective main monitor Replace
2. Connect L07 (6) No
to chassis ground.
B. NOT ACTUATED
Cause Remedy
2 Yes
Defective maintenance Replace
Yes monitor
Does buzzer and
1 lamp work?
Short circuit with power
1. Turn starting No source in harness between Repair or
Does buzzer and switch ON. L07 (female) (6) and L19 replace
lamp work? 2. Disconnect L19. (female) (5)
1. Turn starting
switch ON. Defective main monitor Replace
2. Disconnect L07 No
20-922 WA500-3H
TROUBLESHOOTING M-15 ABNORMALITY IN BUZZER
12
M-15 ABNORMALITY IN BUZZER
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3
SECONDS) (DURING SELF-CHECK)
Cause Remedy
Yes Defective contact or
disconnection in wiring Repair or
1 harness between L06 replace
(female) (8) and L43
(male) (1)
Does buzzer
sound?
2 Yes
Defective buzzer Replace
1. Turn starting Is voltage between
switch ON. L42 (female) and
2. Contact L43 No chassis ground
(female) to normal? Defective contact or
chassis ground. disconnection in wiring Repair or
1. 20 - 30 V. No harness between L42 replace
2. Turn starting (female) (1) and FS2
switch ON. (female) (9)
1. Disconnect L43.
2. Turn starting Defective buzzer Replace
switch ON. No
WA500-3H 20-923
TROUBLESHOOTING M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN
12
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN
MEMORY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L07 (10) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or
1. 20 - 30 V. No harness between L07 replace
2. turn starting (female) (10) and L09
switch ON. (female) (2)
20-924 WA500-3H
TROUBLESHOOTING M-17 ABNORMALITY IN FAILURE DISPLAY MODE
12
M-17 ABNORMALITY IN FAILURE DISPLAY MODE
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. DOES NOT ENTER FAILURE DISPLAY MODE
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (5) and
chassis ground Short circuit with power
normal? source in wiring harness
between L05 9female) (5) Repair or
1. 0 - 5 V. No - LR4 (6) - ER1 (9) - replace
2. Turn starting alternator terminal R, or
switch ON. defective alternator
WA500-3H 20-925
TROUBLESHOOTING M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CON-
20-926 WA500-3H
TROUBLESHOOTING M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DIS-
12
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL
DISPLAY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP
Cause Remedy
2 Yes
Defective main monitor Replace
Yes Is voltage between
L05 (10) and chassis
1 ground normal? Defective contact or
disconnection in wiring Repair or
1. 20 - 30 V. No harness between L05
Is emergency 2. Turn starting (female) (10) and EST replace
steering selection switch ON. (female) (2)
connector
disconnected?
Defective disconnection of
emergency steering Disconnect
No selector connector
WA500-3H 20-927
TROUBLESHOOTINGM-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DIS-
12
M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION
DISPLAY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP
Cause Remedy
2 Yes
Defective main monitor Replace
Yes Is voltage between
L05 (11) and chassis
1 ground normal? Defective contact or
disconnection in wiring Repair or
1. 20 - 30 V. No harness between L05
Is emergency 2. Turn starting (female) (11) and EST replace
steering selection switch ON. (female) (1)
connector
disconnected?
Defective disconnection of
emergency steering Disconnect
No selector connector
20-928 WA500-3H
TROUBLESHOOTING M-21 NOT USED
12
M-21 NOT USED
WA500-3H 20-929
TROUBLESHOOTING M-22 ABNORMALITY IN ECSS SYSTEM
12
M-22 ABNORMALITY IN ECSS SYSTEM
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● ECSS: Electronic Controlled Suspension System.
A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED
Cause Remedy
B. MONITOR DISPLAY LIGHTS UP, BUT ECSS FUNCTION DOES NOT WORK
Cause Remedy
2 Yes Go to Troubleshooting for
ECSS Controller System ---
Yes Is voltage between (D Mode)
C3B (9) and chassis
1 ground normal?
Defective contact or
Is voltage between 1. Max. 3 V. disconnection in wiring Repair or
L06 (7) and 2. Turn starting harness between L06 (7) replace
chassis ground switch ON. No and C3B (9)
normal?
1. Max. 3 V.
2. Turn starting Defective main monitor Replace
switch ON. No
20-930 WA500-3H
TROUBLESHOOTING M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNOR-
12
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNOR-
MALITY IN NETWORK)
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Set dipswitch 3 at the rear of the main monitor to "F".
● MDC: Multiple Display and Condition.
Cause Remedy
2 Yes
Applicable controller is Replace
1 Yes defective
Is voltage normal
Is voltage between between pins of
L08 (male) (1) and connectors in table Defective contact or
(2) normal? below? disconnection in wiring
harness between L08 Repair or
1. Repeats 0 V and 1. Repeats 0 V and No (female) (1) (3), L08 replace
12 V. 12 V. (female) (2) (4) -
2. Turn starting 2. Turn starting applicable connector pins
switch ON. switch ON.
3. Disconnect L08. 3. Disconnect
connector to be
measured.
Defective main monitor Replace
No
WA500-3H 20-931
TROUBLESHOOTING M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNOR-
12
MEMORANDUM
20-932 WA500-3H
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM (T MODE)
WA500-3H 20-1201
TROUBLESHOOTING
T-24 KICK-DOWN SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1254
T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1255
T-26 NEUTRALIZER RELAY SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1256
T-27 BUZZER SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1257
T-28 NETWORK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1258
T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1259
T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1260
T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM . . . . . . . . . . . . 20-1261
T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1262
T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1263
T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1264
T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1265
T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1266
T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1267
Remark
See Electrical Diagram in section 90.
20-1202 WA500-3H
TROUBLESHOOTING
12
MEMORANDUM
WA500-3H 20-1203
TROUBLESHOOTING JUDGEMENT TABLE FOR TRANSMISSION
12
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER
SYSTEM RELATED PARTS
T-12
T-13
T-14
T-15
T-16
T-17
T-18
T-19
T-20
T-11
T-1
T-2
T-3
T-4
T-5
T-6
T-7
T-8
T-9
20-1204 WA500-3H
12
WA500-3H
TROUBLESHOOTING
X
T-21 Disconnection in F or R ECMV fill switch system
X
T-22
32 33
Disconnection in 1st, 2nd, 3rd, or 4th ECMV fill switch system
-
Abnormality in hold switch signal system
X
-
-
Abnormality in kick-down switch signal system
X
X
-
-
Abnormality in transmission cut-off signal system
X
-
-
Abnormality in neutralizer signal system
X
(Failure code)
-
-
Abnormality in alarm buzzer signal system
X
X
(abnormality display)
Self diagnostic display
-
Abnormality in network signal system
X
Transmission controller error
-
Abnormality in network signal system or main monitor
X
T-29
T-28
T-26
T-25
T-23
display is given
E-1, H-1
T-28, J-1
H-2, H-3
T-24, E-9
20-1205
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
OCCURS AND PROBLEMS ON MACHINE
1. TRANSMISSION CONTROLLER SYSTEM
Failure
Abnormal System Nature of Abnormality
Code
1) Defective F ECMV.
2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C2
(female) (7) - TM2 (4) - CN16 (1).
12 Abnormality in F ECMV system b
3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between transmission controller C2 (female) (17) - TM2 (5) - CN16
(2).
4) Defective transmission controller.
1) Defective R ECMV.
2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C2
(female) (8) - TM2 (1) - CN14 (1).
13 Abnormality in R ECMV system c
3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between transmission controller C2 (female) (18) - TM2 (2) - CN14
(2).
4) Defective transmission controller.
20-1206 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
WA500-3H 20-1207
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
Failure
Abnormal System Nature of Abnormality
Code
When the wiring harness is in any of the following conditions with switch not
pressed:
3) Defective contact or disconnection in wiring harness between transmission
controller C5 (female) (8) - JS14 (2) - joystick lever connector (2), or short
circuit with chassis ground in wiring harness between C5 (female) (16) - JS14
19 Abnormality in joystick directional switch (3) - joystick lever connector (3). h
4) Defective contact or disconnection in wiring harness between transmission
controller C5 (female) (7) - JS14 (4) - joystick lever connector (4), or short
circuit with chassis ground in wiring harness between C5 (female) (15) -
JS14 (5) - joystick lever connector (5).
5) Defective contact or disconnection in wiring harness between transmission
controller C5 (female) (9) - JS14 (6) - joystick lever connector (6), or short
circuit with chassis ground in wiring harness between C5 (female) (7) -
JS14 (7) - joystick lever connector (7).
Abnormality in directional switch signal Short circuit with power source, short circuit with chassis ground, defective contact,
20 i
system disconnection in the following wiring harness:
3) Wiring harness between transmission controller C3B (female) (5) and L04 (2).
4) Wiring harness between transmission controller C3B (female) (13) and L04 (3).
5) Wiring harness between transmission controller C3B (female) (6) and L04 (4).
Short circuit with power source, short circuit with chassis ground, defective contact,
21 Abnormality in range switch signal system disconnection in the following wiring harness: j
3) Wiring harness between transmission controller C3B (female) (7) and L04 (5).
4) Wiring harness between transmission controller C3B (female) (15) and L04 (6).
5) Wiring harness between transmission controller C3B (female) (8) and L04 (7).
6) Wiring harness between transmission controller C3B (female) (16) and L04 (8).
20-1208 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
Action by controller Problem that appears Trouble-
Condition when normal (voltage, current, resistance) when abnormality is on machine with shooting
detected abnormality Code
1) Voltage between combination switch L04 (1) and chassis ground: • Shift to neutral
immediately when short
20 - 30 V.
circuit with power source
2) Voltage for only 1 system in accordance with position of directional
is detected.
i lever: 20 - 30 V (Others: Less than 1 V) It is impossible to travel T-9
• When there is no signal
F: Between transmission controller C3B (5) - chassis ground.
(disconnection), holds
N: Between transmission controller C3B (13) - chassis ground. previous signal condition
R: Between transmission controller C3B (6) - chassis ground. for 2 seconds.
1) Voltage between combination switch L04 (1) and chassis ground: • If signals are input, it 1) Auto-shift limit is
20 - 30 V. judges speed range different from
2) Voltage for only 1 system in accordance with position of directional position in order of range position
lever: 20 - 30 V (Others: Less than 1V) priority 4←3←2←1. selected by
j T-10
1st: Between transmission controller C3B (7) - chassis ground. • When there is no signal operator.
2nd: Between transmission controller C3B (15) - chassis ground. (disconnection), holds 2) Impossible to shift
3rd: Between transmission controller C3B (8) - chassis ground. previous signal condition gear in manual
4th: Between transmission controller C3B (16) - chassis ground. (speed range position). mode.
1) Switches to manual
1) Does not carry out
1) Resistance between speed sensor CN3 (1) and (2): 500 - 1,000 Ω. mode.
auto-shift.
k 2) Voltage between transmission controller C5 (female) (2) and (10): 2) Shifts gear according T-11
2) Switches to manual
Min. 0.5 V. to operation of speed
shift.
lever
WA500-3H 20-1209
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
Failure
Abnormal System Nature of Abnormality
Code
20-1210 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
Action by controller Problem that appears Trouble-
Condition when normal (voltage, current, resistance) when abnormality is on machine with shooting
detected abnormality Code
1) Resistance between transmission oil temperature sensor CN11 (1) Uses low temperature data
and (2): 38 - 48 kΩ {approx. 25° C (77° F)} for transmission oil There is gearshifting
n T-14
2) Voltage between transmission controller C3A (female) (11) and temperature when shifting shock.
(17): 1 - 5 V. gear
WA500-3H 20-1211
TROUBLESHOOTING T-1 FAILURE CODE [10] (SHORT CIRCUIT,
12
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN BACK-UP LAMP
RELAY) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
L54 (female) (1) and
3 chassis ground
normal? Short circuit with chassis
Is resistance between ground in wiring harness Repair or
1) Min. 1 MΩ. No between C1 (female) (11) replace
2 Yes C1 (female) (11) and and L54 (female) (1)
chassis normal when 2) Turn starting switch
L54 (female) (1) is OFF.
grounded to chassis? 3) Disconnect C1 and
Is resistance between L54.
Yes L54 (female) (2) and
chassis ground 1) Max. 1 Ω. Disconnection in wiring
normal? 2) Turn starting switch harness between C1 Repair or
OFF. No (female) (11) and L54 replace
1 (female) (1)
3) Disconnect C1 and
Is troubleshooting code 1) Max. 1 Ω . L54.
10 displayed when the 2) Turn starting switch
relay is interchanged OFF.
with a relay of same 3) Disconnect L54.
type? Disconnection in wiring
harness between L54 Repair or
1) Turn starting switch No (female) (2) - LR5 (2) - replace
OFF. chassis ground
2) Interchange relay with
of same type.
3) Turn starting switch
ON. Defective back-up lamp Replace
4) Directional lever: R No relay
20-1212 WA500-3H
TROUBLESHOOTING T-1 FAILURE CODE [10] (SHORT CIRCUIT,
12
MEMORANDUM
WA500-3H 20-1213
TROUBLESHOOTING T-2 FAILURE CODE [12] (SHORT CIRCUIT,
12
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN16 (female) (1)
and chassis normal
when C2 (female)
(7) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes Is resistance between 1) Max. 1 Ω. No (female) (7) - TM2 (4) -
2) Turn starting switch CN16 (female) (1)
C2 (female) (17) and OFF.
2 chassis ground 3) Disconnect C2 and
normal? CN16.
Is resistance between Short circuit with chassis
CN16 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (17) replace
OFF. No - TM2 (5) - CN16 (female)
(17) is grounded to 3) Disconnect C2 and (2)
chassis? CN16.
1
Is resistance between 1) Max. 1 Ω.
CN16 (male) (1) and 2) Turn starting switch Defective contact or
(2), and between (1), (2) OFF. disconnection in wiring
and chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN16. (female) (17) - TM2 (5) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN16 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN16. Defective F solenoid Replace
No
1) 5 - 15 Ω.
2) Turn starting switch
OFF. Short circuit with chassis
5 ground in wiring harness
3) Disconnect C2 and
Is resistance between CN16. between C2 (female) (17)
A C2 (female) (7) and - TM2 (5) - CN16 (female) Repair or
chassis normal? No (2) and wiring harness replace
between C2 (female) (7) -
1) Min. 1 MΩ. TM2 (4) - CN16 (female)
2) Turn starting switch (1)
OFF.
3) Disconnect C2 and
CN16.
Short circuit with chassis
ground in wiring harness Repair or
between C2 (female) (7) - replace
No TM2 (4) - CN16 (female)
(1)
20-1214 WA500-3H
TROUBLESHOOTING T-2 FAILURE CODE [12] (SHORT CIRCUIT,
12
T-2 Related electrical circuit diagram
WA500-3H 20-1215
TROUBLESHOOTING T-3 FAILURE CODE [13] (SHORT CIRCUIT,
12
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN14 (female) (1)
and chassis normal
when C2 (female)
(8) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes 1) Max. 1 Ω. No (female) (8) - TM2 (1) -
Is resistance between 2) Turn starting switch CN14 (female) (1)
2 C2 (female) (18) and OFF.
chassis normal? 3) Disconnect C2 and
CN14.
Is resistance between Short circuit with chassis
CN14 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (18) replace
OFF. No - TM2 (2) - CN14 (female)
(18) is grounded to 3) Disconnect C2 and (2)
chassis? CN14.
1
Is resistance between 1) Max. 1 Ω.
CN14 (male) (1) and 2) Turn starting switch Defective contact or
(2), and between (1), (2) OFF. disconnection in wiring
and chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN14. (female) (18) - TM2 (2) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN14 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN14. Defective R solenoid Replace
No
1) 5 - 15 Ω.
2) Turn starting switch
5 OFF. Short circuit with chassis
3) Disconnect C2 and ground in wiring harness
Is resistance between CN14. between C2 (female) (18)
A C2 (female) (8) and - TM2 (2) - CN14 (female) Repair or
chassis normal? (2) and wiring harness replace
No between C2 (female) (8) -
TM2 (1) - CN14 (female)
1) Min. 1 MΩ. (1)
2) Turn starting switch
OFF.
3) Disconnect C2 and
CN14.
Short circuit with chassis
ground in wiring harness Repair or
between C2 (female) (8) - replace
No TM2 (1) - CN14 (female)
(1)
20-1216 WA500-3H
TROUBLESHOOTING T-3 FAILURE CODE [13] (SHORT CIRCUIT,
12
T-3 Related electrical circuit diagram
WA500-3H 20-1217
TROUBLESHOOTING T-4 FAILURE CODE [14] (SHORT CIRCUIT,
12
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN4 (female) (1)
and chassis normal
when C2 (female)
(9) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes Is resistance between 1) Max. 1 Ω. No (female) (9) - TM1 (1) -
2) Turn starting switch CN4 (female) (1)
C2 (female) (19) and OFF.
2 chassis ground 3) Disconnect C2 and
normal? CN4.
Is resistance between Short circuit with chassis
CN4 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (19) replace
OFF. No - TM1 (2) - CN4 (female)
(19) is grounded to 3) Disconnect C2 and (2)
chassis? CN4.
1
Is resistance between 1) Max. 1 Ω.
CN4 (male) (1) and (2), 2) Turn starting switch Defective contact or
and between (1), (2) and OFF. disconnection in wiring
chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN4. (female) (19) - TM1 (2) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN4 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN4. Defective 1st solenoid Replace
No
20-1218 WA500-3H
TROUBLESHOOTING T-4 FAILURE CODE [14] (SHORT CIRCUIT,
12
T-4 Related electrical circuit diagram
WA500-3H 20-1219
TROUBLESHOOTING T-5 FAILURE CODE [15] (SHORT CIRCUIT,
12
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN6 (female) (1)
and chassis normal
when C2 (female)
(10) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes Is resistance between 1) Max. 1 Ω. No (female) (10) - TM1 (4) -
2) Turn starting switch CN6 (female) (1)
C2 (female) (20) and OFF.
2 chassis ground 3) Disconnect C2 and
normal? CN6.
Is resistance between Short circuit with chassis
CN6 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (20) replace
OFF. No - TM1 (5) - CN6 (female)
(20) is grounded to 3) Disconnect C2 and (2)
chassis? CN6.
1
Is resistance between 1) Max. 1 Ω.
CN6 (male) (1) and (2), 2) Turn starting switch Defective contact or
and between (1), (2) and OFF. disconnection in wiring
chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN6. (female) (20) - TM1 (5) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN6 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN6. Defective 2nd solenoid Replace
No
20-1220 WA500-3H
TROUBLESHOOTING T-5 FAILURE CODE [15] (SHORT CIRCUIT,
12
T-5 Related electrical circuit diagram
WA500-3H 20-1221
TROUBLESHOOTING T-6 FAILURE CODE [16] (SHORT CIRCUIT,
12
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN12 (female) (1)
and chassis normal
when C2 (female)
(2) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes Is resistance between 1) Max. 1 Ω. No (female) (2) - TM1 (7) -
2) Turn starting switch CN12 (female) (1)
C2 (female) (13) and OFF.
2 chassis ground 3) Disconnect C2 and
normal? CN12.
Is resistance between Short circuit with chassis
CN12 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (13) replace
OFF. No - TM1 (8) - CN12 (female)
(13) is grounded to 3) Disconnect C2 and (2)
chassis? CN12.
1
Is resistance between 1) Max. 1 Ω.
CN12 (male) (1) and 2) Turn starting switch Defective contact or
(2), and between (1), (2) OFF. disconnection in wiring
and chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN12. (female) (13) - TM1 (8) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN12 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN12. Defective 3rd solenoid Replace
No
20-1222 WA500-3H
TROUBLESHOOTING T-6 FAILURE CODE [16] (SHORT CIRCUIT,
12
T-6 Related electrical circuit diagram
WA500-3H 20-1223
TROUBLESHOOTING T-7 FAILURE CODE [17] (SHORT CIRCUIT,
12
T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN8 (female) (1)
and chassis normal
when C2 (female)
(4) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes Is resistance between 1) Max. 1 Ω. No (female) (4) - TM1 (10) -
2) Turn starting switch CN8 (female) (1)
C2 (female) (15) and OFF.
2 chassis ground 3) Disconnect C2 and
normal? CN8.
Is resistance between Short circuit with chassis
CN8 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (15) replace
OFF. No - TM1 (11) - CN8 (female)
(15) is grounded to 3) Disconnect C2 and (2)
chassis? CN8.
1
Is resistance between 1) Max. 1 Ω.
CN8 (male) (1) and (2), 2) Turn starting switch Defective contact or
and between (1), (2) and OFF. disconnection in wiring
chassis normal? 3) Disconnect C2 and harness between C2 Repair or
1) Between (1) and (2): CN8. No (female) (15) - TM1 (11) - replace
5 - 15 Ω. CN8 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN8. Defective 4th solenoid Replace
No
20-1224 WA500-3H
TROUBLESHOOTING T-7 FAILURE CODE [17] (SHORT CIRCUIT,
12
T-7 Related electrical circuit diagram
WA500-3H 20-1225
TROUBLESHOOTING T-8 FAILURE CODE [19] (SHORT CIRCUIT,
12
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN
JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes Defective transmission
controller Replace
Yes Is voltage between
C5 (female) (7), (8),
(9), (15), (16), (17) Short circuit, short circuit
and chassis as shown with chassis ground,
3 in Table 1? defective contact, or
disconnection in wiring Repair or
Yes Is resistance between 1) Turn starting switch No harness between JS15 replace
ON. (female) (2), (3), (4), (5),
JS15 (female) (8) (6), (7) - C5 (female) (7),
2 and chassis normal? (8), (9), (15), (16), (17)
Yes Is voltage between 1) Min. 1 MΩ.
JS15 (1) and chassis 2) Turn starting switch Defective contact, or
normal? OFF. disconnection in wiring
3) Disconnect JS15. harness between JS15 Repair or
1) 20 - 30 V. No (female) (8) - JS14 (8) - replace
1
2) Turn starting switch LR5 (2) - chassis
ON.
