Wa600-3 Sebd013216.pdf

SEBM013216

MACHINE MODEL

SERIAL NUMBER

WA600-3 50001 and up WA600-3D (TBG SPEC.) 50001 and up •

This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.

•

WA600-3 mounts the SA6D170E-2 or SAA6D170E-3 engine. For details of the engine, see the 6D170-2 or 6D170-3 Series Engine Shop Manual.

© 2005 1 All Rights Reserved Printed in Japan 06-05(02)

00-1 (16)

CONTENTS

01

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

10

STRUCTURE AND FUNCTION

20

TESTING AND ADJUSTING

30

DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

40

MAINTENANCE STANDARD ............................................................... 40-1

90

OTHERS

00-2 2

........................................................... 10-1

................................................................ 20-1

............................................................................................................... 90-1

WA600-3

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(6) (6) (6) (8) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6)

(16) (16) (6) (16) (16) (16) (16) (16) (16) (16) (16) (16) (6) (16) (16) (16) (6)

(6) (6)

(6) (6) (6) (6)

00-2-5 (16)

SAFETY

SAFETY NOTICE

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

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and 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, hand shield, 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. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. 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. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.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. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.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 prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-4

SAFETY NOTICE

19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

FOREWORD

GENERAL

FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISIONS

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

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 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

00-6

Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks

k

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

5

Oil, water

Places where oil, water or fuel must be added, and the capacity.

6

Drain

Places where oil or water m u s t b e d r a i n ed , a n d quantity to be drained.

a

4

3 2

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 •

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

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 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

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.

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load.

k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

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 kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

! The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ! The adapter can be pushed in about 3.5 mm. ! Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ! Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ! Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ! When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

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

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

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

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

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

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

•

•

Disassembly

Type 2

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

Connection

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

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS ! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. ! For coating materials not listed below, use the equivalent of products shown in this list. Category

Komatsu code

Part No.

LT-1A

790-129-9030

LT-1B

790-129-9050

LT-2

09940-00030

LT-3

790-129-9060 (Set of adhesive and hardening agent)

LT-4

790-129-9040

Holtz MH 705

790-126-9120

Three bond 1735

790-129-9140

Aron-alpha 201

790-129-9130

Loctite 648-50

79A-129-9110

LG-1

790-129-9010

LG-5

790-129-9080

LG-6

790-129-9020

LG-7

790-129-9070

Three bond 1211

790-129-9090

Three bond 1207B

419-15-18131

Adhesives

Gasket sealant

00-10

Q’ty

Container

Main applications, features

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, 20 g Polyethylene polyprophylene, tetrafluoroethlene and (2 pcs.) container vinyl chloride), rubber, metal and nonmetal. • Features: Resistance to heat and chemicals Polyethylene 50 g • Used for anti-loosening and sealant container purpose for bolts and plugs. • Used as adhesive or sealant for metal, Adhesive: glass and plastic. 1 kg Hardening Can agent: 500 g Polyethylene • Used as sealant for machined holes. 250 g container • Used as heat-resisting sealant for 75 g Tube repairing engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive • Quick cure type Polyethylene (max. strength after 30 minutes) 2g container • Used mainly for adhesion of rubbers, plastics and metals. • Resistance to heat, chemicals Polyethylene • Used at joint portions subject to high 50 cc container temperatures. • Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold 200 g Tube • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, 1 kg Tube intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for 100 g Tube repairing engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material • Used as sealing material for transfer case 150 g

Tube

FOREWORD

Molybdenum disulphide lubricant

Komatsu code

Part No.

Q’ty

Container

LM-G

09940-00051

60 g

Can

LM-P

09940-00040

200 g

Tube

Various

Various

G2-LI

G2-CA

Grease

Primer

Adhesive

Caulking material

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95

SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381

SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)

Various

Various

400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can

400 g 16 kg

400 g 16 kg

Main applications, features • Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc. • General purpose type

• Used for normal temperature, light load bearing at places in contact with water or steam.