Is voltage between JS15
(8) and terminals (2),
(3), (4), (5), (6), and (7) Short circuit, short circuit
as shown in Table 1? with chassis ground,
defective contact, or Repair or
disconnection in wiring replace
1) Turn starting switch No harness between C3A
ON. (male) (6) - JS14 (1) - LR5
(1) - chassis
JS15 (male) (8) - (2) Between C5 (8) and chassis 20 - 30 V Max. 1 V Max. 1 V
JS15 (male) (8) - (4) Between C5 (7) and chassis Max. 1 V 20 - 30 V Max. 1 V
JS15 (male) (8) - (6) Between C5 (9) and chassis Max. 1 V Max. 1 V 20 - 30 V
20-1226 WA500-3H
TROUBLESHOOTING T-8 FAILURE CODE [19] (SHORT CIRCUIT,
12
T-8 Related electrical circuit diagram
WA500-3H 20-1227
TROUBLESHOOTING T-9 FAILURE CODE [20] (SHORT CIRCUIT,
12
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN
DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Yes
a
6
Is resistance
between C3B
Yes (female) (6) and
chassis, and
between C3B
(female) (6) and
5 (13) normal?
2
Yes Is resistance
between L04
(female) (1) and
chassis normal?
1 1) Min. 1 MΩ.
2) Disconnect FS2 e
Is resistance and L04. No
between L04 (male) 3) Turn starting
(1) and (2), (3), and switch OFF.
(4) as shown in
Table 1?
1) Disconnect L04.
2) Turn starting f
switch OFF. No
g
No
20-1228 WA500-3H
TROUBLESHOOTING T-9 FAILURE CODE [20] (SHORT CIRCUIT,
Cause Remedy
10 Yes Defective transmission
controller Replace
9 Yes Is voltage between
C3B (13) and chassis
Yes Is failure code normal? Defective contact, or
displayed when L57 disconnection in wiring Repair or
8 1) 20 - 30 V. No harness between L04
is replaced with 2) Turn starting switch (female) (3) and C3B replace
relay of same type? ON. (female) (13)
Yes Is resistance between
C3B (13) and chassis 3) Directional lever: N
normal? 1) Turn starting switch
OFF. Defective neutral relay Replace
7 1) Min. 1 MΩ. 2) Interchange with No
2) Disconnect L04, relay of same type.
Is voltage between C3B, L57, and L05. 3) Turn starting switch Short circuit with chassis
a C3B (6) and 3) Turn starting switch ON. ground in wiring harness
chassis normal? OFF. 4) Directional lever: N between L04 (female) (3)
and C3B (female) (13), Repair or
1) 20 - 30 V. No between L04 (female) (3) - replace
2) Turn starting JSA (1) - L05 (female) (8),
switch ON. and between JSA (female)
3) Directional lever: (1) and L57 (female) (1)
R
Defective contact, or
disconnection in wiring Repair or
No harness between L04
(female) (4) and C3B replace
(female) (6)
Defective contact, or
disconnection in wiring Repair or
c harness between L04 replace
(female) (2) and C3B
(female) (5)
Defective contact, or
disconnection in wiring
e harness between fuse I (9) Repair
replace
or
- FS2 (8) - L04 (female)
(1)
WA500-3H 20-1229
TROUBLESHOOTING T-9 FAILURE CODE [20] (SHORT CIRCUIT,
12
Table 1
Directional Position
Terminal
F N R
L04 (male) (1) - (2) Max. 1Ω Min. 1 MΩ Min. 1 MΩ
L04 (male) (1) - (3) Min. 1 MΩ Max. 1Ω Min. 1 MΩ
L04 (male) (1) - (4) Min. 1 MΩ Min. 1 MΩ Max. 1Ω
20-1230 WA500-3H
TROUBLESHOOTING T-9 FAILURE CODE [20] (SHORT CIRCUIT,
12
MEMORANDUM
WA500-3H 20-1231
TROUBLESHOOTING T-10 FAILURE CODE [21] (SHORT CIRCUIT,
12
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN
RANGE SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Yes
a
6
Is resistance
between C3B
Yes (female) (8) and
chassis, and
between C3B
(female) (8) and
5 (15) (16) normal?
2
Yes Is resistance
between L04
(female) (1) and
chassis normal?
1 1) Min. 1 MΩ.
2) Disconnect FS2 e
Is resistance and L04. No
between L04 (male) 3) Turn starting
(1), (5), (6), (7), and switch OFF.
(8) as shown in
Table 1?
1) Disconnect L04.
2) Turn starting f
switch OFF. No
g
No
20-1232 WA500-3H
TROUBLESHOOTING T-10 FAILURE CODE [21] (SHORT CIRCUIT,
Cause Remedy
10 Yes
Go to A -
Yes Is resistance between
C3B (16) and chassis
9 normal?
8 Yes Is voltage between 1) Min. 1 MΩ. Short circuit with chassis
C3B (15) and chassis 2) Disconnect L04 ground in wiring harness Repair or
normal? and C3B. No between L04 (female) (8) replace
Is resistance between 3) Turn starting switch and C3B (female) (16)
C3B (female) (15) 1) 20 - 30 V. OFF.
Yes and chassis, and
2) Turn starting switch
between C3B ON.
(female) (15) and 3) Speed lever: 2nd
(16) normal? Defective contact, or
7 disconnection in wiring Repair or
harness between L04
Is voltage between 1) Min. 1 MΩ. No (female) (6) and C3B replace
a C3B (8) and 2) Disconnect L04 (female) (15)
chassis normal? and C3B.
3) Turn starting switch
1) 20 - 30 V. OFF. Short circuit with chassis
2) Turn starting ground in wiring harness
switch ON. between L04 (female) (6)
3) Speed lever: 3rd and C3B (female) (15), or
No short circuit in wiring
harness between L04 Repair or
(female) (6) - C3B replace
(female) (15) and wiring
harness between L04
(female) (8) - C3B
(female) (16)
Defective contact, or
disconnection in wiring Repair or
harness between L04 replace
(female) (7) and C3B
No (female) (8)
Defective contact, or
disconnection in wiring Repair or
c harness between L04 replace
(female) (5) and C3B
(female) (7)
Defective contact, or
disconnection in wiring
harness between fuse I (9) Repair
replace
or
e - FS2 (8) - L04 (female)
(1)
WA500-3H 20-1233
TROUBLESHOOTING T-10 FAILURE CODE [21] (SHORT CIRCUIT,
11 Yes
h
Is voltage between C3B
From A (16) and chassis
normal?
1) 20 - 30 V.
2) Turn starting switch i
ON. No
3) Speed lever: 4th.
20-1234 WA500-3H
TROUBLESHOOTING T-10 FAILURE CODE [21] (SHORT CIRCUIT,
12
Cause Remedy
Defective contact, or
disconnection in wiring Repair or
i harness between L04 replace
(female) (8) and C3B
(female) (16)
Table 1
Directional Position
Terminal
1st 2nd 3rd 4th
L04 (male) (1) - (5) Max. 1Ω Min. 1 MΩ Min. 1 MΩ Min. 1 MΩ
L04 (male) (1) - (6) Min. 1 MΩ Max. 1Ω Min. 1 MΩ Min. 1 MΩ
L04 (male) (1) - (7) Min. 1 MΩ Min. 1 MΩ Max. 1Ω Min. 1 MΩ
L04 (male) (1) - (8) Min. 1 MΩ Min. 1 MΩ Min. 1 MΩ Max. 1Ω
WA500-3H 20-1235
TROUBLESHOOTING T-11 FAILURE CODE [22] (DISCONNECTION
12
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED
SENSOR SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (10) and
chassis normal when
CN3 (female) (2) is Defective contact, or
2 grounded to chassis? disconnection in wiring
harness between C5 Repair or
Yes Is resistance between 1) Max. 1 Ω. No (female) (2) - TM2 (9) - replace
C5 (female) (2) and 2) Disconnect C3, C5, CN3 (female) (1)
1 chassis normal when and L07.
CN3 (female) (1) is 3) Turn starting switch
grounded to chassis? OFF.
Is resistance between Defective contact, or
CN3 (male) (1) and (2), 1) Max. 1 Ω. disconnection in wiring
and between (1), (2) and 2) Disconnect C3, C5, harness between C5 Repair or
chassis normal? and L07. No (female) (10) - TM2 (10) - replace
3) Turn starting switch CN3 (female) (2)
1) Between (1) and (2): OFF.
500 - 1000 Ω.
2) Between (1), (2) and
chassis: Min. 1 MΩ. Defective speed sensor Replace
3) Disconnect CN3. No
4) Turn starting switch
OFF.
20-1236 WA500-3H
TROUBLESHOOTING T-11 FAILURE CODE [22] (DISCONNECTION
12
MEMORANDUM
WA500-3H 20-1237
TROUBLESHOOTING T-12 FAILURE CODE [23] (SHORT CIRCUIT,
12
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN
ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
C4 (female) (9) and
3 chassis normal when
E04 (female) (3) is Defective contact, or
Yes Is resistance between grounded to chassis? disconnection in wiring
C4 (female) (2) and harness between C4 Repair or
chassis normal? 1) Max. 1 Ω. No (female) (9) - LR3 (8) - replace
2
2) Disconnect C4, ER2 (7) - E04 (female) (3)
Yes Is resistance between 1) Min. 1 MΩ. E04, and L07.
C4 (female) (2) and 2) Disconnect C4, 3) Turn starting switch
chassis normal when E04, and L07. OFF. Short circuit with chassis
E04 (female) (2) is 3) Turn starting switch ground in wiring harness
1 grounded to chassis? OFF. between C4 (female) (2) - Repair or
LR3 (7) - ER2 (6) - E04
Is resistance between 1) Max. 1 Ω. No (female) (2), and between replace
E04 (male) (2) and (3) 2) Disconnect C4, C4 (female) (2) and L07
normal? E04, and L07. (female) (3)
3) Turn starting switch
1) 100 - 500 Ω. OFF.
2) Disconnect CN3. Defective contact, or
3) Turn starting switch disconnection in wiring
OFF. harness between C4 Repair or
No (female) (2) - LR3 (7) - replace
ER2 (6) - E04 (female) (2)
20-1238 WA500-3H
TROUBLESHOOTING T-12 FAILURE CODE [23] (SHORT CIRCUIT,
T-12 Related electrical circuit diagram
WA500-3H 20-1239
TROUBLESHOOTING T-13 FAILURE CODE [24] (SHORT CIRCUIT,
12
T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN
EEP ROM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-1240 WA500-3H
TROUBLESHOOTING T-14 FAILURE CODE [25] (SHORT CIRCUIT
12
T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL
TEMPERATURE SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 Yes Defective transmission
controller Replace
Yes
Is resistance between
2 C3A (female) (11) and Short circuit in wiring
(17) normal? harness between C3A
Yes Is resistance between (female) (11) - TM2 (13) - Repair or
C3A (female) (11) CN11 (female) (1) and replace
1 and chassis normal? 1) Min. 1 MΩ. No wiring harness between
2) Turn starting switch C3A (female) (17) - TM2
1) Min. 1 MΩ. OFF. (14) - CN11 (female) (2)
Is resistance between 2) Turn starting switch 3) Disconnect C3A
CN11 (male) (1) and OFF. and CN11.
(2), and between (1), (2) 3) Disconnect C3A
chassis normal? Short circuit with chassis
and CN11. ground in wiring harness
between C3A (female) Repair or
1) Between (1) and (2): No (11) - TM2 (13) - CN11 replace
38 - 48 kΩ (normal (female) (1)
temperature: 25o C
[77o F])
2) Between (1), (2) and Defective transmission oil Replace
chassis: Min. 1 MΩ. No temperature sensor
3) Turn starting switch
OFF.
4) Disconnect CN11.
WA500-3H 20-1241
TROUBLESHOOTING T-15 FAILURE CODE [26] (SHORT CIRCUIT
12
T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (2) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness Repair or
CN17 (male) (1) and 2) Disconnect C3B and between C3B (female) (2) replace
chassis normal? CN17. No - TM2 (6) - CN17 (female)
3) Turn starting switch (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN17.
3) Turn starting switch
OFF. Defective F ECMV fill Replace
No switch
20-1242 WA500-3H
TROUBLESHOOTING T-16 FAILURE CODE [27] (SHORT CIRCUIT
12
T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (10) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness
CN15 (male) (1) and 2) Disconnect C3B and between C3B (female) Repair or
chassis normal? CN15. No (10) - TM2 (3) - CN15 replace
3) Turn starting switch (female) (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN15.
3) Turn starting switch
OFF. Defective R ECMV fill Replace
No switch
WA500-3H 20-1243
TROUBLESHOOTING T-17 FAILURE CODE [28] (SHORT CIRCUIT
12
T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (3) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness Repair or
CN5 (female) (1) and 2) Disconnect C3B and between C3B (female) (3) replace
chassis normal? CN5. No - TM1 (3) - CN5 (female)
3) Turn starting switch (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN5.
3) Turn starting switch
OFF. Defective 1st ECMV fill Replace
No switch
20-1244 WA500-3H
TROUBLESHOOTING T-18 FAILURE CODE [29] (SHORT CIRCUIT
12
T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (11) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness
CN7 (female) (1) and 2) Disconnect C3B and between C3B (female) Repair or
chassis normal? CN7. No (11) - TM1 (6) - CN7 replace
3) Turn starting switch (female) (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN7.
3) Turn starting switch
OFF. Defective 2nd ECMV fill Replace
No switch
WA500-3H 20-1245
TROUBLESHOOTING T-19 FAILURE CODE [30] (SHORT CIRCUIT
12
T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are property inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (11) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness Repair or
CN13 (female) (1) and 2) Disconnect C5 and between C5 (female) (11) - replace
chassis normal? CN13. No TM1 (9) - CN13 (female)
3) Turn starting switch (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN13.
3) Turn starting switch
OFF. Defective 3rd ECMV fill Replace
No switch
20-1246 WA500-3H
TROUBLESHOOTING T-20 FAILURE CODE [31] (SHORT CIRCUIT
12
T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (12) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness Repair or
CN9 (female) (1) and 2) Disconnect C5 and between C5 (female) (12) replace
chassis normal? CN9. No - TM1 (12) - CN9 (female)
3) Turn starting switch (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN9.
3) Turn starting switch
OFF. Defective 4th ECMV fill Replace
No switch
WA500-3H 20-1247
TROUBLESHOOTING T-21 FAILURE CODE [32] (SHORT CIRCUIT
12
T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Yes
Defective transmission Replace
controller
4
Yes Is E32 displayed
when CN15 (female)
3 (1) is grounded to
Yes chassis?
Is E32 displayed
when CN17 (female) 1) Turn starting switch
(1) is grounded to OFF. Defective R ECMV fill
chassis? 2) Disconnect CN15 No switch Replace
2
3) Start engine
Yes Is resistance between 1) Turn starting switch 4) Transmission cut-
C3B (female) (2) OFF. off switch: OFF
and chassis normal 2) Disconnect CN17 5) Parking brake
when CN15 (female) 3) Start engine switch: OFF
(1) is grounded to 4) Transmission cut- 6) Depress brake.
1 chassis? off switch: OFF 7) Directional lever: R
5) Parking brake
Is resistance between 1) Max. 1 Ω. switch: OFF
C3B (female) (10) and 2) Turn starting switch 6) Depress brake.
chassis normal when OFF. 7) Directional lever: F
CN17 (female) (1) is 3) Disconnect C3B. Defective F ECMV fill Replace
grounded to chassis? No switch
1) Max. 1 Ω.
2) Turn starting switch Defective contact, or
OFF. disconnection in wiring
3) Disconnect C3B. harness between C3B Repair or
No (female) (2) - TM2 (3) - replace
CN15 (female) (1)
Defective contact, or
disconnection in wiring Repair or
harness between C3B replace
No (female) (10) - TM2 (6) -
CN17 (female) (1)
20-1248 WA500-3H
TROUBLESHOOTING T-21 FAILURE CODE [32] (SHORT CIRCUIT
12
MEMORANDUM
WA500-3H 20-1249
TROUBLESHOOTING T-22 FAILURE CODE [33] (SHORT CIRCUIT
12
T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD, OR
4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Yes
a
6
Yes Is E33 displayed
when CN7
5 (female) (1) is
grounded to
Yes Is E33 displayed chassis?
when CN5 (female) 1) Turn starting
4 (1) is grounded to switch OFF.
chassis? 2) Disconnect
Is resistance
between C5 CN7. b
Yes (female) (12) and 1) Turn starting 3) Start engine. No
chassis normal switch OFF. 4) Directional
3 when CN9 (female) 2) Disconnect CN5. lever: N
(1) is grounded to 3) Start engine. 5) Speed lever:
chassis? 4) Directional lever: 2nd
Is resistance N c
between C5
Yes (female) (11) and 1) Max. 1 Ω. 5) Speed lever: 1st No
2) Turn starting
chassis normal switch OFF.
2 when CN13 3) Disconnect CN9
(female) (1) is and C5.
Is resistance grounded to
between C3B chassis? d
Yes (female) (11) and No
chassis normal
when CN7 (female) 1) Max. 1 Ω.
(1) is grounded to 2) Turn starting
1 chassis? switch OFF.
3) Disconnect CN13
Is resistance 1) Max. 1 Ω. and C5.
between C3B 2) Turn starting e
(female) (3) and switch OFF. No
chassis normal 3) Disconnect CN7
when CN5 (female) and C3B.
(1) is grounded to
chassis?
1) Max. 1 Ω.
2) Turn starting f
switch OFF. No
3) Disconnect CN5
and C3B.
g
No
20-1250 WA500-3H
TROUBLESHOOTING T-22 FAILURE CODE [33] (SHORT CIRCUIT
12
Cause Remedy
8 Yes Defective transmission
controller Replace
7 Yes Is E33 displayed when
CN9 (female) (1) is
Is E33 displayed grounded to chassis?
a when CN13 Defective 4th ECMV fill Replace
(female) (1) is 1) Turn starting switch No switch
grounded to OFF.
chassis? 2) Disconnect CN9.
3) Start engine.
1) Turn starting 4) Directional lever: N
switch OFF. 5) Speed lever: 4th
2) Disconnect
CN13. Defective 3rd ECMV fill Replace
3) Start engine. No switch
4) Directional lever:
N
5) Speed lever: 3rd Defective 2nd ECMV fill
b switch Replace
Defective contact, or
disconnection in wiring Repair or
d harness between C5
(female) (12) - TM1 (12) - replace
CN9 (female) (1)
Defective contact, or
disconnection in wiring Repair or
e harness between C5 replace
(female) (11) - TM1 (9) -
CN13 (female) (1)
Defective contact, or
disconnection in wiring Repair or
f harness between C3B replace
(female) (11) - TM1 (6) -
CN7 (female) (1)
Defective contact, or
disconnection in wiring Repair or
g harness between C3B replace
(female) (3) - TM1 (3) -
CN5 (female) (1)
WA500-3H 20-1251
TROUBLESHOOTING T-22 FAILURE CODE [33] (SHORT CIRCUIT
12
T-22 Related electrical circuit diagram
20-1252 WA500-3H
TROUBLESHOOTING T-23 HOLD SWITCH SYSTEM
12
T-23 HOLD SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
Cause Remedy
Yes Defective transmission
controller Replace
1
WA500-3H 20-1253
TROUBLESHOOTING T-24 KICK-DOWN SWITCH SYSTEM
12
T-24 KICK-DOWN SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
Cause Remedy
Yes Defective transmission
controller Replace
1
20-1254 WA500-3H
TROUBLESHOOTING T-25 TRANSMISSION CUT-OFF SIGNAL
12
T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
Cause Remedy
Yes Defective transmission
controller Replace
1
1) Short circuit with
chassis ground,
Is resistance between C5 defective contact, or
(female) (6) and disconnection in
chassis normal? wiring harness
between C5 (female)
(6) and L12 (female)
1) Disconnect C5. Yes (1)
2) Transmission cut-off Repair or
switch 2) Short circuit with replace
2
ON: Max. 1 Ω. chassis ground,
OFF: Min. 1 MΩ. defective contact, or
Is resistance between disconnection in
No L12 (male) (1) and (2) wiring harness
normal? between C5 (female)
(6) and L06 (female)
(3)
1) Disconnect L12.
2) Transmission cut-off
switch
ON: Max. 1 Ω. Defective transmission Replace
OFF: Min. 1 MΩ. No cut-off switch
WA500-3H 20-1255
TROUBLESHOOTING T-26 NEUTRALIZER RELAY SIGNAL SYS-
12
T-26 NEUTRALIZER RELAY SIGNAL SYSTEM
• Check that the parking brake works normally.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter.
Cause Remedy
Yes Defective transmission
controller Replace
1 4 Yes
Defective contact, or
disconnection in wiring Repair or
No harness between L58 replace
(female) (2) and chassis
20-1256 WA500-3H
TROUBLESHOOTING T-27 BUZZER SIGNAL SYSTEM
12
T-27 BUZZER SIGNAL SYSTEM
• Check that the main monitor and alarm buzzer work normally.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
Cause Remedy
3 Yes Defective transmission
controller Replace
2 Yes Is resistance between
C1 (female) (2) and
Yes Is resistance between chassis normal?
C1 (female) (2) and Short circuit, defective
1 chassis normal? 1) Disconnect C1 and contact, or disconnection Repair or
L08. in wiring harness between replace
Is resistance between C1 1) Disconnect C1. 2) 4k - 7kΩ. No C1 (female) (2) - L34 (5) -
(female) (2) and chassis 2) Make short circuit RES (female) (1)
normal? between L08, and
chassis.
1) Disconnect C1, L08, 3) Max. 1 Ω.
and RES. Defective contact, or
3) Min. 1 MΩ. disconnection in wiring
harness between C1 Repair or
No (female) (2) L08 (female) replace
(6)
WA500-3H 20-1257
TROUBLESHOOTING T-28 NETWORK SYSTEM
12
T-28 NETWORK SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (4),
1 (12) and chassis Defective contact, or
normal? disconnection in wiring
harness between C3B
Is resistance between (female) (4), (12), and L08 Repair or
C3B (female) (4), (12) 1) Max. 1 Ω. No (female) (1, (3), or L34 replace
and chassis normal? 2) Turn starting switch (male) (1), or LM1 (male
OFF. (5))
3) Disconnect C3B, L08,
1) Min. 1 MΩ. L34, and LM1.
2) Turn starting switch 4) Make short circuit Short circuit with chassis
OFF. between L08 (female) ground in wiring harness
3) Disconnect C3B, L08, (1), (3), and chassis. between C3B (female) (4), Repair or
L34, and LM1. (12), and L08 (female) (1), replace
No (3), or L34 (male) (1), or
LM1 (male) (5)
20-1258 WA500-3H
TROUBLESHOOTING T-29 TRANSMISSION CONTROLLER POW-
12
T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM
• Check that fuse (II) is normal.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
Cause Remedy
Yes Defective transmission
controller Replace
1
WA500-3H 20-1259
TROUBLESHOOTING T-30 SHORT CIRCUIT IN TRAVEL SPEED
12
T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Yes Defective transmission
controller Replace
2
Yes Is resistance between
C5 (female) (2) and Short circuit in wiring
1 (10) normal? harness between C5
(female) (2) - L07
Is resistance between C5 1) Min. 1 MΩ. (female) (1) - TM2 (9) -
(female) (2) and chassis 2) Turn starting switch CN3 (male) (1) and wiring Repair
replace
or
normal? OFF. No harness between C5
3) Disconnect C5, CN3, (female) (10) - L07
1) Min. 1 MΩ. and L07. (female) (2) - TM2 (10) -
2) Turn starting switch CN3 (female) (2)
OFF.
3) Disconnect C5, CN3,
and L07.
Short circuit in wiring
harness between C5
(female) (2) - TM2 (9) - Repair or
No CN3 (female) (1) and replace
between C5 (female) (2) -
L07 (female) (1)
20-1260 WA500-3H
TROUBLESHOOTING T-31 DISCONNECTION IN TRANSMISSION
12
T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE
SENSOR SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes Defective transmission
controller Replace
Yes
Is resistance between
3 C3A (female) (17)
and chassis normal? Short circuit with chassis
Is resistance between ground in wiring harness Repair or
between C3A (female) replace
C3A (female) (17)
Yes and chassis normal 1) Min. 1 MΩ. No (17) - TM2 (14) - CN11
when CN11 (female) 2) Turn starting switch (female) (2)
2 (2) is grounded to OFF.
chassis? 3) Disconnect C3A
and CN11.
Is resistance between Defective contact or
Yes C3A (female) (17) 1) Max. 1 Ω. disconnection in wiring
and chassis normal 2) Turn starting switch harness between C3A Repair or
when CN11 (female) OFF. No (female) (17) - TM2 (14) - replace
1 (1) is grounded to
chassis? 3) Disconnect C3A. CN11 (female) (2)
Is resistance between
CN11 (male) (1) - (2) 1) Max. 1 Ω.
and between (1), (2) 2) Turn starting switch
chassis normal? Defective contact or
OFF. disconnection in wiring
3) Disconnect C3A. harness between C3A Repair or
1) Between (1) and (2): No (female) (11) - TM2 (13) - replace
3.8 - 4.8 Ω (normal CN11 (female) (1)
temperature: 25o C
[77o F])
3.6 - 3.9 Ω (100o C Defective transmission oil Replace
temperature sensor
[212o F] No
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN11.
WA500-3H 20-1261
TROUBLESHOOTING T-32 DISCONNECTION IN F ECMV FILL
12
T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (2) and
1 chassis normal when
CN17 (female) (1) is Defective contact or
Is voltage between grounded to chassis? disconnection in wiring
CN17 (1) and chassis harness between C3B Repair or
normal? 1) Max. 1 Ω. No (female) (2) - TM2 (6) - replace
2) Disconnect C3B. CN17 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN17. Defective F ECMV fill Replace
4) Start engine. No switch
5) Transmission cut-off
switch: OFF (lamp
out).
6) Parking brake switch:
OFF
7) Depress brake.
20-1262 WA500-3H
TROUBLESHOOTING T-33 DISCONNECTION IN R ECMV FILL
12
T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (10) and
1 chassis normal when
CN15 (female) (1) is Defective contact or
Is voltage between grounded to chassis? disconnection in wiring
CN15 (1) and chassis harness between C3B Repair or
normal? 1) Max. 1 Ω. No (female) (10) - TM2 (3) - replace
2) Disconnect C3B. CN15 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN15. Defective R ECMV fill Replace
4) Start engine. No switch
5) Transmission cut-off
switch: OFF (lamp
out).
6) Parking brake switch:
OFF
7) Depress brake.
WA500-3H 20-1263
TROUBLESHOOTING T-34 DISCONNECTION IN 1ST ECMV FILL
12
T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (3) and
1 chassis normal when
CN5 (female) (1) is Defective contact or
grounded to chassis? disconnection in wiring
Is voltage between CN5 harness between C3B Repair or
(1) and chassis normal? 1) Max. 1 Ω. No (female) (3) - TM1 (3) - replace
2) Disconnect C3B. CN5 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN5. Defective 1st ECMV fill Replace
4) Start engine. No switch
5) Directional lever: N
6) Manual switch: ON
7) Speed lever: 1st.
20-1264 WA500-3H
TROUBLESHOOTING T-35 DISCONNECTION IN 2ND ECMV FILL
12
T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (11) and
1 chassis normal when
CN7 (female) (1) is Defective contact or
grounded to chassis? disconnection in wiring
Is voltage between CN7 harness between C3B Repair or
(1) and chassis normal? 1) Max. 1 Ω. No (female) (11) - TM1 (6) - replace
2) Disconnect C3B. CN7 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN7. Defective 2nd ECMV fill Replace
4) Start engine. No switch
5) Directional lever: N
6) Manual switch: ON
7) Speed lever: 2nd.
WA500-3H 20-1265
TROUBLESHOOTING T-36 DISCONNECTION IN 3RD ECMV FILL
12
T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (11) and
1 chassis normal when
CN13 (female) (1) is Defective contact or
Is voltage between grounded to chassis? disconnection in wiring
CN13 (1) and chassis harness between C5 Repair or
normal? 1) Max. 1 Ω. No (female) (11) - TM1 (9) - replace
2) Disconnect C5. CN13 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN13. Defective 3rd ECMV fill Replace
4) Start engine. No switch
5) Directional lever: N
6) Manual switch: ON
7) Speed lever: 3rd.
20-1266 WA500-3H
TROUBLESHOOTING T-37 DISCONNECTION IN 4TH ECMV FILL
12
T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (12) and
1 chassis normal when
CN9 (female) (1) is Defective contact or
grounded to chassis? disconnection in wiring
Is voltage between CN9 harness between C5 Repair or
(1) and chassis normal? 1) Max. 1 Ω. No (female) (12) - TM1 (12) - replace
2) Disconnect C5. CN9 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Start engine. Defective 4th ECMV fill Replace
4) Disconnect CN9. No switch
5) Directional lever: N
6) Manual switch: ON
7) Speed lever: 4th.
WA500-3H 20-1267
TROUBLESHOOTING T-37 DISCONNECTION IN 4TH ECMV FILL
12
MEMORANDUM
20-1268 WA500-3H
TROUBLESHOOTING AIR CONDITIONING
(DENSO)
WA500-3H 20-1301
TROUBLESHOOTING AIR CONDITIONER / HEATER (DENSO)
12
AIR CONDITIONER / HEATER (DENSO)
Worn mounting
Idle pulley
Worn or damaged bearing
20-1302 WA500-3H
12
TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE)
• Trouble often can be detected and diagnosed for repair with the help of a manifold gauge. The manifold gauge unit
indicates the refrigeration system pressure on both sides (high and low pressure sides) simultaneously on the two dials.
Remark
Be sure air has been purged from the charging hoses of the manifold gauge by using the refrigerant pressure in the
system.
NORMAL CONDITIONS
Blower speed HI
INSUFFICIENT REFRIGERANT
Check and
Problem Cause
remedy
MOISTURE IN SYSTEM
Check and
Problem Cause
remedy
COMPRESSOR FAILURE
Check and
Problem Cause
remedy
20-1304 WA500-3H
12
EXCESSIVE
REFRIGERANT OR INSUFFICIENT
CONDENSER COOLING
Check and
Problem Cause
remedy
Pressure high on Excessive -Check refrigerant
both sides. refrigerant. quantity and slowly
vent excess if
Bubbles not visible Poor condenser overcharged.
in the sight glass. cooling.
-Check and repair
Poor cooling condenser fan.
performance.
-Check engine
cooling system.
BLOWER TROUBLESHOOTING
Start the engine and allow it to run at idle speed with the vehicle stationary. Follow the steps as shown in the chart.
Descriptions of the inspection methods can be found on the pages that follow the flow chart.
20-1306 WA500-3H
12
TROUBLESHOOTING TROUBLESHOOTING THE ELECTRICAL
12
ELECTRICAL CIRCUIT CHECKS
HEATER RELAY
Steps 4 and 5
Turn on the ignition switch and check input voltage at terminal 5 and 3.
If no voltage (0V), there should be open circuit between heater relay and
gauge fuse, or between heater relay and the battery. Inspect the
continuity with a circuit tester or ohmmeter. Repair or replace as
necessary.
BLOWER SWITCH
Step 6
Check continuity between the heater relay terminals and the blower
switch terminals as follows.
When changing blower switch position from OFF to HI, the resistance
value should change from a high value to a low value.
20-1308 WA500-3H
12
Consult this troubleshooting flow chart for procedures to check the cooler equipment after problems with the blower circuit
have been ruled out. Details about these procedures appear on the pages that follow.
TROUBLESHOOTING TROUBLESHOOTING THE ELECTRICAL
12
COOLER CIRCUIT TROUBLESHOOTING
AIR CONDITIONER SWITCH
Step 1 and 2
Turn on blower switch and air conditioner switch, check voltage of the
amplifier at terminal 10. If 12 volts is not present (battery voltage),
wiring between the air conditioner fuse and amplifier input terminals is
faulty (open circuit), or the A/C switch is defective.
Check that continuity exists between terminal no. 1 and 3 but not
between terminals 2 and 4. Apply battery voltage between terminal 1
and 3, check continuity between terminals 2 and 4 (the point is closed).
20-1310 WA500-3H
12
CONDENSER FAN OPERATION CIRCUIT
Step 2-2
Turn on the blower switch and A/C switch. Then inspect the condenser
fan operation.
Conditions
Fan
A/C Magnetic Coolant Refrigerant speed
switch Clutch Temperature pressure
Below 83o C
Stop
ON or (181o F)
OFF
OFF
Above 90o C Below 12.5 kg/cm2
HI
(194o F) (178 psi)
Below 83o C
ON ON LO
(181o F)
Under low coolant temperature and low thermal load (low room and
ambient temperature) conditions, fan rotates at low speed with the
magnetic clutch on, while as the coolant temperature increases, fan
starts high speed rotation.
In case of high thermal load, the fan rotates at high speed also.
When the air conditioner switch is turned ON, idle speed should
increase. Make sure the speed changes.
20-1312 WA500-3H
12
TROUBLESHOOTING ERROR MESSAGE TABLES
12
ERROR MESSAGE TABLES
• Setup: Controller set on Temp. 60o F (16o C), defrost “off”, and fan on high.
Check for output voltage on the yellow a. Repair the connections / wiring.
2. Defective electric condenser relay wire, at the relay coil. Check the b. Replace the defective relay.
(circuit). voltage and continuity across the relay
contacts.
3. Open electric condenser voltage Check for input voltage on the brown
a. Repair the wiring or connector.
detection circuit. wire, at the controller.
4. Improper wiring installation. Applicable to systems without an EC. a. See note #3.
1. Abnormal A/C refrigerant Check the refrigerant pressures with a. Check the condenser operation for
pressure(s). gauges. air and refrigerant blockage.
* Cool weather operation may cause High side greater than: b. Leak check system, repair the
low pressure short cycling. 320 psig (R12), or 350 psig leaks and recharge the system.
(R134a). c. Relocate the low pressure switch
Low side less than: to the evaporator outlet.
3 - 6 psig.*
2. Opened compressor clutch circuit. Check for output voltage on the green a. Repair the connections/wiring.
wire at the compressor. Check the wire b. Replace the defective switch(es)
connections. Check for continuity or the thermostat.
across the pressure switch(es) and c. Replace the defective compressor
thermostat. Check continuity of clutch clutch.
solenoid to the ground.
3. Opened pressure switch detection Check for an input voltage on the tan a. Repair the connections/ wiring.
circuit. wire, at the controller.
4. Defective controller. Check for output voltage on the green a Replace the controller.
wire, at the controller.
20-1314 WA500-3H
12
C. FALSE E1 ERROR MESSAGE / COLD WEATHER CHARGING PROBLEMS
• Occurs particularly when vapor charging in cold weather.
1. E1 error message may occur during charging when the low pressure switch (LPS) opens at 3 psig. The suction side
pressure must rise above 45 psig to reset the E1 error message.
2. When the system is fully charged, the E1 error message should not appear under normal operating conditions.
3. In order to continue charging, by-pass the LPS, turn the controller “off” then “on”, and set the controller to 60o F (16o C).
This will reset the controller and force into the air conditioning mode.
4. If the LPS can’t be easily reached, disconnect the clutch wire at the compressor, and run a hot wire directly to the
compressor clutch solenoid. Take care not to short out the controller clutch circuit.
5. E1 error message may occur while charging, when the compressor is wired hot.
D. PROBLEM - NO HEAT
1. Opened heat solenoid circuit. Poor Check for an output voltage on the a. Repair connections/wiring.
connection, loss of voltage. white wire, at the heat solenoid valve.
Check solenoid continuity to the
ground.
2. Defective heat solenoid or improper Check for coolant blockages in the a. Repair or replace the valve.
installation. heat solenoid valve and hoses. Check b. Reverse the coolant hoses to the
the direction of coolant flow (feel the valve.
hoses).
3. Defective controller. Check for output voltage on the white a. Replace the controller.
wire, at the controller.
1. Fan wires shorted to ground or Disconnect controller from the a. Disconnect the ground and repair
vehicle chassis. external harness, Individually check the shorted wiring.
continuity of the orange and black fan
wires to ground, in the external
harness.
TROUBLESHOOTING ERROR MESSAGE TABLES
12
F. PROBLEM - COMPRESSOR CLUTCH WILL NOT ENGAGE, UNLESS
DEFROST BUTTON IS PUSHED.
2. Ambient cab temperature too cool Set controller at 68-70o F (20-21o C), a. Verify if compressor clutch will
{below 60o F (16o C)}. in A/C mode. Warm-up ambient pull in or not.
temperature probe with fingers or heat b. If not go to step 3.
gun.
3. Opened ambient cab temperature Push, hold temp. Decrease/increase a. If display reads 49o F (9o C), at
probe (thermistor). buttons simultaneously. Display will room temperature, replace
read 40o F (4o C) if probe is defective. thermistor.
Disconnect the controller, check for b. Repair connections/wiring.
continuity across black probe leads. c. If 10k Ω ±20%, thermistor is
Check resistance of thermistor. good. If 100k-1M Ω, replace
thermistor.
20-1316 WA500-3H
12
Notes:
1. Wire colors may vary with installation. Refer to the wiring schematic.
2. For 24V controllers, resistor (R17) must be clipped and removed from the circuit board, refer to illustration. If resistor
is not clipped on 24V system, the controller display will light up, but the blower fan will not turn on.
3. For air conditioning systems that do not use an electric condenser, the blue and brown wires must be connected together,
on the external harness. The brown wire must be connected to the battery voltage, or the EO error message will result.
4. Care must be taken during installation, not to pinch or cut wiring from the controller. Shorted wiring may result in
damage to the controller.
5. Improper probe location of the evaporator coil thermostat sensor, or ambient cab temperature sensor, may cause short
cycling of the compressor.
6. Eagle climate controllers are designed to use normally closed heat solenoid valves.
7. Disconnect the vehicle battery leads, if a machine is to be inactive, or put into storage, for a period of a week or more.
The current drain from the controller’s memory may result in a dead vehicle battery. An optional ignition relay may be
installed to disable the controller’s memory function, when the key switch is turned off.
TROUBLESHOOTING WIRING DIAGRAM
12
WIRING DIAGRAM
20-1318 WA500-3H
12
NOTES:
1. Position the ambient temperature probe near waist high level, out of air flow and sun load.
2. Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the 1st
and 2nd rows, to a depth of the coil height minus 1 inch.
WIRE CHART
Dk.
8 16GA Clutch out
Green
Dk.
9 18GA Ignition switch in
Blue
Sensor circuit
Wire harness
Body ground
Servomotors
Connectors
No. Problem
Fuse
Other inspection items
20-1320 WA500-3H
30 DISASSEMBLY AND ASSEMBLY
WA500-3H 30-1
DISASSEMBLY AND ASSEMBLY
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
DIFFERENTIAL, NORMAL - (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
REMOVAL (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
INSTALLATION (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120
REMOVAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121
INSTALLATION (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-122
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-123
DIFFERENTIAL GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-123
FINE DISASSEMBLY OF PINION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-126
FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 30-127
FINE ASSEMBLY OF PINION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
ORBITAL STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
ENSURE A CLEAN WORKING ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-148
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-157
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-159
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-163
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-167
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-168
BRAKE ASSEMBLY (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-169
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-169
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-169
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-170
30-2 WA500-3H
DISASSEMBLY AND ASSEMBLY
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-181
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-185
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-185
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-187
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-192
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-199
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-215
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
BULKHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
FLOOR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-232
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-235
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-236
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-236
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237
WA500-3H 30-3
DISASSEMBLY AND ASSEMBLY
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
RECEIVER TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239
COMPRESSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
INSTALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242
30-4 WA500-3H
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal
operation; the order of work for the installation operation is not given.
B. Any special techniques applying only to the installation procedure are marked , and the same mark is placed
after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
Example Explanation
(COMPONENT) REMOVAL Title of operation
(Component/assembly) Specification
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when performing out
the operation.
WA500-3H 30-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
12
PRECAUTIONS DURING OPERATION
★ Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or
assembly) of units.
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
30-6 WA500-3H
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
3. If the part is not under hydraulic pressure, the following corks can be
used:
Dimensions
Nominal
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
WA500-3H 30-7
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
12
PRECAUTIONS WHEN COMPLETING THE OPERATIONS
• 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.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
OTHER PRECAUTIONS
• To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the
degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters,
check that the oil container and area around the filler of the hydraulic tank are clean.
• To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when
disassembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be
disassembled.
• Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
• Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that
have failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
• Do not use seal tape for the thread of the plug mounts or connections.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry
out thorough flushing of the hydraulic circuits.
• When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the
air before starting the engine to prevent seizure of the pump. For details, see TESTING AND ADJUSTING, Bleeding air
from piston pump.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
A. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without
going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.)
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air
inside the cylinder will cause damage to the piston packing.
B. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.
C. Raise the engine speed and repeat Step 2 to bleed the air. Repeat this procedure until no more air comes out from the
plugs.
30-8 WA500-3H
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
12
SPECIAL TOOL LIST
Remark
Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured).
Remark
Necessity: ■: . . . . . . . . . . . . Cannot be substituted, should always be installed (used)
●: . . . . . . . . . . .Extremely useful if available, can be substituted with commercially
available part
Remark
New/remodel: N: . . . . . . . . .Tools with new part numbers, newly developed for this model
R: . . . . . . . .Tools with upgraded part numbers, remodeled from items already
available for other models
Blank: . . . . Tools already available for other models, used without any
modification
Remark
Tools marked O in the Sketch column are tools introduced in the sketches of the special tools (See
SKETCHES OF SPECIAL TOOLS).
New
Component Symbol Part Number Part Name Necessity Qty Sketch Nature of work, remarks
Remodeled
Installation of engine
1 790-331-1110 Wrench ■ 1 Tightening of head assembly
cylinder head
1 795-521-1110 Push tool ■ 1
2 790-101-5221 Grip ■ 1
2 Press fitting of front seal
3 01010-51225 Bolt ■ 1
Installation of engine 4 01050-31640 Bolt ■ 3
A
front seal, rear seal 1 795-931-1210 Sleeve jig ■ 1
2 795-931-1220 Sleeve jig ■ 1
3 Press fitting of front sea
3 01050-31625 Bolt ■ 3
4 01050-31645 Bolt ■ 3
1 793T-615-1230 Push tool ■ 1 N ●
2 793T-615-1240 Spacer ■ 1 N ● Press fitting of oil seal and
Assembly of damper 1
3 790-101-5421 Grip ■ 1 dust seal
4 01010-51240 Bolt ■ 1
Removal, installation of round
2 790-102-1871 Wrench ■ 1
nut
B 1 790-201-2730 Spacer ■ 1
2 791-520-4140 Screw ■ 1
Disassembly,
3 02215-11622 Nut ■ 2
assembly of PTO Press fitting of PTO gear
3 4 01643-32780 Washer ■ 2 bearing inner race
Puller (294.2 kN
5 790-101-2102 ■ 1
{30 ton})
6 790-101-1102 Pump ■ 1
WA500-3H 30-9
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New
Component Symbol Part Number Part Name Necessity Qty Sketch Nature of work, remarks
Remodeled
Disassembly, Centering of body and upper
1 790-452-1200 Pilot ring tool ■ 1
assembly of orbital F cover
steering valve 2 790-452-1100 Installer set ■ 1 Press fitting of spacer
Removal, installation 1 790-520-2510 Bracket ■ 1
Removal, installation of
of differential 1
assembly 2 790-520-2610 Plaste ■ 1 differential assembly
4 01010-51240 Bolt ■ 1
1 792-525-1000 Micrometer ■ 1
4 Adjusting preload of bearing
2 792-525-1230 Adapter ■ 2
1 793T-622-1110 Plate ■ 1 N ●
Press fitting of oil seal of
5 2 790-101-5421 Grip ■ 1
outer drum
3 01010-51240 Bolt ■ 1
Removal, installation of
6 793T-622-1150 Fixture ■ 3 N ● wheel hub
1 793-520-1805 Brake tester ■ 1 N
7 Checking leakage of brake oil
H 2 793-520-1851 ■ 1 N
Disassembly, 4
Installation of floating seal
assembly of brake 9 5
(hub end)
assembly 6
7
8
9
30-10 WA500-3H
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New
Component Symbol Part Number Part Name Necessity Qty Sketch Nature of work, remarks
Remodeled
1 793-520-2630 Bar ■ 2
2 793-520-2640 Push tool ■ 1
3 793-520-2530 Guide ■ 1
4 790-101-2300 Push puller ■ 1
Press fitting bearing of top
1 5 center hinge portion
6
Puller (294.2 kN
7 790-101-2102 ■ 1
Removal, installation {30 ton})
K
of center hinge pins 8 790-101-1102 Pump ■ 1
1 793-520-2550 Guide ■ 1
2 01010-31480 Bolt ■ 2
3 01643-31445 Washer ■ 2
Press fitting bearing of bottom
2 4 793-520-2640 Push tool ■ 1 center hinge portion
Puller (294.2 kN
5 790-101-2102 ■ 1
{30 ton})
6 790-101-1102 Pump ■ 1
790-502-1003
1 or Repair stand ■ 1
1 790-502-2000
2 790-101-1102 Pump ■ 1
Wrench Removal, installation of
2 790-330-1100 ■ 1
assembly cylinder head
Socket (width
3 790-302-1290 across flats ■ 1 Removal, installation of nut
60 mm)
1 790-201-1500 Push tool ■ 1 Press fitting of dust seal
2 Steering cylinder
3 Boom cylinder
4
4 Bucket cylinder
5
Disassembly, All cylinders
assembly of hydraulic U 6
cylinder assemblies 1 790-201-1702 Push tool kit ■ 1 Press fitting of roll bushing
2 Steering cylinder
3 Boom cylinder
5
4 Bucket cylinder
5
All cylinders
6
1 790-720-1000 Expander ■ 1 Expansion of piston ring
2 796-720-1660 Ring ■ 1
Steering cylinder
3 07281-01159 Clamp ■ 1
6 4 796-720-1690 Ring ■ 1
Boom cylinder
5 07281-02169 Clamp ■ 1
6 796-720-1720 Ring ■ 1
Bucket cylinder
7 07281-02429 Clamp ■ 1
Wrench
1 790-102-2303 ■ 1
assembly
Removal, installation of round
1 Wrench
2 790-102-2303 ■ 1 head
assembly
Disassembly,
assembly of X 3 790-102-4310 Pin ■ 1
accumulator 1 790-720-1000 Expander ■ 1 Expansion of piston ring
2 2 796-720-1660 Ring ■ 1
3 07281-01159 Clamp ■ 1
3 792-610-1700 Charging tool ■ 1 Charging with N2 gas
WA500-3H 30-11
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New
Component Symbol Part Number Part Name Necessity Qty Sketch Nature of work, remarks
Remodeled
1 799-703-1200 Service tool kit ■ 1
30-12 WA500-3H
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
12
SKETCHES OF SPECIAL TOOLS
Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H3-2 SPACER
H6 FIXTURE
WA500-3H 30-13
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
12
H5-1 PLATE
30-14 WA500-3H
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
12
B1-2 SPACER
WA500-3H 30-15
DISASSEMBLY AND ASSEMBLY ENGINE
ENGINE
Remark
As for the disassembly and assembly of engine components (see the following list). Refer to the ENGINE SHOP
MANUAL.