• Used for heavy load portion

• Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type • Since this grease is white, it does not Can stand out against machine body. • Since this grease is decomposed by bacteria in short period, it has less effects Bellows type on microorganisms, animals, and plants. Can

20 ml

Glass container

20 ml

Glass container

22M-54-27230

20 ml

Glass container

22M-54-27240

150 ml

Can

22M-54-27250

20 ml

Glass container

22M-54-27210

320 ml

Ecocart (Special container)

• Used as primer for cab side (Using limit: 4 months)

417-926-3910

417-926-3910

320 ml

Polyethylene container

20Y-54-39850

310 ml

Polyethylene container

417-926-3920

320 ml

Polyethylene container

20Y-54-55130

333 ml

Polyethylene container

22M-54-27220

333 ml

Cartridge

• Used as primer for glass side (Using limit: 4 months)

Adhesive for cab glass

Category

COATING MATERIALS

• Used as primer for painted surface on cab side (Using limit: 4 months) • Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) • Used as primer for sash (Alumite). (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months) • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt

Width across flats

mm

mm

Nm

kgm

6 8 10 12 14

10 13 17 19 22

11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190

1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5

16 18 20 22 24

24 27 30 32 36

235 – 285 320 – 400 455 – 565 610 – 765 785 – 980

23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100

27 30 33 36 39

41 46 50 55 60

1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630

118 – 147 155 – 195 200 – 250 250 – 310 295 – 370

Thread diameter of bolt

Width across flats

mm

mm

Nm

kgm

6 8 10 12

10 13 14 27

5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

Tightening torque

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ! In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.

SAD00483

Thread diameter

Width across flat

mm

mm

Nm

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49

2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

00-12

Tightening torque

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

10 12 16

14 17 22

59 – 74 98 – 123 235 – 285

6 – 7.5 10 – 12.5 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ! Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

mm

mm

14 20 24 33 42

Varies depending on type of connector.

Tightening torque (Nm {kgm})

Norminal No.

02 03, 04 05, 06 10, 12 14

Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010

{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}

Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

mm

mm

08 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 — 36 — —

Tightening torque (Nm {kgm})

Norminal No.

08 10 12 14 16 18 20 24 30 33 36 42 52

Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5

{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}

Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

6 8 10 12

10 ± 2 24 ± 4 43 ± 6 77 ± 12

1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22

2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

6 8 10 12 14

8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter

Tightening torque

inch

Nm

kgm

1 / 16 1/8 1/4 3/8 1/2 3/4 1

3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ! Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats

Taper seal type

Face seal type

Thread size Nominal thread Root diameter size - Threads per (mm) (Reference) (mm) inch, Thread series

Range

Target

34 – 54 {3.5 – 5.5}

44 {4.5}

–

9 — – 18UN 16

14.3

34 – 63 {3.5 – 6.5}

44 {4.5}

14

–

–

22

54 – 93 {5.5 – 9.5}

74 {7.5}

–

11 — – 16UN 16

17.5

24

59 – 98 {6.0 – 10.0}

78 {8.0}

18

–

–

04

27

84 – 132 {8.5 – 13.5}

103 {10.5}

22

13 — – 16UN 16

20.6

05

32

128 – 186 {13.0 – 19.0}

157 {16.0}

24

1 – 14UNS

25.4

06

36

177 – 245 {18.0 – 25.0}

216 {22.0}

30

3 1 — – 12UN 16

30.2

(10)

41

177 – 245 {18.0 – 25.0}

216 {22.0}

33

–

–

(12)

46

197 – 294 {20.0 – 30.0}

245 {25.0}

36

–

–

(14)

55

246 – 343 {25.0 – 35.0}

294 {30.0}

42

–

–

02

03

00-14

19

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)

Current rating (A)

Applicable circuit

0.88

2.4

12

Starting, lighting, signal etc.

0.32

2.09

3.1

20

Lighting, signal etc.

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

Norminal number

Number of strands

Dia. of strands (mm2)

Cross section (mm2)

0.85

11

0.32

2

26

5

CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification

1

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

W

B

B

R

Y

G

L

Color

White

Black

Black

Red

Yellow

Green

Blue

Code

WR

—

BW

RW

YR

GW

LW

2 Color White & Red

—

Code

—

WB

White & Black Red & White Rellow & Red Green & White Blue & White BY

RB

YB

GR

LR

3

4

Auxiliary

Color White & Black

—

Code

—

WL

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR

Color White & Blue

—

Code

—

—

Color White & Green

—

—

Code

—

—

—

Color

—

—

—

WG

RY

Black & Red Red & Yellow RG

YG

GY

LY

Yellow & Green

Green & Yellow

Blue & Yellow

YL

GB

LB

5 Red & Green Yellow & Blue Green & Black Blue & Black RL

YW

GL

—

6 Red & Blue Yellow & White Green & Blue

—

00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. (B) Millimeters to inches 1 mm = 0.03937 in

(A)