ALTERNATOR
CYLINDER HEAD
NOZZLE HOLDER
STARTING MOTOR
THERMOSTAT
TURBOCHARGER
WATER PUMP
30-16 WA500-3H
DISASSEMBLY AND ASSEMBLY ENGINE
MEMORANDUM
WA500-3H 30-17
DISASSEMBLY AND ASSEMBLY RADIATOR
RADIATOR
REMOVAL
WARNING! Stop the machine on level ground and install the safety bar to the front and rear frames.
Lower the bucket to the ground and stop the engine. Apply the parking brake and put
blocks under the wheels to prevent the machine from moving.
WARNING! Loosen the hydraulic tank filler cap slowly to release the pressure inside the tank. Then
operate the control levers several times to release the remaining pressure in the
hydraulic system.
30-18 WA500-3H
DISASSEMBLY AND ASSEMBLY RADIATOR
9. Remove cover (9) at front bottom of radiator.
11. Sling radiator assembly (11) and remove mounting bolt (10).
• Disconnect supports from radiator, loosen supports at frame,
and rotate out of way.
INSTALLATION
• Add transmission oil through the oil filler to the specified level.
• Run the engine to circulate the oil and coolant through the system.
• Recheck oil and coolant levels again.
WA500-3H 30-19
DISASSEMBLY AND ASSEMBLY DAMPER
DAMPER
REMOVAL
3. Disconnect switch pump suction tube (1) and outlet hose (2), then
remove switch pump + PPC pump (3).
4. Disconnect hydraulic pump suction tube (4) and outlet tube (5), then
remove hydraulic pump (6).
5. Disconnect steering pump outlet hose (7), remove tube (8) at pump end.
• Remove the mounting bolt, insert a guide bolt, then sling the
cover and push the cover out with forcing screws.
11. Sling damper assembly (15), then remove mounting bolt (16) and insert
guide bolt.
• Pull out the damper assembly using forcing screws.
30-20 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER
INSTALLATION
• Carry out installation in the reverse order to removal.
WA500-3H 30-21
DISASSEMBLY AND ASSEMBLY DAMPER
DISASSEMBLY
1. Cover assembly.
C. Remove oil seal (4) and o-ring (5) from cover (3).
30-22 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER
E. Remove snap rings (8) and bearing (9) from shaft (7).
F. Remove snap rings (10). (11), and oil seal (12) from cover (6).
2. Damper.
WA500-3H 30-23
DISASSEMBLY AND ASSEMBLY DAMPER
C. Remove inner body (15) and rubber (16).
D. Remove snap ring (17) and oil seal (18) from the inner body.
30-24 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER
ASSEMBLY
1. Damper assembly.
B. Press fit oil seal (18) in the inner body (15), then assemble
snap ring (17).
• Fit the snap ring securely in the groove. Set the oil seal
with the sleeve on the snap ring side, and fit it close in
contact with the snap ring.
WA500-3H 30-25
DISASSEMBLY AND ASSEMBLY DAMPER
• Fill clearance b at four places evenly with 270 g (9.5 oz)
of grease.
2. Cover assembly.
A. Fit snap ring (11), then fit snap ring (10) after press fitting the oil
seal (12) in cover (6).
• Press fit the oil seal with the lip face on the bearing side.
Remark
Do not leave any space when filling with grease.
30-26 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER
C. Press fit shaft (7) into cover (6).
D. Press fit oil seal (4) into cover (3), and install o-ring (5).
WA500-3H 30-27
DISASSEMBLY AND ASSEMBLY DAMPER
E. Set cover (3) on mounting position, and tighten the mounting bolts.
30-28 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER
3. Greasing.
A. Assemble damper to the engine, and connect the grease hose, then
fill the inside of the damper with grease (310g) from portion e.
WA500-3H 30-29
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-
REMOVAL
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the
bucket to the ground and stop the engine. Then apply the parking brake and put blocks
under the wheels to prevent the machine from moving.
WARNING! Loosen the oil cap slowly to release the pressure inside the hydraulic tank. Then operate
the control levers several times to release the remaining pressure in the hydraulic piping.
1. Drain oil.
3. Remove floor frame assembly. For details, see FLOOR FRAME REMOVAL.
4. Remove drive shaft between switch + PPC pump, loader pump, and engine - torque converter.
For details, see HYDRAULIC PUMP REMOVAL.
7. Disconnect hose (3) from oil cooler on left side of transmission and
hose (4) leading to transmission valve.
30-30 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-
9. Disconnect hoses (6) and (7) leading to steering valve at right side
of transmission.
12. Remove clamps (10) and (11), then remove tube (12).
13. Disconnect hoses (13) and (14) leading to emergency brake valve
from transmission control valve.
15. Disconnect connectors (16), (17), and (18) at bottom left of floor
frame (LR1 - 6 and TM1, 2).
WA500-3H 30-31
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-
17. Remove filler tube (20).
30-32 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-
INSTALLATION
• Carry out installation in the reverse order to removal.
Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil
level again.
WA500-3H 30-33
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-
DISCONNECTION
1. Remove torque converter and transmission assembly. For details,
see TORQUE CONVERTER, TRANSMISSION REMOVAL.
• Using a lever block set, set with the torque converter end at the top.
• After setting the assembly in position, check that it is stable,
before removal of the lifting tool.
CONNECTION
• Carry out connection in the reverse order to disconnection.
• Make the protrusion from the shaft equal.
• Be careful when pushing in. If the assembly is pushed in by force,
seal ring (8) may be damaged.
30-34 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
TORQUE CONVERTER
DISASSEMBLY
1. Disconnect torque converter and PTO assembly from transmission
assembly.
• For details, see TORQUE CONVERTER, TRANSMISSION
DISCONNECTION.
2. PTO assembly
WA500-3H 30-35
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
iv. Using tool B2, remove nut (8).
ix. Using gear puller e, pull out outer races (13a) and (13b)
approx. 10 mm (0.394 in).
x. Remove gear (9), then remove outer races (13a) and (13b)
and spacer (14).
xi. Remove spacer (40) and bearing (10b) from gear (9).
B. Set with case at top and remove remaining two mounting bolts.
30-36 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
D. Disassemble turbine and case assembly as follows.
iv. Insert two round bars f from 8.5 drill hole and remove
turbine assembly (21).
vi. Using snap ring pliers, remove snap ring (23) from case (22).
4. Stator
WA500-3H 30-37
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
5. Stator shaft, pump assembly.
B. Remove stator shaft and pump assembly (28) from housing (29).
ii. Using round bar h, knock out bearing inner race from
hole where plug has been removed, then remove pump
assembly (32).
iii. Remove bolts, then remove retainer (33), pump (34), and
guide (35).
30-38 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
ASSEMBLY
1. Stator shaft, pump assembly.
ii. Align with oil groove and install guide (35) and retainer (33)
to pump (34).
iv. Using push tool k, press fit pump assembly (32) to stator
shaft (30).
WA500-3H 30-39
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
v. Install two plugs (31) to stator shaft (30).
• Do not coat the plugs with adhesive.
2. Stator.
30-40 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
iii. Using push tool l, press fit turbine assembly (21) to
case (22).
• Support the inner race of the case bearing and press fit
the turbine assembly.
• After press fitting, apply drops (6 cc) of engine oil
(EO10-CD or EO30-CD) and rotate 10 times.
vi. Using push tool m, press fit inner race (37) to shaft (17).
WA500-3H 30-41
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
B. Using eyebolt c, install turbine and case assembly (16), then
tighten 24 mounting bolts (15).
4. PTO assembly.
i. Using push tool (n), press fit bearing (10b) {inside diameter:
50 mm (1.969 in)} to gear (9).
ii. Set gear (9) to each pump mount portion of housing (38).
iii. Using push tool p, press fit outer race (13b) {outside
diameter: 90 mm (3.543 in).
• Be careful of the mounting direction.
30-42 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
iv. Install spacer (14).
vi. Fit spacer (40), the using puller q, press fit bearing (10a)
{inside diameter: 50 mm (1.969 in)}.
WA500-3H 30-43
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
ix. Using tool B2, tighten mounting nut (8).
xi. Using push tool, press fit oil seal (6) to retainer (5).
30-44 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
C. Fit O-ring and install coupling (3) and holder (2).
WA500-3H 30-45
DISASSEMBLY AND ASSEMBLY TRANSMISSION
TRANSMISSION
DISASSEMBLY
1. Torque converter and PTO assembly.
2. Cover.
Remove cover (1) from top of transmission control valve.
5. Lubrication tube.
Remove lubrication tube (7) from front of transfer.
6. Sleeves.
30-46 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
7. Transmission, transfer assembly.
8. Transmission assembly.
WA500-3H 30-47
DISASSEMBLY AND ASSEMBLY TRANSMISSION
D. Remove two tie bolts (14) shown in diagram on the right,
and install eyebolts f.
30-48 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
iii. Support housing (21), then using push tool i, push input
shaft (22) with press and remove.
iv. Using snap ring pliers, remove snap ring (166) from input
shaft (22).
vii. Support housing (21), then using push tool j, push No. 1
carrier assembly (26) with press and remove.
WA500-3H 30-49
DISASSEMBLY AND ASSEMBLY TRANSMISSION
D. Disassemble No. 1 carrier assembly as follows:
iii. Remove shaft (29) and ball (173) from No. 1 carrier.
• Be careful not to lose ball (173).
vi. Using push tool k, remove spacer and bearing assembly (32).
vii. Using snap ring pliers, remove snap ring (33) from spacer
and bearing assembly (32).
ix. Using snap ring pliers, remove snap ring (36) from No. 1
carrier.
30-50 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
11. No 1 spring.
Remove No. 1 spring (38).
WA500-3H 30-51
DISASSEMBLY AND ASSEMBLY TRANSMISSION
15. No 1, No 2 piston, housing assembly.
F. Remove seal rings (50) and (51) from No. 1 housing (47).
16. Plate.
Remove plate (54).
30-52 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
18. No. 2 discs, springs, No. 2 plates.
Remove four No. 2 discs (55), 20 springs (56), and four No. 2
plates (57).
19. Spacer.
A. Using eyebolts p, lift off No. 2 carrier and housing assembly (60).
B. Using snap ring pliers, remove snap ring (61) from bearing
inner end.
WA500-3H 30-53
DISASSEMBLY AND ASSEMBLY TRANSMISSION
D. Disassemble No. 2 housing assembly (62) as follows:
ii. Support No. 2 housing (65), then using push tool r, push
bearing (66) with press and remove.
iii. Insert thin rods into four holes (70) for removing snap
ring, then push snap ring (71), and remove No. 2 carrier
assembly (163) from ring gear (72).
30-54 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
iv. Remove shaft (73) and ball (74) from No. 2 carrier (163).
• Be careful not to lose ball (74).
23. No 3 piston.
B. Turn over No. 3 and No. 4 housing (84), and remove No. 4
piston (86).
WA500-3H 30-55
DISASSEMBLY AND ASSEMBLY TRANSMISSION
C. Remove seal ring (87) from No. 4 piston (86).
D. Remove two seal rings (85) from No. 3 and No. 4 housing (84).
i. Using tool D2, pull out No. 3 shaft (93) and remove.
• Be careful not to lose ball (94).
ii. Remove two thrust washers (95), needle bearing (96), and
No. 3 planetary gear (97).
30-56 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
iii. Using round bar, knock pin (98) into No. 4 shaft (99).
iv. Using round bar u, knock out No. 4 shaft (99) from No. 3
carrier end and remove.
vi. Using push tool v, push bearing (103) with press and remove.
WA500-3H 30-57
DISASSEMBLY AND ASSEMBLY TRANSMISSION
30. No. 4 sun gear.
30-58 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
33. No. 5 plate.
Remove No. 5 plate (114).
WA500-3H 30-59
DISASSEMBLY AND ASSEMBLY TRANSMISSION
ii. Remove shaft (125) and ball (126).
• Be careful not to lose ball (126).
iii. Remove two thrust washers (127), needle bearing (128), and
planetary gear (129).
30-60 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
46. No 6 hub.
Remove No. 6 hub (137).
A. Support cage, then push output shaft (139) with press and remove.
C. Using push tool nn, push bearing (145) with press and remove
from cage (146).
WA500-3H 30-61
DISASSEMBLY AND ASSEMBLY TRANSMISSION
49. No. 6 housing assembly.
30-62 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
ASSEMBLY
1. No. 6 housing assembly.
A. Using push tool z, press fit bearing (150) to No. 6 housing (149).
B. Using push tool aa, press fit bushing (151) and ball (152) to
No. 6 housing (149).
2. Cage assembly.
3. Output shaft.
WA500-3H 30-63
DISASSEMBLY AND ASSEMBLY TRANSMISSION
B. Using push tool cc, press fit bearing (145) to output shaft (139)
with press.
D. Using push tool dd, press fit output shaft and bearing
assembly (155).
• Push bearing (145) of the output shaft.
4. Seal ring.
Install seal ring (154) to No. 6 housing (149).
• Set the groove of the seal ring facing the direction receiving
the pressure.
5. Guide pin.
Install guide pin (153).
6. No. 6 piston.
Install seal ring (156) to No. 6 piston (136).
• Set the groove of the seal ring facing the direction receiving
the pressure.
7. No. 6 gear.
30-64 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
B. Install No. 6 piston (136).
9. Pin, spring.
Install pin (132) and spring (131).
WA500-3H 30-65
DISASSEMBLY AND ASSEMBLY TRANSMISSION
C. Align position of dowel pin and install No. 5 carrier
assembly (123).
• Tap with a copper hammer to knock in the dowel pin.
iii. Install two No. 5 discs (116), 10 springs (117), and No. 5
plate (118).
30-66 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
ix. Align position of dowel pin and install No. 5 housing and
No. 5 piston assembly (110).
• Be careful not to drop the No. 5 piston. Tap with a
copper hammer to knock in the dowel pin.
15. Springs.
Install 10 springs (88).
WA500-3H 30-67
DISASSEMBLY AND ASSEMBLY TRANSMISSION
16. No. 4 piston.
Install seal ring (87) to No. 4 piston (86).
• Set the groove of the seal ring facing the direction receiving
the pressure.
A. Install two seal rings (85) to No. 3 and No. 4 housing (84).
• Set the groove of the seal ring facing the direction
receiving the pressure.
B. Install No. 3 piston (82) and No. 4 piston (86) to No. 3 and
No. 4 housing (84).
C. Using eyebolts s, lift off No. 3 and No. 4 housing assembly (159).
• When raising the housing, be careful not to drop the No. 4
piston.
• Tap with a copper hammer to knock in the dowel pin.
30-68 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
ii. Using tool D3, press fit bushing (161) to No. 3 and No. 4
carrier (160).
iii. Using push tool ee, press fit bearing (103) to No. 3 and
No. 4 carrier (160).
WA500-3H 30-69
DISASSEMBLY AND ASSEMBLY TRANSMISSION
B. Install No. 3 and No. 4 carrier assembly (92).
• Put plate ff to No. 3 and No. 4 carrier assembly (92), then
press fit the bearing inner race portion to the output shaft.
i. Set snap ring to No. 2 carrier (163) and install ring gear (72).
30-70 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
iii. Assemble needle bearing (76) to planetary gear (77), put
thrust washers (75) to both ends, then set to No. 2 carrier.
• Align the center of each part with the shaft hole.
ii. Support No. 2 housing (65), then using push tool gg,
press fit bearing (66) with press.
WA500-3H 30-71
DISASSEMBLY AND ASSEMBLY TRANSMISSION
C. Support No. 2 carrier assembly (63), then using push tool hh,
press fit No. 2 housing assembly (62) with press.
• Press fit the bearing inner race.
E. Using eyebolts p, lift off No. 2 carrier and housing assembly (60).
26. Spacer.
30-72 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
• Assemble discs (55), springs (56), and plates (57) in the
order shown in the diagram.
29. Plate.
Install plate (54).
WA500-3H 30-73
DISASSEMBLY AND ASSEMBLY TRANSMISSION
E. Using eyebolts n, lift off No. 1 piston and housing assembly (46).
• When raising the housing assembly, be careful not to drop
No. 2 piston.
• Tap with a copper hammer to knock in the dowel pin.
A. Using push tool ii, press fit bearing (37) to No. 1 carrier (165).
30-74 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
33. Input shaft.
A. Using push tool jj, press fit bearing (34) to spacer (136).
B. Using push tool kk, press fit spacer and bearing assembly (32).
• After assembling, check that the bearing rotates easily.
WA500-3H 30-75
DISASSEMBLY AND ASSEMBLY TRANSMISSION
38. Guide pins.
Install five guide pins (42).
39. Plate.
Install plate (43).
30-76 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
42. Housing.
Piston Travel
WA500-3H 30-77
DISASSEMBLY AND ASSEMBLY TRANSMISSION
44. Transmission assembly.
30-78 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
46. Sleeves.
Fit O-ring and install four sleeves (8) (length: 74 mm {2.913 in}) and
1 sleeve (9) (length: 79 mm {3.110 in}).
49. Cover.
Install cover (1) to top of transmission control valve.
WA500-3H 30-79
DISASSEMBLY AND ASSEMBLY TRANSFER
TRANSFER
DISASSEMBLY
1. Transmission.
Remove transmission assembly from transfer. For details, see
TRANSMISSION DISASSEMBLY.
B. Remove bearings (4) and (5) from input shaft gear assembly (6).
5. Outer race.
A. Using push tool b, remove outer race (7) from input shaft
cage (34).
30-80 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSFER
6. Strainer.
WA500-3H 30-81
DISASSEMBLY AND ASSEMBLY TRANSFER
9. Outer race.
10. Coupling.
Remove holder (18) and coupling (19).
11. Cover.
B. Remove dust seal (25) and oil seal (26) from cover(35).
30-82 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSFER
12. Output shaft.
Using tool D4, remove output shaft (20) and spacer (21).
13. Cage.
14. Spacer.
Remove spacer (30).
WA500-3H 30-83
DISASSEMBLY AND ASSEMBLY TRANSFER
ASSEMBLY
1. Outer race.
Using push tool f, press fit outer race (17) to transfer case.
B. Fit O-ring and install shims (12) and intermediate shaft cage
assembly (11).
• Standard shim thickness: 2 mm (0.078 in)
30-84 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSFER
B. Using tool D6 and torque wrench, measure preload of intermediate
shaft.
5. Outer race.
A. Using push tool i, press fit outer race (35) to transfer case.
B. Using push tool i, press fit outer race (7) to input shaft cage (34).
A. Using push tool j, install bearings (4) and (5) to input shaft gear (6).
WA500-3H 30-85
DISASSEMBLY AND ASSEMBLY TRANSFER
8. Adjusting preload of input shaft bearing.
Using tool D7 and torque wrench, measure preload of input shaft.
If measurement is not within standard, adjust with shim (2).
• Preload standard value: 0.1 - 0.98 Nm (0.074 - 0.723 lbf ft)
• There are four types of shim thickness: t=0.15 mm (0.006 in),
t=0.2 mm (0.008 in), t=0.3 mm (0.012 in), and t=1.0 mm (0.039 in)
• Check that there is no play in the gear. If there is any play,
adjust the shims again.
• Reference: Standard value for preload when assembling input
shaft and intermediate shaft (measure at input shaft end):
0.2 - 1.27 Nm (0.148 - 0.937 lbf ft)
10. Spacer.
Install spacer (30).
30-86 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSFER
14. Bearing.
16. Cover.
A. Using push tool l, press fit oil seal (26) and dust seal (27) to
cover (37).
i. Fit O-ring and install shims (23) and cover assembly (22).
• Do not tighten the mounting bolts.
ii. Put feeler gauge between shims (23) and cover assembly
(22) and measure clearance, adjust number of shims so that
clearance is 0.05 - 0.10 mm (0.002 - 0.004 in), then tighten
mounting bolts.
• Standard shim thickness: 0.25 mm (0.010 in).
WA500-3H 30-87
DISASSEMBLY AND ASSEMBLY TRANSFER
17. Coupling.
30-88 WA500-3H
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
PARKING BRAKE
DISASSEMBLY
1. Transmission.
Disconnect transmission assembly from transfer. For details, see
TRANSMISSION DISASSEMBLY.
2. Coupling.
Remove holder (1) and coupling (2).
3. Sleeve.
WA500-3H 30-89
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
5. Cover assembly.
6. Springs.
Remove 18 outer springs (12) and 18 inner springs (13).
7. Spacer assembly.
B. Using push tool c, remove inner race (15) from spacer (16).
8. Piston.
30-90 WA500-3H
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
9. Snap ring.
Using snap ring pliers, install snap ring (20).
11. Gear.
Remove gear (24).
13. Housing.
Using snap ring pliers, install snap ring (26) from housing (27).
WA500-3H 30-91
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
ASSEMBLY
1. Cover.
iii. Using push tool, press fit oil seal (10) and dust seal (9).
2. Spacer assembly.
A. Using push tool e, press fit inner race (15) to spacer (16).
3. Springs.
Install 18 outer springs (12) and 18 inner springs (13) to cover
assembly (8).
4. Piston.
B. Set piston (17) on outer spring (12) and inner spring (13).
• Align the position of the hole in piston (17) and dowel pin
(27) of the cover assembly.
30-92 WA500-3H
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
5. Housing.
A. Using snap ring pliers, install snap ring (20) to housing (27).
B. Fit O-ring and install housing (27) to cover assembly (8), then
tighten four mounting bolts (6).
• Be careful not to twist the piston against housing (27), and
tighten the bolts uniformly a little at a time.
6. Plugs.
7. Gear.
Install gear (24).
• Be careful of the direction of mounting.
WA500-3H 30-93
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
9. End plate.
Install end plate (25).
13. Sleeve.
30-94 WA500-3H
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
14. Coupling.
15. Transmission.
Connect transmission assembly and transfer. For details,
see TRANSMISSION ASSEMBLY.
WA500-3H 30-95
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE (ECMV)
REMOVAL
4. Remove four mounting bolts (5), then remove ECMV assembly (6).
INSTALLATION
• Carry out installation in the reverse order to removal.
• Clean around the valve before installing the ECMV assembly.
★ When fitting the solenoid connector, align lock and guide as
shown in diagram on the right, and push in. Do not twist
when inserting.
30-96 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
CENTER SUPPORT
REMOVAL
1. Disconnect center drive shaft (1) from center support. Set a block
under the drive shaft when removing.
2. Sling front drive shaft (2) and disconnect from center support.
• If there are shims between the center support and frame, check
the number and thickness of the shims and use as a guide when
assembling.
WA500-3H 30-97
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
INSTALLATION
• Carry out installation in the reverse order to removal.
30-98 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
DISASSEMBLY
1. Coupling
Remove center bolt (1), then remove retainer (2), O-ring (3), and
coupling (4).
2. Retainer
Remove mounting bolts (5) or retainer.
• Remove all mounting bolts while rotating coupling.
3. Shaft
C. Remove spacer (8), bearing cone (9) and retainer (5) from shaft.
WA500-3H 30-99
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
4. Oil seal
5. Case
Remove bearing cone (13) and bearing outer race (14) and (15).
30-100 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
ASSEMBLY
1. Bearing outer race
Assemble bearing outer race (14) and (15), in case (16).
2. Oil seal
Assemble oil seal (10) in retainer (5).
3. Bearing cone
Assemble retainer (5) shaft and press fit bearing cone (9).
• After assembling bearing, check that there is no clearance at tip
of shaft.
• Assemble spacers.
4. Case
WA500-3H 30-101
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
B. Stand shaft and insert case (16).
• Fill a and b of case and inner circumference of oil seal
completely with grease.
5. Retainer
Secure retainer (5) in case.
• Be careful that O-ring does not get caught or damaged when
installing.
6. Bearing seal
7. Coupling
Assemble coupling (4), install O-ring (3) and retainer (2), and secure
center bolt (1).
30-102 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
8. Inspection of end play
Check that end play is within specified range.
• End play: Less than 0.22 mm (0.009 in).
• If end play is 0, with the seal and bearing coated with grease
check that the free rotating torque is less than 3.9 Nm (3 lbf ft).
WA500-3H 30-103
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DRIVE SHAFT
DISASSEMBLY
1. Shaft
30-104 WA500-3H
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
C. Remove bearing caps (6) from spider assembly.
• Remove strap (7) of cap.
D. When replacing bearing (8), seal (9), and derling washer (10)
from bearing cap (6), replace whole cap assembly.
2. Yoke
A. Remove mounting bolts (11) from yoke (3), then remove spider
assembly (12).
• Stamp match marks on the yoke and spider.
WA500-3H 30-105
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
C. When replacing bearing (14), seal (15), and derling washer (16)
from bearing cap (13) replace whole cap assembly.
30-106 WA500-3H
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
ASSEMBLY
1. Yoke
2. Shaft
WA500-3H 30-107
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
B. Assemble washer (10)and bearing cap (6) to spider assembly (5).
• Be careful not to damage bearing with heat when welding
strap.
30-108 WA500-3H
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
E. lf cover (1) and (1A) has been removed, do as follows:
• Front and rear drive shaft.
Insert seal and retainer to cover (1) and shaft (2), assemble
cover (1), then caulk with a punch on diagonally opposite
sides.
• Center drive shaft.
Insert shaft (2) to cover (1A), assemble cover (1A), then
caulk with a punch on diagonally opposite sides.
WA500-3H 30-109
DISASSEMBLY AND ASSEMBLY FRONT AXLE
FRONT AXLE
REMOVAL
1. Insert blocks ➀ and ➁ between top face (1) of left and right rear axle
housings and frame (2).
2. Start engine, operate work equipment to raise front axle, then set
block under front frame on left and right sides and operate work
equipment to lower frame.
• Check that the front wheels can be removed, then lower the work
equipment to the ground.
3. Sling left and right wheels (3), remove hub nuts, then lift off.
30-110 WA500-3H
DISASSEMBLY AND ASSEMBLY FRONT AXLE
7. Sling one side of front axle assembly (8) and set garage jack to other
side.
INSTALLATION
• Carry out installation in the reverse order to removal.
WA500-3H 30-111
DISASSEMBLY AND ASSEMBLY REAR AXLE
REAR AXLE
REMOVAL
1. Jack up chassis, set block ➀ under rear frame, and support bottom of
counterweight with stand ➁.
2. Sling left and right wheels (1), then remove hub nut and lift off.
4. Disconnect hose (3) between brake pedal and slack adjuster at slack
adjuster end.
5. Disconnect tubes (4) and (5) between slack adjuster and left and right
wheel brakes.
• Be sure to remove the brake tube before removing the axle. There
is danger that it may be crushed.
30-112 WA500-3H
DISASSEMBLY AND ASSEMBLY REAR AXLE
6. Disconnect grease tubes (6) and (7) from axle support at rear end.
WA500-3H 30-113
DISASSEMBLY AND ASSEMBLY REAR AXLE
11. Remove front support (10) from rear axle.
• Be careful not to damage the packing.
30-114 WA500-3H
DISASSEMBLY AND ASSEMBLY REAR AXLE
15. Remove thrust washer (15), thrust plate (16), and thrust washer (17)
from rear axle.
WA500-3H 30-115
DISASSEMBLY AND ASSEMBLY REAR AXLE
18. Remove bushing (20) from rear support.
• Remove all dirt and oil from the bushing mounting surface inside
the rear support.
INSTALLATION
• Carry out installation in the reverse order to removal.
Rear support mounting bolt: 1568 ±196 Nm (1157 ±145 lbf ft)
• Soak a cloth with primer for Loctite Prism adhesive, then wipe the adhesion surface at the bushing end.
30-116 WA500-3H
DISASSEMBLY AND ASSEMBLY REAR AXLE
Front support mounting bolt: 1,568 ±196 Nm (1157 ±145 lbf ft)
Thrust cap mounting bolt: 279.3 ±29.4 Nm (206 ±22 lbf ft)
Thrust plate mounting bolt: 279.3 ±29.4 Nm (206 ±22 lbf ft)
WA500-3H 30-117
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
12
DIFFERENTIAL, NORMAL -
(STANDARD)
REMOVAL (FRONT)
2. Operate work equipment to raise front axle, then set stand under left
side of axle.
3. Sling left wheel (3), then remove hub nut and lift off.
5. Using forcing screws ➀, pull out drive shaft (5) approx. 200 mm
(7.874 in) together with sun gear (6).
30-118 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
6. Remove front drive shaft (7).
• Screw in the guide bolt fully and check that all the threads have
entered the hole.
• First, screw in the guide bolt, then remove the remaining
mounting bolts.
8. Set lever block ➁ to differential case (9), and set so that differential
assembly does not fall over.
• Fit both ends of a lever block to the front frame inspection window.
9. Pull out differential (8) approx. 20 mm from axle housing (10) along
guide bolts.
• Be careful not to damage the O-ring.
10. Install tools H1-1 and H1-2 to garage jack, and insert between
differential and axle housing, then install differential to tool H1-1.
11. Adjust lever block and height of jack, and remove differential
assembly slowly.
12. Operate jack and pull out differential assembly (8) to outside of chassis.
WA500-3H 30-119
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
INSTALLATION (FRONT)
• Carry out installation in the reverse order to removal.
30-120 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
REMOVAL (REAR)
1. Remove rear axle assembly from chassis. For details, see REAR
AXLE REMOVAL.
• Do not remove the rear support from the rear axle.
WA500-3H 30-121
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
INSTALLATION (REAR)
• Carry out installation in the reverse order to removal.
30-122 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
DISASSEMBLY
DIFFERENTIAL GEAR ASSEMBLY
1. Set differential assembly (1) on special tools H2-1, H2-2, and H-3.
2. Pinion assembly
B. Remove oil seal (3) and dust seal (3A) from case.
WA500-3H 30-123
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
3. Differential gear case assembly
A. Remove left and right locks (6), and with a bar, turn nut (7) until
it become loose.
C. Remove nut and lift out differential gear case assembly (10).
30-124 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
A. Support cage (11), push shaft with press and tack out pinion.
5. Pinion, bearing
A. Remove snap ring (15), then remove bearing (16).
WA500-3H 30-125
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
30-126 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
12
FINEASSEMBLY OF DIFFERENTIAL GEAR CASE
ASSEMBLY
1. Bearing
Using press fit kit ➂ {120 mm (4.724 in) inner diameter}, press fit
bearing (26) to case (25).
WA500-3H 30-127
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
5. Bevel gear (large)
Using eye-bolts ➁ (thread dia. = 16 mm, Pitch = 2.0 mm), lift and
install bevel gear (18).
• Align pin hole of thrust and dowel pin on case side and install.
B. Using press fit kit ➄ {55 mm (2.165 in) inner diameter}, install
bearing (16).
7. Cage
A. Install outer races (14) and (13).
30-128 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
8. Collar
Install collar (27).
9. Bearing
Using press fit kit ④ (76 mm inner diameter), install bearing (12).
WA500-3H 30-129
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
E. Insert coupling (28), fit O-ring and tighten holder.
Mounting bolt:
Check match marks on bearing cup before installing.
Rotate bevel gear 20 - 30 times to settle in, then tighten bolt.
30-130 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
★ Bearing pre-load adjustment steps are as follows.
C. Install tool H4-1 and H4-2 to cap on both sides.
WA500-3H 30-131
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
13. Adjusting tooth contact, backlash
• Adjust the backlash, and at the same time adjust tooth contact.
30-132 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
C. Adjusting tooth contact
Coat face of 7 or 8 teeth of bevel gear lightly with red lead. Hold the bevel gear by hand to act as a brake, rotate the
pinion gear forward and backward and inspect the pattern left on the teeth.
Correct contact
The tooth contact pattern should start
Adjust the bevel pinion by adjusting the shims at the bevel
from about 5 mm from the toe of the
pinion cage.
bevel gear and cover about 50% of the
Adjust the bevel gear in the same way as when adjusting
length of the tooth.
backlash.
It should be in the center of the tooth
height.
Bevel pinion is too far from bevel gear. 2. Move bevel gear further
away from bevel pinion
and adjust backlash
correctly.
Bevel pinion is too close to bevel gear. 2. Move bevel gear closer to
bevel pinion and adjust
backlash correctly.
Bevel gear is too close to bevel pinion 2. Move bevel gear further
away from bevel pinion
and adjust backlash
correctly.
★ When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left and
right. Always keep the same total thickness of shims.
WA500-3H 30-133
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
14. Lock
After adjusting tooth contact and backlash, install lock (6).
30-134 WA500-3H
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
FINAL DRIVE
DISASSEMBLY
1. Tire assembly
Loosen hub nut, raise chassis with work equipment or jack, insert
support stand under axle, then sling tire assembly, remove hub nuts,
and lift off tire assembly (1).
2. Draining oil
Remove drain plug (2) and drain oil.
Set so that the drain plug is at the bottom.
3. Cover
Remove mounting bolts (3), then remove cover (4).
4. Drive shaft
Screw in bolt (1) (Thread dia.=12 mm, Pitch = 1.75 mm) in drive
shaft, then pull out drive shaft assembly (5) and remove.
WA500-3H 30-135
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
6. Ring gear
A. Using tool H6, secure wheel hub (8) and brake housing (9).
• Install tool H6 at three places at equal distances.
• Do not remove tool H6 until assembly Step 3.
30-136 WA500-3H
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
A. Remove lock plates (18) from ring gear hub (17), then remove
ring gear (19)
WA500-3H 30-137
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
ASSEMBLY
1. Assembly of ring gear
B. Set ring gear hub (17) on ring gear (19), then install lock
plates (18).
• Install the lock plates with the wider ones on the inside.
• Remove all grease and oil from the bolt.
30-138 WA500-3H
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
3. Wheel bearing adjustment
A. Insert ring gear assembly (12) in axle housing, fit retainer (11)
tighten temporarily with mounting bolts (10), and remove tool H6.
WA500-3H 30-139
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
D. After installing tool H6 to brake housing and wheel hub,
remove retainer, insert the required number of shims and
retainer, then tighten mounting bolts.
• When assembling shims, after installing tool H6, always
tighten the mounting bolts uniformly to the specified
tightening torque.
4. Planetary carrier
Fit O-ring, using eye-bolts ➁ (Thread dia. = 12 mm, Pitch = 1.75 mm)
sling planetary carrier assembly (7), set in mounting position and
tighten mounting bolts (6).
• Because balance is bad, adjust the center of gravity with a bar
and install.
5. Axle shaft
Screw in bolt ➀ (Thread dia. = 12 mm, Pitch= 1.75 mm) in axle
shaft and insert axle shaft assembly (5).
• If the position of the sun gear does not match, rotate the wheel
hub to align.
6. Cover
Fit O-ring, install final drive cover (4), then tighten mounting bolts (3).
30-140 WA500-3H
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
7. Refilling with oil
Tighten drain plug (2), then remove level plug, and add oil through
oil filter to specified level. Set the machine so that the level plug of
the final drive is at the bottom when refilling with oil.
8. Tire assembly
Raise tire assembly (1), set to wheel hub, and tighten temporarily
with wheel nuts. Then jack up chassis with work equipment and jack,
remove stand under axle, lower chassis to ground and tighten wheel
nuts to specified torque.
WA500-3H 30-141
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
REMOVAL
4. Remove three mounting bolts (4), then remove orbital steering valve
assembly (5).
5. Remove joint lock bolt (6), then remove joint assembly (7).
INSTALLATION
• Carry out installation in the reverse order to removal.
30-142 WA500-3H
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
DISASSEMBLY
ENSURE A CLEAN WORKING ENVIRONMENT
1. Dirt or debris in the hydraulic system will cause premature wear and erratic operation. Keep all dirt and dust out of the
hydraulic circuit.
3. Remove dirt from the exterior of the unit before disconnecting any piping.
4. Always wipe dirt off the unit before placing it on the work bench.
5. After disassembling, wash with a clean petroleum-base solvent, and blow dry with clean air. Always ensure that there are
no impurities in the solvent or air.
• If any other solvent is used, it may lead to deterioration of the rubber seal. Never wipe any part with a cloth or apply
steam to the unit.
• The solvent is flammable. Keep flames and sparks away.
PREPARATORY WORK
1. Fit blind plugs in the five ports in the valve body, clean the outside,
then remove the blind plugs.
WA500-3H 30-143
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
5. Remove commutator (5) and washer (6).
• Do not remove pin (4).
6. Using two mounting bolts (1), remove commutator ring (7) and
manifold (8).
7. Using two mounting bolts (1), remove rotor set (9) and wear plate
(10) in the same way as commutator ring and manifold.
8. Insert screwdriver between sleeve (3) and valve body (11), then
remove sleeve (3).
11. Remove rod (14), roller (15), rod (16), and spring (17).
30-144 WA500-3H
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
12. Install in vise with input shaft (18) at the top, and make counter
marks with a punch in upper cover (19) and valve body (11).
13. Remove four mounting bolts (20), then grip input shaft (18), move it
up, and remove input shaft, upper cover, and valve spool assembly (23).
14. Remove upper cover assembly (22) from input shaft and valve spool
assembly (23), then remove shim (24) and spacer (25).
• Check the number and thickness of the shims, and keep in a
safe place.
15. Remove seal (26) and snap ring (27), then remove spacer (28),
seal (29), and seal ring (30) from upper cover (19).
WA500-3H 30-145
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
• Seal (29) and seal ring (30) may form one unit.
16. Remove snap ring (31), thrust washer (32), thrust bearing (33),
thrust washer (34), and wave washer (35) from input shaft (18).
18. Set valve spool (37) facing bottom, then remove torsion bar (38)
and spacer (39) from input shaft and valve spool assembly.
• Do not remove needle roller (40) from the torsion bar.
30-146 WA500-3H
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
19. Set valve spool (37) facing bottom, then rotate input shaft (18) until
drive link (41) comes out.
20. Set valve spool (37) facing bottom, then rotate input shaft (18)
clockwise to a point where ball comes out.
• Ball (42) may come out by itself, so be careful not to lose it.
WA500-3H 30-147
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
ASSEMBLY
• Before assembly, wash all parts with clean petroleum based solvent
and dry with air. Never wipe with a cloth.
• Check carefully that there is no debris or paint on the edge of the
lapped surface.
• If there are no special instructions, do not coat any parts with oil
when assembling.
1. Set thrust washer (34), thrust bearing (33), and thrust washer (32) to
input shaft (18), and install snap ring (31).
2. Install wave washer (35) to thrust bearing (33) and thrust washer (34).
5. Fit center portion of torsion bar (38) between thrust washer (34)
and valve spool (37).
30-148 WA500-3H
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
• The positioning of the valve spool and input shaft is carried out
by inserting the torsion bar.
6. Check spline of input shaft (18) and drive link (41), and align spline
of valve spool (37), then install drive link (41).
• If the drive link and input shaft do not mesh, rotate the input
shaft slightly to carry out the meshing.
• When inserting the drive link, make sure that the torsion bar is
securely held in position.
• If the drive link is assembled correctly, there will be a clearance
of 8.89 mm (0.350 in) between the thrust washer and valve spool.
• If the relationship between the spool, drive link, and input shaft
is not correct, the steering unit will not work properly.
8. Set spacer (39) to torsion bar (38), then insert in valve spool and
input shaft assembly (23).
WA500-3H 30-149
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
9. Using pin ➂ (outside diameter: 3 mm), align pin hole of input shaft
(18) and torsion bar (38).
10. Using pin (1), knock pin (36) 0.8 mm in from end face of input shaft.
11. Install spacer (25) on valve spool and input shaft. If there is a lip at
one end inside the spacer, install so that the lip surface is facing the
wave washer.
12. Install input shaft and valve spool assembly (23) to valve body (11).
• The clearance is extremely small, so if any sideways pressure is
applied during assembly, it will not work properly.
13. Set shim (24) on top of thrust washer, fit seal, align counter marks of
upper cover (19), then install and tighten mounting bolts (20)
temporarily.
14. Set tool F1 in position, and install so that valve body and upper
cover are centered.
30-150 WA500-3H
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
16. Measure width w of groove of drive link (12) at several places and
check that the difference does not exceed 0.025 mm.
17. Pull input shaft down, align drive link (12) with spline of valve spool,
then rotate spool so that end face of spool and valve body are level
with each other.
18. Align pin (40) and drive link (12) and install.
WA500-3H 30-151
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
• If installed height h = Within 0.063 mm it is not necessary to
adjust shim.
• If installed height h = 0.064 mm or more, repeat Steps 12
through 19 to adjust the shim height so that h = Within 0.063 mm.
21. Set rod (17) to spring (16), then fit to valve body (11) and install
roller (15) and rod (14).
A. Set the pin end of end cover assembly at top and spline end of
rotor assembly (9) at bottom, then check that rotor rotates freely
inside stator.
30-152 WA500-3H
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
24. Using guide pin ➇, install wear plate (10), rotor assembly (9), and
manifold (8).
26. Set sleeve (3) and end cover assembly (2) in position, tighten
mounting bolts (1) uniformly, then install sleeve, and remove end
cover assembly.
27. Fit washer (6) to end cover assembly (2), and install commutator (5).
• Install the commutator so that the concave part is at the end
cover assembly end.
WA500-3H 30-153
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
28. Install commutator ring (7).
29. Rotate input shaft so that tip of drive shaft is aligned with oval hole
in commutator.
30. Set end cover assembly (2) on sleeve (3), then tighten five mounting
bolts uniformly.
31. Set input shaft end facing top, then install seal ring (30) and seal (29).
• Install the seals from the small diameter end.
• Seal ring (30) and seal (29) are stuck together and are supplied
as one unit.
• Coat the new seal with oil and install from the lip end.
• When doing this, coat the inside with a small amount of grease.
32. Using tool F2, install spacer (28) from small diameter end.
34. Fit seal (26) to input shaft, and fit to upper cover.
30-154 WA500-3H
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
STEERING CYLINDER
REMOVAL
1. Remove bolts (1), loosen bolt (2), then rotate cover (3) carefully
towards rear of machine.
• Rotate the cover using bolt (2) as the fulcrum.
WA500-3H 30-155
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
6. Remove mounting bolt (9), then pull out pin (10).
• Note the number and thickness of the shims to use as a guideline
when assembling.
INSTALLATION
• Carry out installation in the reverse order to removal.
• Adjust the shims so that the clearance is specified value.
• Clearance a + b = Less than 1.0 mm (0.039 in) (The specified value
is the same for both the rod end and the bottom end.)