00-16

0

1

2

3

4

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6

7

8

9

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

FOREWORD

CONVERSION TABLE

Millimeters to Inches 1 mm = 0.03937 in

0

1

2

3

4

5

6

7

8

9

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

0

Kilogram to Pound 1 kg = 2.2046 lb

0 0

0

1

2

3

4

5

6

7

8

9

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon 1l = 0.2642 U.S. Gal

0

1

2

3

4

5

6

7

8

9

0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

0

Liter to U.K. Gallon 1l = 0.21997 U.K. Gal

0

1

2

3

4

5

6

7

8

9

0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

0

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb 1 kgm = 7.233 ft. lb

0

1

2

3

4

5

6

7

8

9

0

0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-19

FOREWORD

CONVERSION TABLE

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

0

1

2

3

4

5

6

7

8

9

0

0

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

FOREWORD

CONVERSION TABLE

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice 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, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F

°C

°F

°C

°F

°C

°F

°C

°F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 0

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-21

FOREWORD

UNITS

UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses {

}.

Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}

00-22

04-05

01 GENERAL

General assembly drawing .......................... 01- 2 Specifications ............................................... 01- 5 Weight table .................................................. 01-11 List of lubricant and coolant ........................ 01-14

WA600-3

01-1 (16)

GENERAL

WA600-3D (TBG SPEC.)

GENERAL ASSEMBLY DRAWING

Unit: mm

Serial No. : 50001 – 52000

01-2-2 0

WA600-3

GENERAL

GENERAL ASSEMBLY DRAWING

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

WA600-3

01-3 0

GENERAL

GENERAL ASSEMBLY DRAWING

WA600-3D (TBG SPEC.) Serial No. : 53001 and up

01-4 0

WA600-3

GENERAL

SPECIFICATIONS

SPECIFICATIONS WA600-3 Machine model

WA600-3

Weight

Serial No.

52001 and up

Operating weight

kg

43,950

45,180

Distribution (front)

kg

20,970

21,960

Distribution (rear)

kg

22,980

23,220

Bucket capacity (piled)

m3

6.1

Rated load

kg

10,980

Performance

Travel speed

Max. rimpull

FORWARD 1st

km/h

7.4

6.4

FORWARD 2nd

km/h

12.7

11.1

FORWARD 3rd

km/h

21.0

18.8

FORWARD 4th

km/h

33.5

30.3

REVERSE 1st

km/h

8.2

7.1

REVERSE 2nd

km/h

13.9

12.2

REVERSE 3rd

km/h

23.0

20.5

REVERSE 4th

km/h

35.2

32.7

FORWARD

kN {kg}

323.6 {33,000}

333.4 {34,000}

REVERSE

kN {kg}

291.3 {29,700}

300.1 {30,600}

deg

25

25

Gradeability Min. turning radius

Center of outside wheel Outside portion of chassis (with tooth)

mm

6,980

mm

8,265

Overall length (with tooth)

mm

10,775

10,840

Overall width (chassis)

mm

3,570

3,570

Bucket width (with tooth)

mm

3,685

3,685

Overall height (top of ROPS canopy)

mm

4,250

4,250

mm

7,165

7,165

Wheelbase

mm

4,100

4,100

Tread

mm

2,650

2,650

Min. ground clearance

mm

495

495

Height of bucket hinge pin

mm

5,155

5,155

Dumping clearance (tip of edge)

mm

3,805

3,805

Dumping reach (tip of edge)

mm

1,610

1,610

Bucket dump angle

deg

45

45

Bucket tilt angle (travel posture)

deg

49.5

49.5

Digging depth (10° dump) (with tooth)

mm

440

440

(Bucket raised) Dimensions

50001 – 52000

WA600-3

01-5 0

GENERAL

SPECIFICATIONS

Machine model

WA600-3

Serial No. Model

6 – 170 x 170

Piston displacement

¬ {cc}

23.15 {23,150}

23.15 {23,150}

Flywheel horsepower

kW/rpm {HP/rpm}

328/2,000 {440/2,000}

357/2,000 {478/2,000}

Maximum torque

Nm/rpm {kgm/rpm}

2,060/1,400 {210/1,400}

2,373/1,400 {242/1,400}

Fuel consumption ratio

g/kW•h {g/HP•h}

209 {156}

221 {167}

High idle speed

rpm

2,150

2,175

Low idle speed

rpm

700

750

Performance

Engine

6 – 170 x 170

24V, 7.5kW x 2 24V, 50A (12V, 200Ah) x 2

Battery Torque converter

Power train

SAA6D170E-3

mm

Alternator

Axle, wheel

SA6D170E-2

No. of cylinders - bore x stroke

Starting motor

3-element, 1-stage, single-phase (TCA45-2B)

3-element, 1-stage, single-phase (TCA43-7B)