30-156 WA500-3H
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
DISASSEMBLY
1. Set cylinder assembly (1) in tool U1.
2. Raise lock of cylinder head (2), then using tool U2, remove cylinder
head (2) from cylinder.
3. Pull cylinder head and piston rod assembly (3) out from cylinder (4),
then lift off.
• Oil will come out when the piston rod assembly is removed from
the cylinder, so catch it in a container.
5. Set cylinder head and piston rod assembly in tool U1, and, using
power wrench ➀ and socket U3, loosen nut (5).
• Power wrench: x 16
• Socket U3: Width across flats: 60 mm
6. Remove nut (5), then remove piston assembly (6), and cylinder head
assembly (7) from rod (8).
WA500-3H 30-157
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
7. Disassembly of piston assembly
30-158 WA500-3H
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
ASSEMBLY
• Clean all parts, and check for dirt or damage. Coat the sliding
surfaces of all parts with engine oil before installing. Be careful not
to damage the rod packing, dust seals or O-ring when assembling.
A. Using tool U5, press fit bushing (23) to cylinder head (24).
• Be extremely careful not to deform the bushing when press
fitting.
D. Using push tool, install dust seal (17) to cylinder head (24).
C. Fit tool U6-2, on piston ring, then using clamp U6-3, contact
piston ring.
WA500-3H 30-159
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
3. Set piston rod (8) in tool U1.
4. Assemble cylinder head assembly (7) and piston assembly (6) no rod,
then fit nut (5).
8. Raise piston rod and head assembly (3), and assemble in cylinder (4).
30-160 WA500-3H
DISASSEMBLY AND ASSEMBLY STEERING VALVE
STEERING VALVE
REMOVAL
1. Remove bolt (1), loosen bolt (2),then rotate cover (3) carefully
towards rear of machine.
• Rotate the cover using bolt (2) as the fulcrum.
• The operating space is confined, so be extremely careful when
carrying out the operation.
6. Disconnect hoses (10) and (11) between cut-off valve and loader circuit.
WA500-3H 30-161
DISASSEMBLY AND ASSEMBLY STEERING VALVE
8. Disconnect tubes (13) between steering valve and steering cylinder.
10. Disconnect hose (15) between stop valve and steering valve.
11. Disconnect hose (16) between stop valve and steering valve.
• It is connected to both ends of the steering valve.
12. Disconnect hose (17) between steering valve and steering pump.
13. Disconnect tube (18) between switch pump and steering valve.
14. Disconnect hose (19) between steering valve and cut-off valve.
16. Using guide bolt ➀, pull out steering valve assembly (21) together
with bracket approx. 200 mm (7.874 in) to center of machine.
• Remove the cut-off valve at this point.
30-162 WA500-3H
DISASSEMBLY AND ASSEMBLY STEERING VALVE
17. Lift off steering valve assembly (21) together with bracket.
INSTALLATION
• Carry out installation in the reverse order to removal.
• Install the cut-off valve after lowering the steering valve assembly together with the bracket to the mounting position.
• After installing the cut-off valve, use the guide bolt to move close to the frame and install.
WA500-3H 30-163
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
BRAKE VALVE
REMOVAL
5. Remove hoses (5) between R.H. brake valve and slack adjuster.
7. Disconnect hose (7) between R.H. brake valve and L.H. brake valve.
11. Pull out snap pin (11), then pull out pin (12).
• Be careful not to lose L-shaped pin (13).
30-164 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
12. Remove mounting bolts (14), then remove brake valve assembly (15).
• Carry out the operation with two workers and remove the valve
assembly from under the floor plate.
INSTALLATION
• Reverse the removal procedure to install a brake valve assembly.
WA500-3H 30-165
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
SLACK ADJUSTER
REMOVAL
3. Disconnect tube (3) between slack adjuster and left and right brake
pistons.
INSTALLATION
• Carry out installation in the reverse order to removal.
30-166 WA500-3H
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
DISASSEMBLY
1. Bleeder
Remove bleeder (2) from body (1).
2. Cylinder
Remove mounting bolts, then disconnect body (1) and cylinder (4)
together with bracket (3).
3. Piston
4. Poppet
★ Do not disassemble the poppet unless necessary. If it is disassembled,
replace the whole cylinder assembly.
A. Remove cover (8) from cylinder (4), then remove plug (9),
spring (10) and poppet (11).
• When removing the poppet, blow in air from the oil hole in
the cylinder.
• Hold the oil port of the cylinder by hand, and do not pump
in air suddenly.
• Be careful not to change the combination of poppet (11)
and cylinder (4).
• When replacing, replace the poppet and cylinder as an assembly.
WA500-3H 30-167
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
ASSEMBLY
1. Poppet
B. Install poppet (11), spring (10), plug (9) and cover (8), then
assemble cylinder (4).
2. Piston
3. Cylinder
B. Install body (1) and cylinder (4) together with bracket (3).
4. Bleeder
Install bleeder (2).
30-168 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
REMOVAL
3. Set tool H6 in position, and sling brake and wheel hub assembly,
remove mounting bolts (2), then lift off brake and wheel hub
assembly (3).
INSTALLATION
• Carry out installation in the reverse order to removal.
Brake, wheel hub mounting bolt: 548.8 ±58.8 Nm (405 ±43 lbf ft)
WA500-3H 30-169
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
DISASSEMBLY
1. Cylinder
Using eyebolt ➀ (Thread dia. = 16 mm, Pitch = 2.0 mm), lift out
cylinder (1).
2. Plate, disc
30-170 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
B. Remove disc (7).
i. When removing the disc and plates, put match marks on the
inner gear and disc, and outer gear and plate before removing.
3. Gear assembly
B. Using eyebolt ➂ (Thread dia.=12 mm, Pitch =1.75 mm), lift off
gear (8).
D. Remove floating seal (10) and oil seal (11) from gear (8).
WA500-3H 30-171
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
4. Floating seal, outer race
30-172 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
ASSEMBLY
1. Outer race, floating seal
A. Using push tool ④, press fit outer race (15) to hub (13).
B. Using push tool ➄, press fit outer race (14) to hub (13).
2. Gear assembly
WA500-3H 30-173
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
B. Using tool H8, install floating seal (10) to gear (8).
30-174 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
5. Disc, plate
6. Cylinder
★ Assemble cylinder with following steps:
WA500-3H 30-175
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
D. Fit O-ring and using eyebolts ➀ (Thread dia. = 16 mm,
Pitch = 2.0 mm), match with guide bolt (1) and lift and install
cylinder assembly.
30-176 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
MEMORANDUM
WA500-3H 30-177
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
HYDRAULIC PUMP
REMOVAL
A. Remove bolts (5), and disconnect tube (6) together with hose.
30-178 WA500-3H
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
5. Steering pump assembly.
INSTALLATION
• Carry out installation in the reverse order to removal.
WA500-3H 30-179
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL
1. Remove plug (3), then loosen valve (4) and drain hydraulic oil.
2. Sling ladder floor (5), then remove mounting bolts and lift off.
• Be careful of the center of gravity when lifting off the ladder.
30-180 WA500-3H
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
6. Disconnect hose (9) between brake valve and hydraulic tank.
7. Disconnect stop valve, charge valve, PPC, orbital steering valve, and
drain hoses (10).
INSTALLATION
• Carry out installation in the reverse order to removal.
WA500-3H 30-181
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
HYDRAULIC FILTER
REMOVAL
2. Loosen plug (2) on top of the hydraulic tank filler and bleed air from
the tank, then remove mounting bolts, and remove cover (3).
INSTALLATION
• Carry out installation in the reverse order to removal.
30-182 WA500-3H
DISASSEMBLY AND ASSEMBLY PPC VALVE
PPC VALVE
REMOVAL
4. Remove mounting bolts (11), then remove PPC valve assembly (12).
INSTALLATION
• Carry out installation in the reverse order to removal.
WA500-3H 30-183
DISASSEMBLY AND ASSEMBLY PPC VALVE
DISASSEMBLY
1. Remove bolt (1).
4. Remove valve assembly and center spring (7) from valve body (10).
5. Remove collar (11), then remove retainer (6), shim (12), and
spring (8) from valve (9).
ASSEMBLY
1. Push shim (12), spring (8), and retainer (6) into valve (9), and install
collar (11).
2. Install center spring (7) and valve assembly to valve body (10).
30-184 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL
2. Loosen plug (2) on top of the hydraulic tank filter and bleed air from
tank.
5. Remove bolt (5), and loosen bolt (6), then rotate cover (7) carefully
to right.
• Rotate the cover on the right side of the chassis to the left.
• Rotate the cover using bolt (6) as the fulcrum.
• The operating space is confined, so be extremely careful when
carrying out the operation.
6. Disconnect hose (13) for bucket spool between PPC valve (P1) and
main control valve (PB1).
WA500-3H 30-185
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
7. Disconnect hose (14) for boom spool between PPC valve (P3) and
main control valve (PB2).
8. Disconnect hose (15) for bucket spool between PPC valve (P4) and
main control valve (PA1).
9. Disconnect hose (16) for boom spool between PPC valve (P2) and
main control valve (PA2).
• Remove the hose clamp.
• After disconnecting the hose, move it to the rear of the machine.
• After disconnecting the hoses, fit tags to distinguish them.
10. Disconnect hose (17) between main control valve and hydraulic tank.
11. Remove tube (18) between main control valve and bucket cylinder
together with hose.
12. Remove tube (19) between main control valve and boom cylinder.
15. Disconnect hose (22) between steering valve and main control valve
from main control valve.
16. Disconnect tube (23) between hydraulic tank and main control valve
from main control valve.
30-186 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
17. Remove tube (24) between main control valve and bucket cylinder
together with hose.
18. Disconnect tube (25) between main control valve and boom cylinder
from main control valve.
20. Remove mounting bolts and rotate main control valve (26) 90°.
INSTALLATION
• Carry out installation in the reverse order to removal.
WA500-3H 30-187
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
12
DISASSEMBLY
30-188 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
1. Spool assembly
WA500-3H 30-189
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
2. Main relief valve
i. Loosen nut (15), and pull out adjustment screw (16), then
remove retainer (17), spring (18), spacer (19), and poppet (20).
• Before loosening nut (15), measure the protrusion of
screw (16) from the end face of the nut.
ii. Loosen nut (21), then remove holder (22), seat (23), and
backup ring (24).
iii. Remove snap ring (25), then remove retainer (26), valve (27),
and spring (28) from sleeve (29).
30-190 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
4. Suction valve assembly
ii. Remove nipple (40), then remove shim (41), spring (42), and
piston (43).
• Check the number and thickness of the shims, and keep
in a safe place.
A. Remove plate (44), then remove spring (45) and check valve (46).
B. Remove flange (47), then remove spring (48), seal (49), and
valve (50).
WA500-3H 30-191
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
12
ASSEMBLY
30-192 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
12
1. Check valve assembly
A. Assemble valve (50), seal (49), and spring (48) in valve body (51),
then fit O-ring and install flange (47).
B. Assemble check valve (46) and spring (45) in valve body, then fit
O-ring and install plate (44).
B. Assemble piston (43), spring (42), and shim (41) in sleeve (38),
then fit O-ring and install nipple (40).
ii. Assemble seal (34) in valve (33), and install to sleeve (36).
WA500-3H 30-193
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
5. Main relief valve assembly
ii. Assemble spring (28), valve (27), and retainer (26) in sleeve
(29), and install snap ring (25).
iii. Fit backup ring (24) and O-ring, and assemble seat (23) in
sleeve.
iv. Screw nut (21) into holder (22), then fit O-ring and assemble
in sleeve, and tighten nut.
6. Spool assembly
E. Assemble retainer (6), spring (5), retainer (4), and spring (3), then fit
O-ring and install case (2) and sleeve (1).
30-194 WA500-3H
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
12
BUCKET CYLINDER
REMOVAL
WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks
under the wheels to prevent the machine from moving.
WARNING! Pressure in the hydraulic system must be released. Loosen oil filler cap slowly to release
pressure inside the hydraulic tank. Operate steering wheel and control levers several
times to release remaining pressure in the hydraulic piping.
5. Sling cylinder then remove lock bolt, and remove head pin (5).Sling
from two points and be careful of the center of gravity.
• If there are shims, check the number and thickness of the shims.
WA500-3H 30-195
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
7. Remove bucket cylinder assembly (7).
• Be careful not to damage the cylinder rod.
INSTALLATION
• Carry out installation in the reverse order to removal.
• When aligning the pin hole at the bottom end, assemble shims so that
the total clearance between cylinder and frame is within specified
value, then assemble pin (6) and lock with the bolt.
★ Clearance a + b = Less than 1.0 mm (0.039 in)
30-196 WA500-3H
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
DISASSEMBLY
1. Set cylinder assembly (1) tool U1.
3. Pull cylinder head and piston rod assembly (3) out from cylinder (4),
then lift off.
• Oil will come out when the piston rod assembly is removed from
the cylinder, so catch it in a container.
4. Remove piston bolts (5), then remove spacer (6), piston assembly (7)
and cylinder head assembly (8).
5. Remove O-ring (10) and backup ring (11) from piston rod (9).
WA500-3H 30-197
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
6. Disassembly of piston assembly
Remove wear ring (12) and piston ring (13) from piston (14).
30-198 WA500-3H
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
ASSEMBLY
★ Clean all parts, and check for dirt or damage. Coat the sliding surfaces
of all parts with engine oil before installing. Be careful not to damage
U-packings, dust seals, or O-rings when assembling.
A. Using push tool U5, press fit bushing (19) on cylinder head (20).
• Be careful not to deform the bushing when press fitting.
E. Using push tool U4, install dust seal (17) to cylinder head, then
secure with snap ring.
WA500-3H 30-199
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
2. Assembly of piston assembly
B. Remove piston ring from tool U6-1, and assemble on piston (14).
C. Fit tools U6-2, on piston ring, then using clamp U6-3, compress
piston ring.
3. Assemble O-ring (10) and backup ring (11) on piston rod (9).
30-200 WA500-3H
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
6. Set cylinder (4) in tool U1, then raise piston rod and head assembly
(3), and assemble in cylinder (4).
WA500-3H 30-201
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
BOOM CYLINDER
REMOVAL
2. Sling boom cylinder, then remove lock bolt, and remove pin (3).
• Start the engine and operate the control lever to retract the
cylinder rod of the cylinder where the pin has been removed.
• After stopping the engine, release the remaining pressure from
the hydraulic piping.
4. Fit lifting tool to bottom of boom cylinder (2), then use lever block ➀
to pull out to rear of machine.
• If there are shims, check the number and thickness of the shim.
30-202 WA500-3H
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
6. Lift off boom cylinder assembly (2).
• Be careful not to damage the cylinder rod.
INSTALLATION
• Carry out installation in the reverse order to removal.
• When aligning the pin hole at the bottom end, assemble shims so that
the total clearance between cylinder and frame is within specified
value, then assemble pin and lock with the bolt.
★ Clearance a + b = Less than 1.0 mm (0.039 in)
WA500-3H 30-203
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
DISASSEMBLY
1. Set cylinder assembly (1) tool U1.
3. Pull cylinder head and piston rod assembly (3) out from cylinder (4),
then lift off.
• Oil will come out when the piston rod assembly is removed from
the cylinder, so catch it in a container.
4. Remove piston bolts (5), then remove spacer (6), piston assembly (7)
and cylinder head assembly (8).
5. Remove O-ring (10) and backup ring (11) from piston rod (9).
30-204 WA500-3H
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
6. Disassembly of piston assembly
Remove wear ring (12) and piston ring (13) from piston (14).
WA500-3H 30-205
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
ASSEMBLY
★ Clean all parts, and check for dirt or damage. Coat the sliding surfaces
of all parts with engine oil before installing. Be careful not to damage
U-packings, dust seals, or O-rings when assembling.
A. Using push tool U5, press fit bushing (19) on cylinder head (20).
• Be careful not to deform the bushing when press fitting.
E. Using push tool U4, install dust seal (17) to cylinder head, then
secure with snap ring.
30-206 WA500-3H
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
2. Assembly of piston assembly
B. Remove piston ring from tool U6-1, and assemble on piston (14).
C. Fit tools U6-2, on piston ring, then using clamp U6-3, compress
piston ring.
3. Assemble O-ring (10) and backup ring (11) on piston rod (9).
WA500-3H 30-207
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
6. Set cylinder (4) in tool U1, then raise piston rod and head assembly
(3), and assemble in cylinder (4).
30-208 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
REMOVAL
1. Open cover (1) and loosen plug (2) on top of hydraulic tank to
prevent oil from flowing out from tank.
3. Remove plug (5), then loosen valve (6) and drain hydraulic oil.
When draining the hydraulic oil, drain to the level of the bottom of
each pipe.
WA500-3H 30-209
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
5. Remove left and right steering cylinder pins (9).
• If there are shims between the pin and frame, check the number
and thickness.
9. Disconnect hoses (15) and (16) between steering valve and stop
valve at steering valve end.
10. Disconnect hose (17) between steering valve and oil cooler.
11. Disconnect hose (18) between work equipment control valve and
hydraulic tank.
12. Disconnect hose (19) between work equipment control valve and
loader pump.
30-210 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
13. Disconnect bypass hose (20) from hydraulic circuit at top of tank.
16. Using hydraulic jack to rear frame, insert block ➀ while adjusting
height.
• Put support stands ➁ under the left and right side of the frame.
• If there are shims between the retainer and frame, check the
number and height.
WA500-3H 30-211
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
20. Adjust height carefully so that lower hinge pin (26) can be removed
easily by hand.
23. Using puller, remove upper hinge pin (29) and spacer(30).
30-212 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
24. Remove safety bar, then pull out front frame towards front and
disconnect frame.
• Be careful not to let the spacer at the top of the lower hinge get
caught in the rear frame.
• Carry out the operation carefully and pay attention to maintaining
the balance.
• Move approx. 100 mm (3.9 in) at a time.
27. Remove spacer (33) and dust seal (34) from front frame.
WA500-3H 30-213
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
28. Remove bearing (35).
• If there are shims between the retainer and frame, check the
number and thickness.
30-214 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
INSTALLATION
• Carry out installation in the reverse order to removal.
• Measure clearance c between retainer and frame at four places on the inside circumference, and select a shim thickness
to make the value 0.08 - 0.18 mm (0.003 - 0.007 in) less than the measured value.
• When adjusting the shim, temporarily tighten the retainer mounting bolts to act as a stopper.
• When tightening the mounting bolts, first tighten the retainer mounting bolts to the specified torque, then tighten the pin
mounting bolts.
• After selecting the shim, assemble the retainer to the specified torque.
• Remove all oil and grease from the mounting bolts and mount holes.
Mounting bolt (48) when adjusting shims: 276.3 ±29.4 Nm (206 ±22 lbf ft)
Mounting bolt (49) when adjusting shims: 382.2 ±34.3 Nm (282 ±25 lbf ft)
WA500-3H 30-215
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
• Assemble spacer (30), insert upper hinge (29), then tap three times
with a copper hammer to settle the parts.
• Never coat spacer (30) with grease.
• Grease on spacer (28) may prevent the mounting bolts being tightened
to the specified tightening torque. Remove any grease and tighten again.
• Use tool K2 to press fit the bearing and spacer to the frame. Make
sure the bearing is not at an angle.
• Fill the inside of the bearing with grease.
• When assembling the bearing, be sure to assemble the spacer.
• The clearance of the bearing is adjusted, so do not change the
combination of bearing and spacer.
• When replacing, replace as a set.
• Press fit so that the lip of the dust seal is facing the outside.
30-216 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
• Using tool K1, press fit the bearing and spacer to the frame.
• When press fitting the bearing, be careful that the bearing is not at an
angle.
• Fill the inside of the bearing with grease.
• When assembling the bearing, be careful not to forget to assemble the
spacer.
• The clearance of the bearing is adjusted, so do not change the
combination of bearing and spacer.
• When replacing, replace as a set.
• Press fit so that the lip of the dust seal is facing the outside.
• After completion of mounting the hinge pin, fill with oil and bleed the air.
A. Tighten the plug on the top of the hydraulic tank filter, then add hydraulic oil through oil filler to the specified level.
B. Run the engine to circulate the oil through the system. Then check the oil level again.
C. Bleed the air from the brake system. For details, see TESTING AND ADJUSTING.
WA500-3H 30-217
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL
4. Temporarily sling bucket cylinder (3), pull pin (4), then disconnect
cylinder rod and tilt lever.
• Attach lifting tool to bucket cylinder and secure in the rear.
30-218 WA500-3H
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
6. Temporarily sling bellcrank (7) and bucket link, remove mounting
pin (8), then lift out from boom (9).
• Remove with the bucket link still fitted.
• Three technicians are required for removal of mounting pin
operation.
7. Temporarily sling bucket link (10), remove mounting pin (11), then
lift out from bellcrank (7).
9. Temporarily sling boom (9), pull out mounting pin of boom, then lift
out boom.
• Shims are installed at connecting point of front frame and boom,
so check the number of shims.
WA500-3H 30-219
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
10. Pull out dust seal (14) and bushing (15) from boom (9).
11. Pull out dust seal (16) and bushing (17) from bellcrank (7)
30-220 WA500-3H
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12. Pull out dust seal (18) and bushing (19) from bucket link (10).
• After long use, wear can make the pin difficult to remove. A
puller (pin puller jig) such as the one shown here can be helpful
when removing a pin.
WA500-3H 30-221
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION
• Align the hole in the boom mount and the front frame, then insert
shims to make the clearance equal on the left and right.
• Clearance a + b = Less than 1.0 mm (0.039 in).
• After assembling the pin, set the support stand to the tip of the boom.
• Grease each pin.
30-222 WA500-3H
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
MEMORANDUM
WA500-3H 30-223
DISASSEMBLY AND ASSEMBLY BULKHEAD
BULKHEAD
REMOVAL
30-224 WA500-3H
DISASSEMBLY AND ASSEMBLY BULKHEAD
8. Disconnect brake hoses (9), (10), and (11).
INSTALLATION
WA500-3H 30-225
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
ENGINE HOOD
REMOVAL
6. Remove six mounting bolts (5) and four mounting bolts (6).
INSTALLATION
• Carry out installation in the reverse order to removal.
30-226 WA500-3H
DISASSEMBLY AND ASSEMBLY CAB
CAB
REMOVAL
WA500-3H 30-227
DISASSEMBLY AND ASSEMBLY CAB
6. Remove plastic mounting bolts and pull up rubber boot (6) at bottom
of steering post.
7. Remove four bolts (7), then tip steering post over fully towards
operator’s seat.
• At the same time, set the column tilt lever to the unlock position
and tip the steering column over fully toward the operator’s seat.
8. Remove two cab mounting bolts (8) and four mounting bolts (9) each
at intermediate position and rear.
9. Raise cab assembly (10) slowly and keep horizontal when lifting off.
• Be careful that there is no interference with the electric wiring at
the rear right of the floor frame
.
• Cover the steering post and plastic cover with a sheet to prevent
any damage.
30-228 WA500-3H
DISASSEMBLY AND ASSEMBLY CAB
INSTALLATION
• Carry out installation in the reverse order to removal.
WA500-3H 30-229
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
FLOOR FRAME
REMOVAL
9. Disconnect hoses (11) between orbital steering valve (6) and stop valve.
10. Disconnect return hose (12) between orbital steering valve and
hydraulic tank.
30-230 WA500-3H
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
13. Remove mounting bolts (15), then remove brake hose bracket (16).
16. Disconnect accumulator charge valve connecting hoses (19) and (20).
• There are hose clamps at two places inside the engine hood.
Remove the hose clamps.
21. Remove clamp (25) and joint (26), then remove accelerator cable (27).
WA500-3H 30-231
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
23. Remove floor frame mount mounting nuts (30) (four places).
INSTALLATION
• Carry out installation in the reverse order to removal.
• Tighten radiator drain valve and add coolant through water filler to the specified level.
• Run the engine to circulate the coolant through the system. Then check the water level again.
30-232 WA500-3H
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT
REMOVAL
INSTALLATION
• Carry out installation in the reverse order to removal.
WA500-3H 30-233
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK
REMOVAL
8. Sling fuel tank assembly (8), then remove mounting bolts and slowly
lower the tank.
30-234 WA500-3H
DISASSEMBLY AND ASSEMBLY FUEL TANK
INSTALLATION
• Carry out installation in the reverse order to removal.
Fuel tank mounting bolt: 931.0 ±98.0 Nm (686 ±72 lbf ft)
WA500-3H 30-235
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL
3. Install freon gas collector and regenerator to plug (2), and collect
refrigerant.
30-236 WA500-3H
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
12. Remove mounting bolt (11), then remove air conditioner unit
assembly (12).
• Pull the unit out to the left and remove it.
INSTALLATION
• Carry out installation in the reverse order to removal.
• Using a gas charger (X3), charge with new freon gas (R134a).
WA500-3H 30-237
DISASSEMBLY AND ASSEMBLY CONDENSER
CONDENSER
REMOVAL
2. Install freon gas collector and regenerator to plugs (2), and collect
refrigerant.
INSTALLATION
• Carry out installation in the reverse order to removal.
30-238 WA500-3H
DISASSEMBLY AND ASSEMBLY RECEIVER TANK
RECEIVER TANK
REMOVAL
2. Install freon gas collector and regenerator to plugs (2), and collect
refrigerant.
INSTALLATION
• Carry out installation in the reverse order to removal.
WA500-3H 30-239
DISASSEMBLY AND ASSEMBLY COMPRESSOR ASSEMBLY
COMPRESSOR ASSEMBLY
REMOVAL
2. Install freon gas collector and regenerator to plugs (2), and collect
refrigerant.
3. Loosen adjustment bolt (3) and lock bolt (4), then remove belt (5)
and remove from compressor.
INSTALLATION
• Carry out installation in the reverse order to removal.
30-240 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
MAIN MONITOR
REMOVAL
1. After disconnecting the battery cable from the negative (-) terminal,
remove dashboards (1) and (2).
4. Remove mounting bolt caps (7) from steering post cover (6), them
remove bolts.
5. Remove mounting bolt caps (9) from steering post cover (8), them
remove bolts and tip cover forward.
WA500-3H 30-241
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
7. Remove eight mounting bolts (12), when removing main monitor
(11), be careful not to subject it to any strong shock.
8. Disconnect wiring connectors (13), (14), (15), and (16) from the
monitor.
INSTALLING
• Install the monitor in the reverse order of removal, and be sure to
lock connectors securely.
• For adjustment procedures, see TESTING AND ADJUSTING in
section 20.
30-242 WA500-3H
40 MAINTENANCE STANDARD
WA500-3H 40-1
MAINTENANCE STANDARD ENGINE MOUNT
12
ENGINE MOUNT
40-2 WA500-3H
MAINTENANCE STANDARD ENGINE MOUNT
3.0 - 7.0 mm
1 Clearance between engine mounting bracket and adjusting bolt Adjust
(0.118 - 0.276 in)
Torque Values
Item Nm lbf ft
a 275 +34
-29 203 +25
-22
WA500-3H 40-3
MAINTENANCE STANDARD TRANSMISSION MOUNT
TRANSMISSION MOUNT
40-4 WA500-3H
MAINTENANCE STANDARD TRANSMISSION MOUNT
Torque Values
Item Nm lbf ft
WA500-3H 40-5
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
40-6 WA500-3H
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
14 +0
-0.5 mm
3 Insertion depth of pin Replace
(0.006 +0
-0.002 in)
6.9 - 11.8 Nm
4 Rotating torque of spline shaft
(5 - 9 lbf ft)
Torque Values
Item Nm lbf ft
WA500-3H 40-7
MAINTENANCE STANDARD DAMPER
DAMPER
40-8 WA500-3H
MAINTENANCE STANDARD DAMPER
-0.009 mm -0.003 mm
Clearance between bearing 40 mm -0.034 mm -0.012 mm -0.034 mm 0.05 mm
1
and shaft (1.575 in) (-0.0004 in (-0.0005 in) (-0.0001 in (0.002 in)
-0.0013 in) -0.0013 in)
-0.013 mm
Clearance between bearing 80 mm -0.013 mm -0.030 mm -0.030 mm 0.035 mm
2
and housing (3.150 in) (-0.0005 in) (-0.0012 in) (-0.0005 in (0.0014 in)
-0.0012 in)
+0.012 mm -0.007 mm
Clearance between bearing 75 mm -0.007 mm -0.015 mm -0.027 mm 0.025 mm
3
and shaft (2.953 in) (+0.0005 in (-0.0006 in) (-0.0003 in (0.0010 in)
-0.0003 in) -0.0011 in)
-0.014 mm 0.014 mm
Clearance between retainer 135 mm -0.054 mm +0.04 mm 0.094 mm 0.13 mm
5
and cover (5.315 in) (-0.0006 in (+0.0015 in (0.0006 in (0.005 in)
-0.002 in) 0.004 in)
Torque Values
Item Nm lbf ft
b 66 ±7 49 ±5
c 4 ±1 3 ±1
d 88 ±34 65 ±25
WA500-3H 40-9
MAINTENANCE STANDARD TORQUE CONVERTER AND PTO
40-10 WA500-3H
MAINTENANCE STANDARD TORQUE CONVERTER AND PTO
0.18 - 0.49 mm
4 Backlash of PTO gear (drive gear)
(0.007 - 0.019 in)
Torque Values
Item Nm lbf ft
b 66 ±7 49 ±5
c 4 ±1 3 ±1
d 88 ±34 65 ±25
WA500-3H 40-11
MAINTENANCE STANDARD TORQUE CONVERTER AND PTO
MEMORANDUM
40-12 WA500-3H
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
WA500-3H 40-13
MAINTENANCE STANDARD TRANSMISSION
+0.016 mm +0.031 mm
Clearance between
-0.015 mm -0.006 mm -0.006 mm +0.037 mm
7 transmission input shaft
90 mm (-0.0006 in) (+0.0006 in (+0.0012 in (+0.0015 in)
bearing and housing
(3.543 in) -0.0002 in) -0.0002 in)
+0.016 mm +0.026 mm
Clearance between
72 mm -0.013 mm -0.006 mm -0.006 mm +0.031 mm
8 transmission output shaft
(2.835 in) (-0.0005 in) (+0.0006 in (+0.0010 in (+0.0012 in)
bearing and carrier
-0.0002 in) -0.0002 in)
+0.016 mm +0.031 mm
Clearance between
100 mm -0.015 mm -0.006 mm -0.006 mm +0.037 mm
9 transmission output shaft
(3.937 in) (-0.0006 in) (+0.0006 in (+0.0012 in (+0.0015 in)
bearing and housing
-0.0002 in) -0.0002 in)
40-14 WA500-3H
MAINTENANCE STANDARD TRANSMISSION
5 mm ±0.1 mm
16 Thickness of 1 disc
(0.197 in) (±0.004 in)
5 mm ±0.1 mm
17 Thickness of 1 plate
(0.197 in) (±0.004 in)
Torque Values
Item Nm lbf ft
b 110 ±12 81 ±9
WA500-3H 40-15
MAINTENANCE STANDARD TRANSMISSION
40-16 WA500-3H
MAINTENANCE STANDARD TRANSMISSION
Standard Repair
Tolerance
size limit
-0.01 mm
3.0 mm -0.03 mm 2.6 mm
Width
(0.118 in) (-0.0004 in (0.102 in)
1 Wear of seal ring for input shaft -0.0012 in)
-0.01 mm
4.0 mm -0.03 mm 3.5 mm
Width
(0.158 in) (-0.0004 in (0.138 in)
2 Wear of seal ring for output shaft -0.0012 in)
0.13 - 0.32 mm
3 Backlash between No. 1 sun gear and planet gear
(0.005 - 0.013 in)
0.15 - 0.38 mm
4 Backlash between No. 1 planet gear and ring gear and inside teeth
(0.006 - 0.015 in) Replace
0.13 - 0.32 mm
5 Backlash between No. 2 sun gear and planet gear
(0.005 - 0.013 in)
0.15 - 0.38 mm
6 Backlash between No. 2 planet gear and ring gear and inside teeth
(0.006 - 0.015 in)
0.12 - 0.30 mm
7 Backlash between No. 3 sun gear and planet gear
(0.005 - 0.012 in)
0.15 - 0.38 mm
8 Backlash between No. 3 planet gear and ring gear and inside teeth
(0.006 - 0.015 in)
0.13 - 0.32 mm
9 Backlash between No. 4 sun gear and planet gear
(0.005 - 0.013 in)
0.15 - 0.38 mm
10 Backlash between No. 4 planet gear and ring gear and inside teeth
(0.006 - 0.015 in)
0.14 - 0.35 mm
11 Backlash between No. 5 sun gear and planet gear
(0.006 - 0.014 in)
0.15 - 0.38 mm
12 Backlash between No. 5 planet gear and ring gear and inside teeth
(0.006 - 0.015 in)
WA500-3H 40-17
MAINTENANCE STANDARD TRANSFER
TRANSFER
40-18 WA500-3H
MAINTENANCE STANDARD TRANSFER
+0.045 mm -0.023 mm
85 mm +0.023 mm -0.020 mm -0.065 mm
1 Clearance between drive gear and bearing
(3.347 in) (+0.002 in (-0.0008 in) (-0.001 in
+0.001 in) (-0.003 in)
-0.012 mm 0.006 mm
150 mm -0.018 mm -0.052 mm -0.052 mm
2 Clearance between drive gear bearing and cage
(5.906 in) (-0.0007 in) (-0.0005 in (0.0002 in
-0.002 in) -0.002 in)
0.018 mm
150 mm -0.018 mm -0.040 mm -0.040 mm
3 Clearance between drive gear bearing and cage
(5.906 in) (-0.0007 in) (-0.002 in) (-0.0007 in
-0.002 in)
+0.059 mm -0.037 mm
95 mm -0.037 mm -0.020 mm -0.079 mm
4 Clearance between idler gear and bearing
(3.740 in) (+0.002 in (-0.0008 in) (-0.002 in
-0.002 in) -0.003 in)
0.025 mm
Clearance between drive gear bearing and case 170 mm -0.025 mm -0.040 mm -0.020 mm
5
(cover) (6.693 in) (-0.002 in) (-0.002 in) (0.001 in
Replace
-0.002 in)
+0.039 mm -0.020 mm
80 mm -0.020 mm -0.015 mm -0.054 mm
6 Clearance between output shaft and bearing
(3.150 in) (+0.0002 in (-0.0006 in) (-0.0008 in
-0.0008 in) -0.002 in)
-0.012 mm 0.006 mm
140 mm -0.018 mm -0.052 mm -0.052 mm
7 Clearance between output shaft bearing and cage
(5.512 in) (-0.0007 in) (-0.0005 in (0.0002 in
-0.002 in) -0.002 in)
+0.045 mm -0.023 mm
95 mm +0.023 mm -0.020 mm -0.065 mm
8 Clearance between spacer and bearing
(3.740 in) (+0.002 in (-0.0008 in) (-0.023 in
+0.001 in) -0.003 in)
-0.012 mm 0.013 mm
170 mm -0.025 mm -0.052 mm -0.052 mm
9 Clearance between output shaft bearing and housing
(6.693 in) (-0.002 in) (-0.0005 in (-0.0005 in
-0.002 in) -0.002 in)
Standard Repair
Tolerance
size limit
95 mm -0.087 mm 94.8 mm
10 Coupling oil seal contact surface
(3.740 in) (-0.003 in) (3.732 in)
WA500-3H 40-19
MAINTENANCE STANDARD TRANSFER
14 Backlash between drive gear and idler gear 0.17 - 0.44 mm (0.007 - 0.017 in)
Replace
15 Backlash between idler gear and driven gear 0.17 - 0.44 mm (0.007 - 0.017 in)
Torque Values
Item Nm lbf ft
b 110 ±12 81 ±9
c 69 ±10 51 ±7
40-20 WA500-3H
MAINTENANCE STANDARD TRANSFER
MEMORANDUM
WA500-3H 40-21
MAINTENANCE STANDARD MAIN RELIEF, T. C. RELIEF VALVE
40-22 WA500-3H
MAINTENANCE STANDARD MAIN RELIEF, T. C. RELIEF VALVE
-0.035 mm 0.035 mm
Clearance between main relief 25 mm -0.045 mm +0.013 mm 0.058 mm 0.08 mm
1
valve and valve body (0.984 in) (-0.0014 in (+0.0005 in) (0.0014 in (0.003 in)
-0.0018 in) 0.0023 in)
-0.035 mm 0.035 mm
Clearance between torque 22 mm -0.045 mm +0.013 mm 0.058 mm 0.08 mm
2
converter valve and valve body (0.866 in) (-0.0014 in (+0.0005 in) (0.0014 in (0.003 in)
-0.0018 in) 0.0023 in)
Replace
Standard size Repair limit
Torque Values
Item Nm lbf ft
a 49 ±4.9 Nm 36 ±4
WA500-3H 40-23
MAINTENANCE STANDARD LUBRICATION RELIEF VALVE
40-24 WA500-3H
MAINTENANCE STANDARD LUBRICATION RELIEF VALVE
WA500-3H 40-25
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
40-26 WA500-3H
MAINTENANCE STANDARD DRIVE SHAFT
Torque Values
Item Nm lbf ft
b 110 ±12 81 ±9
WA500-3H 40-27
MAINTENANCE STANDARD CENTER SUPPORT
CENTER SUPPORT
40-28 WA500-3H
MAINTENANCE STANDARD CENTER SUPPORT
-0.036 mm -0.018 mm
140 mm -0.018 mm -0.061 mm -0.061 mm -0.015 mm
1 Clearance between case and bearing
(5.512 in) (-0.0007 in) (-0.0014 in (-0.0007 in (-0.0006 in)
-0.0024 in) -0.0024 in)
-0.036 mm -0.018 mm
130 mm -0.018 mm -0.061 mm -0.061 mm -0.015 mm
2 Clearance between case and bearing
(5.118 in) (-0.0007 in) (-0.0014 in (-0.0007 in (-0.0006 in) Replace
-0.0024 in) -0.0024 in)
+0.051 mm 0.032 mm
Clearance between coupling shaft
80 mm +0.032 mm -0.015 mm 0.066 mm 0.029 mm
3 and
(3.150 in) (+0.0020 in (-0.0006 in) (0.0013 in (0.0011 in)
bearing
+0.0013 in) 0.0026 in)
+0.051 mm 0.032 mm
Clearance between coupling shaft
75 mm +0.032 mm -0.015 mm 0.066 mm 0.029 mm
4 and
(2.953 in) (+0.0020 in (-0.0006 in) (0.0013 in (0.0011 in)
bearing
+0.0013 in) 0.0026 in)
Torque Values
Item Nm lbf ft
b 66 ±7 49 ±5
WA500-3H 40-29
MAINTENANCE STANDARD DIFFERENTIAL, NORMAL - (STANDARD)
40-30 WA500-3H
MAINTENANCE STANDARD DIFFERENTIAL, NORMAL - (STANDARD)
+0.054 mm 0.014 mm
Clearance of side bearing (outer race) in differential 180 mm -0.025 mm +0.014 mm 0.079 mm
1
gear assembly (7.087 in) (-0.0010 in) (+0.0021 in (0.0006 in
+0.0006 in) 0.0031 in)
+0.045 mm -0.023 mm
Clearance of side bearing (inner race) in differential 120 mm +0.023 mm -0.020 mm -0.065 mm
2
gear assembly (4.724 in) (+0.0018 in (-0.0008 in) (-0.0009 in
+0.0009 in) -0.0026 in)
+0.026 mm 0.026 mm
171.45 mm +0.025 mm -0.014 mm -0.039 mm
3 Clearance of pinion shaft bearing (outer race)
(6.75 in) (+0.0010 in) (+0.0010 in (0.0010 in
-0.0006 in) -0.0015 in)
+0.064 mm -0.025 mm
76.2 mm +0.038 mm +0.013 mm -0.064 mm
4 Clearance of pinion shaft bearing (inner race)
(3.00 in) (+0.0025 in (+0.0005 in) (0.0010 in
+0.0015 in) -0.0025 in)
+0.030 mm
0.002 mm
76.2 mm +0.011 mm +0.013 mm
5 Clearance of pinion shaft bearing (inner race) -0.030 mm
(3.00 in) (+0.0012 in (+0.0005 in)
(-0.002 in)
+0.0004 in)
13 Free rotating torque of bevel gear Max. 8.34 Nm {6.15 lbf ft)
15 Standard thickness of shims for stop shaft Clearance "a" + (0.1 ±0.05 mm / 0.0039 ±0.002 in)
WA500-3H 40-31
MAINTENANCE STANDARD DIFFERENTIAL, NORMAL - (STANDARD)
40-32 WA500-3H
MAINTENANCE STANDARD DIFFERENTIAL, NORMAL - (STANDARD)
Standard Repair
Tolerance
size limit
+0.05 mm
4 mm -0.05 mm 3.8 mm
1 Thickness of side gear washer
(0.158 in) (+0.002 in (0.150 in)
-0.002 in)
Replace
+0.09 mm
1.5 mm -0.01 mm 1.35 mm
2 Thickness of pinion gear washer
(0.059 in) (+0.004 in (0.053 in)
-0.0004 in)
100 mm -0.087 mm
3 Wear of oil seal surface -
(3.937 in) (-0.0034 in)
Torque Values
Item Nm lbf ft
f 31 ±3 23 ±3
WA500-3H 40-33
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-34 WA500-3H
MAINTENANCE STANDARD FINAL DRIVE
+0.033 mm -0.004 mm
Clearance between ring gear hub 190 mm +0.004 mm -0.030 mm -0.063 mm
2 -
and bearing (7.480 in) (+0.0013 in (-0.0012 in) (-0.0002 in
+0.0002 in) -0.0025 in)
Replace
Standard
Tolerance Repair limit
size
3 Thickness of spacer
22 mm ±0.1 mm 21.5 mm
(0.866 in) (±0.0039 in) (0.847 in)
Torque Values
Item Nm lbf ft
a 31 ±3 23 ±3
c 110 ±12 81 ±9
e 69 ±10 51 ±7
WA500-3H 40-35
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
40-36 WA500-3H
MAINTENANCE STANDARD AXLE MOUNT
-0.056 mm 0.056 mm
Clearance of shaft and hole front
310 mm -0.137 mm +0.489 mm 0.626 mm 1.6 mm
1 support side (after press fitting
(12.205 in) (-0.002 in (+0.019 in) (0.002 in (0.063 in)
bushing)
-0.005 in) 0.025 in)
+2.30 mm
Clearance of shaft and hole front
320.2 mm -0.80 mm +0.089 mm
2 support side (before installing - - Replace
(12.606 in) (+0.090 in (+0.004 in)
bushing) (see note)
-0.032 in)
+2.30 mm
Clearance of shaft and hole front
270.2 mm -0.80 mm +0.081 mm
4 support side (before installing - -
(10.638 in) (+0.090 in (+0.003 in)
bushing
-0.032 in)
Standard
Tolerance Repair limit
size
-0.10 mm
20 mm -0.25 mm
5 Thickness of wear plate -
(0.787 in) (-0.0039 in
-0.010 in)
+0.1 mm
Replace
5 mm -0.3 mm
6 Thickness of wear plate -
(0.197 in) (+0.0039 in
-0.012 in)
5 mm ±0.1 mm
7 Thickness of rear bushing -
(0.197 in) (±0.0039 in)
5 mm ±0.1 mm
8 Thickness of front bushing -
(0.197 in) (±0.0039 in)
note The bushings must be in contact with the support at both the front and rear
Torque Values
Item Nm lbf ft
WA500-3H 40-37
MAINTENANCE STANDARD CENTER HINGE PIN
40-38 WA500-3H
MAINTENANCE STANDARD CENTER HINGE PIN
-0.036 mm 0.036 mm
Clearance between lower hinge pin and rear 100 mm -0.058 mm +0.054 mm 0.112 mm
1
frame (3.937 in) (-0.001 in (+0.002 in) (0.001 in
-0.002 in) 0.004 in)
-0.036 mm 0.036 mm
Clearance between lower hinge pin and spacer 100 mm -0.058 mm +0.054 mm 0.112 mm
2
(small) (3.937 in) (-0.001 in (+0.002 in) (0.001 in
-0.002 in) 0.004 in)
-0.036 mm 0.016 mm
Clearance between lower hinge pin and 100 mm -0.058 mm -0.020 mm 0.058 mm
3
bearing (3.937 in) (-0.001 in (-0.001 in) (0.001 in
-0.002 in) 0.002 in)
-0.036 mm 0.036 mm
Clearance between lower hinge pin and spacer 100 mm -0.058 mm +0.054 mm 0.112 mm
4
(large) (3.937 in) (-0.001 in (+0.002 in) (0.001 in
-0.002 in) 0.004 in)
-0.043 mm 0.043 mm
Clearance between rear frame and spacer 130 mm -0.106 mm +0.063 mm 0.169 mm
5
(large) (5.118 in) (-0.002 in (+0.003 in) (0.002 in
-0.004 in) 0.007 in)
-0.048 mm -0.023 mm
Clearance between front frame and upper 155 mm -0.025 mm -0.088 mm -0.088 mm
6
hinge bearing (6.102 in) (-0.001 in) (-0.002 in (-0.001 in Replace
-0.004 in) -0.004 in)
-0.036 mm 0.036 mm
Clearance between upper hinge pin and rear 100 mm -0.058 mm +0.054 mm 0.112 mm
7
frame (3.937 in) (-0.001 in (+0.002 in) (0.001 in
-0.002 in) 0.004 in)
-0.036 mm 0.016 mm
Clearance between upper hinge pin and 100 mm -0.058 mm -0.020 mm 0.058 mm
8
bearing (3.937 in) (-0.001 in (-0.001 in) (0.001 in
-0.002 in) 0.002 in)
-0.050 mm -0.025 mm
Clearance between front frame and lower 160 mm -0.025 mm -0.090 mm -0.090 mm
9
hinge bearing (6.299 in) (-0.001 in) (-0.002 in (-0.001 in
-0.004 in) -0.004 in)
-0.043 mm 0.043 mm
125 mm -0.106 mm +0.063 mm 0.169 mm
10 Clearance between rear frame and bushing
(4.921 in) (-0.002 in (+0.003 in) (0.002 in
-0.004 in) 0.007 in)
+0.280 mm -0.126 mm
Clearance at press fitted part of seal of upper 115 mm +0.180 mm +0.054 mm -0.280 mm
11
hinge pin (4.528 in) (+01011 in (+0.002 in) (-0.005 in
+0.007 in) -0.011 in)
+0.310 mm -0.147 mm
Clearance at press fitted part of seal of lower 135 mm +0.210 mm +0.063 mm -0.310 mm
12
hinge pin (5.315 in) (+0.012 in (+0.003 in) (-0.006 in
+0.008 in) -0.012 in)
WA500-3H 40-39
MAINTENANCE STANDARD CENTER HINGE PIN
13 Height of lower hinge spacer (small) 35 mm (1.387 in) ±0.1 (±0.0039 in) Replace
14 Height of lower hinge spacer (large) 101.5 mm (3.996 in) ±0.1 (±0.0039 in)
15 Shim thickness for lower hinge and retainer 2.3 mm (0.090 in)
16 Shim thickness for lower hinge and retainer 1.6 mm (0.063 in ) Adjust
Torque Values
Item Nm lbf ft
40-40 WA500-3H
MAINTENANCE STANDARD CENTER HINGE PIN
MEMORANDUM
WA500-3H 40-41
MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
40-42 WA500-3H
MAINTENANCE STANDARD STEERING COLUMN
+0.150 mm 0.050 mm
Clearance between steering shaft and column 19 mm -0.080 mm +0.050 mm 0.230 mm Replace
1
bushing (0.748 in) (-0.003 in) (+0.006 in (0.002 in
+0.002 in) 0.010 in)
Torque Values
Item Nm lbf ft
a 34 ±5 25 ±4
b 44 ±10 33 ±7
c 29 ±3 21 ±2
d 52 ±8 38 ±5
e 55 ±7 41 ±5
WA500-3H 40-43
MAINTENANCE STANDARD STEERING PUMP
STEERING PUMP
Clearance between gear case and side plate, 0.10 - 0.15 mm 0.19 mm
1
gear (0.004 - 0.006 in) (0.007 in)
Replace
Clearance between inside diameter of plain 0.06 - 0.149 mm 0.20 mm
2
bearing and outside diameter of gear shaft (0.002 - 0.006 in) (0.008 in)
+0 +0
3 insertion depth of pin 14 -0.5 mm (0.55 -0.02 in)
Torque Values
Item Nm lbf ft
40-44 WA500-3H
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
37.2 mm 32 mm 57 N 45 N
1 Steering spool return spring -
(1.465 in) (1.260 in) (13 lbf) (10 lbf)
20.9 mm 13.2 mm 9 ±5 N 8N
2 Load check valve spring -
(0.823 in) (0.520 in) (2 ±1 lbf) (2 lbf) Replace
21.6 mm 17.0 mm 2N 2N
5 Check valve return spring -
(0.850 in) (0.669 in) (0.5 lbf) (0.45 lbf)
WA500-3H 40-45
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
40-46 WA500-3H
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
Tolerance Standard
Standard size
Shaft Hole clearance
0 mm +0.200 mm 0.100 mm
Clearance between mounting pin and
60 mm -0.074 mm +0.100 mm 0.248 mm
1 bushing connection of steering cylinder
(2.362 in) (0 in (+0.008 in (0.004 in Replace
rod and frame
-0.003 in) +0.004 in) 0.010 in)
0 mm +0.200 mm 0.100 mm
Clearance between mounting pin and
60 mm -0.074 mm +0.100 mm 0.248 mm
2 bushing connection of steering cylinder
(2.362 in) (0 in (+0.008 in (0.004 in
bottom and frame
-0.003 in) +0.004 in) 0.010 in)
Standard clearance
Width of boss Width of hinge
(Clearance a + b) Max. 1.0 mm
(0.030 in)
Connection of steering cylinder and 70 +0.8 mm 74 ±1 mm 2.2 - 5.0 mm
3 after
front frame (2.756 +0.032 in) (2.913 ±0.039 in) (0.087 - 0.197 in)
adjusting
Connection of steering cylinder and 70 -0.5 mm 74 ±1 mm 3.0 - 5.5 mm shim
4
rear frame (2.756 -0.020 in) (2.913 ±0.039 in) (0.118 - 0.217 in)
WA500-3H 40-47
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
RIGHT
40-48 WA500-3H
MAINTENANCE STANDARD BRAKE VALVE
-0.025 mm 0.175 mm
Clearance between pedal mount 10 mm -0.075 mm +0.1 mm 0.025 mm 0.25 mm
1
hole and bracket hole (0.394 in) (-0.001 in (+0.004 in) (0.007 in (0.010 in)
-0.003 in) 0.001 in)
-0.025 mm 0.175 mm
10 mm -0.075 mm +0.1 mm 0.025 mm 0.25 mm
2 Clearance between roller and pin
(0.394 in) (-0.001 in (+0.004 in) (0.007 in (0.010 in)
-0.003 in) 0.001 in)
Standard
Tolerance Repair limit
size
30 mm
3 Outside diameter of roller -0.5 mm (0.020 in) 29.2 mm (1.150 in)
(1.181 in)
Replace
Standard size Repair limit
Free Free
Test height Test load Test load
length length
34 mm 21.8 mm 93.2 N 33 mm
4 Control spring
(1.339 in) (0.858 in) (21 lbf) (1.299 in)
86.2 mm 58 mm 60.8 N 78 mm
6 Return spring
(3.394 in) (2.284 in) (14 lbf) (3.071 in)
17 mm 15 mm 69.6 N 16.2 mm
7 Spring
(0.669 in) (0.591 in) (16 lbf) (0.638 in)
Torque Values
Item Nm lbf ft
a 66 ±7 49 ±5
c 8 ±2 6 ±1.5
WA500-3H 40-49
MAINTENANCE STANDARD BRAKE VALVE
LEFT
40-50 WA500-3H
MAINTENANCE STANDARD BRAKE VALVE
-0.025 mm 0.175 mm
Clearance between pedal mount 10 mm -0.075 mm +0.1 mm 0.025 mm 0.25 mm
1
hole and bracket hole (0.394 in) (-0.001 in (+0.004 in) (0.007 in (0.010 in)
-0.003 in) 0.001 in)
-0.025 mm 0.175 mm
10 mm -0.075 mm +0.1 mm 0.025 mm 0.25 mm
2 Clearance between roller and pin
(0.394 in) (-0.001 in (+0.004 in) (0.007 in (0.010 in)
-0.003 in) 0.001 in)
Standard
Tolerance Repair limit
size
30 mm
3 Outside diameter of roller -0.5 mm (0.020 in) 29.2 mm (1.150 in)
(1.181 in)
Replace
Standard size Repair limit
Free Free
Test height Test load Test load
length length
34 mm 21.8 mm 93.2 N 33 mm
4 Control spring
(1.339 in) (0.858 in) (21 lbf) (1.299 in)
86.2 mm 58 mm 60.8 N 78 mm
6 Return spring
(3.394 in) (2.284 in) (14 lbf) (3.071 in)
17 mm 15 mm 69.6 N 16.2 mm
7 Spring
(0.669 in) (0.591 in) (16 lbf) (0.638 in)
Torque Values
Item Nm lbf ft
a 66 ±7 49 ±5
c 8 ±2 6 ±1.5
WA500-3H 40-51
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
40-52 WA500-3H
MAINTENANCE STANDARD SLACK ADJUSTER
-0.030 mm 0.030 mm
55 mm -0.076 mm +0.074 mm 0.150 mm 0.25 mm
1 Clearance between body and piston
(2.165 in) (-0.001 in (+0.003 in) (0.001 in (0.010 in)
-0.003 in) 0.006 in)
Free Free
Test length Test load Test load
length length
198 mm 38 mm 43.2 N
2 Spring - -
(7.795 in) (1.496 in) (10 lbf)
39.2 mm 33 mm 66.7 N
3 Spring - -
(1.543 in) (1.299 in) (15 lbf)
Torque Values
Item Nm lbf ft
a 56 ±7 41 ±5
b 66 ±7 49 ±5
WA500-3H 40-53
MAINTENANCE STANDARD BRAKE
BRAKE
40-54 WA500-3H
MAINTENANCE STANDARD BRAKE
Repair
Standard size Tolerance
limit
42.0 mm +0.097 mm
5 Wear of piston seal contact surface -
(1.654 in) (+0.004 in)
38.3 mm +0.089 mm
6 Wear of piston seal contact surface -
(1.509 in) (+0.004 in)
Torque Values
Item Nm lbf ft
WA500-3H 40-55
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
40-56 WA500-3H
MAINTENANCE STANDARD PARKING BRAKE
Repair
Standard size Tolerance
limit
WA500-3H 40-57
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
SAR(4)-160
40-58 WA500-3H
MAINTENANCE STANDARD HYDRAULIC PUMP
Clearance between gear case and side plate, 0.11 - 0.16 mm 0.19 mm
1 gear (0.004 - 0.006 in) (0.007 in)
Replace
Clearance between inside diameter of plain 0.06 - 0.140 mm 0.20 mm
2
bearing and outside diameter of gear shaft (0.002 - 0.006 in) (0.008 in)
+0 +0
3 Insertion depth of pin 14 -0.5 mm (0.55 -0.02 in)
Torque Values
Item Nm lbf ft
WA500-3H 40-59
MAINTENANCE STANDARD SWITCH, PPC PUMP
SAR(3)-63 + SAR(1)-28
40-60 WA500-3H
MAINTENANCE STANDARD SWITCH, PPC PUMP
10 mm -0.5 mm
SAR(3)-63
(0.394 in) (-0.020 in)
3 Insertion depth of pin
10 mm -0.5 mm
SAR(1)-28
(0.394 in) (-0.020 in)
WA500-3H 40-61
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
Torque Values
Item Nm lbf ft
a 44.1 ±4.9 33 ±4
b 17.7 ±3.9 13 ±3
40-62 WA500-3H
MAINTENANCE STANDARD PPC VALVE
Torque Values
Item Nm lbf ft
a 44.1 ±4.9 33 ±4
b 17.7 ±3.9 13 ±3
WA500-3H 40-63
MAINTENANCE STANDARD CUT-OFF VALVE
CUT-OFF VALVE
Torque Values
Item Nm lbf ft
a 66.2 ±7.4 49 ±6
b 2.21 ±0.25 2
b 34.3 ±4.9 25 ±4
40-64 WA500-3H
MAINTENANCE STANDARD CUT-OFF VALVE
MEMORANDUM
WA500-3H 40-65
MAINTENANCE STANDARD MAIN CONTROL VALVE
2 SPOOL VALVE
40-66 WA500-3H
MAINTENANCE STANDARD MAIN CONTROL VALVE
42.0 mm 42.0 mm
6 Boom spool return spring (small) 0 - -
(1.654 in) (1.654 in)
42.0 mm 42.0 mm
8 Bucket spool return spring (small) 0 - -
(1.654 in) (1.654 in)
82.7 mm 47.0 mm 49 N 39 N
14 Unloader valve spring -
(3.256 in) (1.850 in) (11 lbf) (9 lbf)
Torque Values
Item Nm lbf ft
c 88 ±10 65 ±7
e 69 ±10 51 ±7
f 22 ±3 16 ±2
WA500-3H 40-67
MAINTENANCE STANDARD MAIN CONTROL VALVE
3-SPOOL
40-68 WA500-3H
MAINTENANCE STANDARD MAIN CONTROL VALVE
42.0 mm 42.0 mm
8 Boom spool return spring (small) 0 - -
(1.654 in) (1.654 in)
42.0 mm 42.0 mm
10 Bucket spool return spring (small) 0 - -
(1.654 in) (1.654 in)
42.0 mm 42.0 mm
12 Attachment spool return spring (small) 0 - -
(1.654 in) (1.654 in)
82.7 mm 47.0 mm 49 N 39 N
18 Unloader valve spring -
(3.256 in) (1.850 in) (11 lbf) (9 lbf)
WA500-3H 40-69
MAINTENANCE STANDARD MAIN CONTROL VALVE
Torque Values
Item Nm lbf ft
c 88 ±10 65 ±7
e 69 ±10 51 ±7
f 22 ±3 16 ±2
40-70 WA500-3H
MAINTENANCE STANDARD MAIN CONTROL VALVE
MEMORANDUM
WA500-3H 40-71
MAINTENANCE STANDARD HYDRAULIC CYLINDERS
HYDRAULIC CYLINDERS
40-72 WA500-3H
MAINTENANCE STANDARD HYDRAULIC CYLINDERS
+0.174 mm 0.100 mm
60 mm -0.074 mm +0.100 mm 0.248 mm 1.0 mm
Steering
(2.362 in) (-0.003 in) (+0.007 in (0.004 in (0.039 in)
+0.004 in) 0.010 in)
Clearance between piston
120 mm +0.100 mm
2 rod mounting pin and Boom - - -
(4.724 in) (+0.004 in)
diameter of hole
+0.307 mm
120 mm +0.220 mm
Bucket - - - Replace
(4.724 in) (+0.012 in
+0.009 in)
0.100 mm
60 mm -0.074 mm +0.174 mm 0.248 mm 1.0 mm
Steering
(2.362 in) (-0.003 in) +0.100 mm (0.004 in (0.039 in)
0.010 in)
+0.307 mm
Clearance between cylinder
120 mm +0.220 mm
3 bottom mounting pin and Boom - - -
(4.724 in) (+0.012 in
bushing
+0.009 in)
+0.307 mm
120 mm +0.220 mm
Bucket - - -
(4.724 in) (+0.012 in
+0.009 in)
Repair
Standard size Tolerance
limit
110 mm +0.150
Steering -
(4.331 in) (+0.006 in)
200 mm +0.200
4 Cylinder bore Boom -
(7.874 in) (+0.008 in)
225 mm +0.200
Bucket -
(7.874 in) (+0.008 in)
WA500-3H 40-73
MAINTENANCE STANDARD HYDRAULIC CYLINDERS
Torque Values
Item Nm lbf ft
40-74 WA500-3H
MAINTENANCE STANDARD HYDRAULIC CYLINDERS
MEMORANDUM
WA500-3H 40-75
MAINTENANCE STANDARD BUCKET LINKAGE
BUCKET LINKAGE
40-76 WA500-3H
MAINTENANCE STANDARD BUCKET LINKAGE
WA500-3H 40-77
MAINTENANCE STANDARD BUCKET LINKAGE
40-78 WA500-3H
MAINTENANCE STANDARD BUCKET
BUCKET
61 mm 23 mm Replace
1 Wear of bucket tooth
(2.402 in) (0.906 in)
Max. 0.5 mm
2 Thickness of shims for tooth (Clearance between tooth and bucket) Adjust
(Max. 0.020 in)
WA500-3H 40-79
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-
3 Tightening torque of mounting bolt for adjuster 88 ±34 Nm (65 ±25 lbf ft)
Retighten
3 Tightening torque of mounting bolt for switch 18 ±2 Nm (13 ±2 lbf ft)
40-80 WA500-3H
MAINTENANCE STANDARD ROPS CAB
ROPS CAB
Torque Values
Item Nm lbf ft
WA500-3H 40-81
MAINTENANCE STANDARD ROPS CAB
MEMORANDUM
40-82 WA500-3H
90 OTHERS
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 90-49
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 90-51
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 90-53
STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-55
STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-57
STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-59
HYDRAULIC LINE ASSEMBLY (PART 1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-61
HYDRAULIC LINE ASSEMBLY (PART 2 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-63
HYDRAULIC LINE ASSEMBLY (PART 3 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-65
WA500-3H 90-1
12
MEMORANDUM
OTHERS FOLDOUT 10-18
TRANSMISSION CUTAWAY
WA500-3H 90-3
OTHERS MEMORANDUM
MEMORANDUM
90-4 WA500-3H
OTHERS FOLDOUT 10-225-1
ELECTRIACL DIAGRAMS
ECSS WIRING DIAGRAM
WA500-3H 90-5
OTHERS MEMORANDUM
MEMORANDUM
90-6 WA500-3H
OTHERS FOLDOUT 10-225-2
WA500-3H 90-7
OTHERS MEMORANDUM
MEMORANDUM
90-8 WA500-3H
OTHERS FOLDOUT 10-225-3
WA500-3H 90-9
OTHERS MEMORANDUM
MEMORANDUM
90-10 WA500-3H
OTHERS FOLDOUT 10-225-4
WA500-3H 90-11
OTHERS MEMORANDUM
MEMORANDUM
90-12 WA500-3H
OTHERS FOLDOUT 10-225-5
WA500-3H 90-13
OTHERS MEMORANDUM
MEMORANDUM
90-14 WA500-3H
OTHERS FOLDOUT 10-225-6
WA500-3H 90-15
OTHERS MEMORANDUM
MEMORANDUM
90-16 WA500-3H
OTHERS FOLDOUT 10-225-7
WA500-3H 90-17
OTHERS MEMORANDUM
MEMORANDUM
90-18 WA500-3H
OTHERS FOLDOUT 10-225-8
WA500-3H 90-19
OTHERS MEMORANDUM
MEMORANDUM
90-20 WA500-3H
OTHERS FOLDOUT 10-225-9
WA500-3H 90-21
OTHERS MEMORANDUM
MEMORANDUM
90-22 WA500-3H
OTHERS FOLDOUT 10-225-10
WA500-3H 90-23
OTHERS MEMORANDUM
MEMORANDUM
90-24 WA500-3H
OTHERS FOLDOUT 10-225-11
WA500-3H 90-25
OTHERS MEMORANDUM
MEMORANDUM
90-26 WA500-3H
OTHERS FOLDOUT 10-225-12
WA500-3H 90-27
OTHERS MEMORANDUM
MEMORANDUM
90-28 WA500-3H
OTHERS FOLDOUT 10-225-13
WA500-3H 90-29
OTHERS MEMORANDUM
MEMORANDUM
90-30 WA500-3H
OTHERS FOLDOUT 10-54-1-1
WA500-3H 90-31
OTHERS MEMORANDUM
MEMORANDUM
90-32 WA500-3H
OTHERS FOLDOUT 20-153-2
WA500-3H 90-33
OTHERS MEMORANDUM
MEMORANDUM
90-34 WA500-3H
OTHERS FOLDOUT 20-153-3
WA500-3H 90-35
OTHERS MEMORANDUM
MEMORANDUM
90-36 WA500-3H
OTHERS FOLDOUT 20-153-4
WA500-3H 90-37
OTHERS MEMORANDUM
MEMORANDUM
90-38 WA500-3H
OTHERS FOLDOUT 20-153-5
WA500-3H 90-39
OTHERS MEMORANDUM
MEMORANDUM
90-40 WA500-3H
OTHERS FOLDOUT 20-153-6
WA500-3H 90-41
OTHERS MEMORANDUM
MEMORANDUM
90-42 WA500-3H
OTHERS FOLDOUT 20-153-7
WA500-3H 90-43
OTHERS MEMORANDUM
MEMORANDUM
90-44 WA500-3H
OTHERS FOLDOUT 10-96
2. Neutralizer relay
9. Charge valve
10. Accumulator
WA500-3H 90-45
OTHERS MEMORANDUM
MEMORANDUM
90-46 WA500-3H
OTHERS FOLDOUT 10-105
HYDRAULIC
CIRCUIT DIAGRAM
WA500-3H 90-47
OTHERS MEMORANDUM
MEMORANDUM
90-48 WA500-3H
OTHERS FOLDOUT 10-54-1-1
WA500-3H 90-49
OTHERS MEMORANDUM
MEMORANDUM
90-50 WA500-3H
OTHERS FOLDOUT 10-54-1-2
WA500-3H 90-51
OTHERS MEMORANDUM
MEMORANDUM
90-52 WA500-3H
OTHERS FOLDOUT 10-54-1-3
WA500-3H 90-53
OTHERS MEMORANDUM
MEMORANDUM
90-54 WA500-3H
OTHERS FOLDOUT 10-54-2-1
WA500-3H 90-55
OTHERS MEMORANDUM
MEMORANDUM
90-56 WA500-3H
OTHERS FOLDOUT 10-54-2-2
WA500-3H 90-57
OTHERS MEMORANDUM
MEMORANDUM
90-58 WA500-3H
OTHERS FOLDOUT 10-54-2-3
WA500-3H 90-59
OTHERS MEMORANDUM
MEMORANDUM
90-60 WA500-3H
OTHERS FOLDOUT 10-100-1
WA500-3H 90-61
OTHERS MEMORANDUM
MEMORANDUM
90-62 WA500-3H
OTHERS FOLDOUT 10-100-2
WA500-3H 90-63
OTHERS MEMORANDUM
MEMORANDUM
90-64 WA500-3H
OTHERS FOLDOUT 10-54-2-3
WA500-3H 90-65
OTHERS MEMORANDUM
MEMORANDUM
90-66 WA500-3H