Planetary gear, constant-mesh Planetary gear, constant-mesh multiple-disc, hydraulically multiple-disc, hydraulically actuated, pressure rised actuated, pressure rised lubrication, modulation type lubrication, modulation type

Transmission

Spiral bevel gear, splash lubrication

Spiral bevel gear, splash lubrication

Differential

Straight bevel gear

Straight bevel gear

Final drive

Planetary gear single stage, splash lubrication

Planetary gear single stage, splash lubrication

Reduction gear

Drive type

Front/rear-wheel drive

Front axle

Fixed-frame, full-floating

Rear axle

Center pin support type, full-floating

Tire

35/65 x 33 – 24 PR (L4)

Wheel rim Inflation pressure

28.00 x 33 WTB Front tire Rear tire

Main brake Brakes

52001 and up

4-cycle, water-cooled, in-line, 4-cycle, water-cooled, in-line, 6-cylinder, direct injection, with 6-cylinder, direct injection, with turbocharger, and after-cooler turbocharger, and after-cooler

Type

Parking brake

01-6 (16)

50001 – 52000

kPa {kg/cm2} 2

kPa {kg/cm }

392 {4.0} 343 {3.5} Front/rear wheel braking, separate front/rear wheel, wet disc, hydraulically actuated Drive shaft, dry caliper type disc brake, Hydraulically released spring type

WA600-3

GENERAL

SPECIFICATIONS

Machine model

WA600-3

Steering system

Serial No.

50001 – 52000

Type

Articulated type

Structure

Hydraulic pump Delivery

Fully hydraulically power steering

Work equipment pump

¬ /min

496 (Gear type: SAR(4) 140 + 125) 492(Gear type: SAL(4) 125 + 125)

Switch pump

¬ /min

187 (Gear type: SAR(3) 100) 199(Gear type: SAL(4) 100)

Steering pump

¬ /min

232 (Gear type: SAR(4) 125) 246 (Gear type: SAL(4) 125)

PPC pump

¬ /min

59 (Gear type: SAR(1) 32)

Hydraulic system

Main control valve Control valve

Set pressure

MPa {kg/cm }

MPa {kg/cm }

mm

Work equipment

Link type Bucket edge type

WA600-3

2 – 130 x 529 Reciprocating piston

mm

Bucket cylinder No. – bore x stroke

20.6 {210} Reciprocating piston

Lift cylinder No. – bore x stroke

20.6 {210} Orbitroll + spool valve type

2

Steering cylinder No. – bore x stroke

63 (Gear type: SAL(1) 32)

2-spool type 2

Steering valve Set pressure

Cylinder

52001 and up

2 – 225 x 1,130 Reciprocating piston

mm

1 – 280 x 710

Single link Flat edge with tooth

01-7 (16)

GENERAL

SPECIFICATIONS

WA600-3D Machine model

WA600-3D

Weight

Serial No.

50001 – 52000

52001 – 53000

53001 and up

Operating weight

kg

44,850

45,740

46,110

Distribution (front)

kg

21,635

22,020

21,490

Distribution (rear)

kg

23,215

23,720

24,620

Bucket capacity (piled)

m3

6.1

Rated load

kg

10,980

FORWARD 1st

km/h

7.4

6.4

FORWARD 2nd

km/h

12.7

11.1

FORWARD 3rd

km/h

21.0

18.8

FORWARD 4th

km/h

33.5

30.3

REVERSE 1st

km/h

8.2

7.1

REVERSE 2nd

km/h

13.9

12.2

REVERSE 3rd

km/h

23.0

20.5

REVERSE 4th

km/h

35.2

32.7

FORWARD

kN {kg}

323.6 {33,000}

333.4 {34,000}

REVERSE

kN {kg}

291.3 {29,700}

300.1 {30,600}

Gradeability

deg

25

25

Min. Center of outside wheel turning radius Outside portion of chassis (with tooth)

mm

6,980

mm

8,265

Overall length (with tooth)

mm

10,775

10,840

Overall width (chassis)

mm

3,570

3,570

Bucket width (with tooth)

mm

3,685

3,685

Overall height (top of ROPS canopy)

mm

4,250

4,250

mm

7,165

7,165

Wheelbase

mm

4,100

4,100

Tread

mm

2,650

2,650

Min. ground clearance

mm

495

495

Height of bucket hinge pin

mm

5,155

5,155

Dumping clearance (tip of edge)

mm

3,805

3,805

Dumping reach (tip of edge)

mm

1,610

1,610

Bucket dump angle

deg

45

45

Bucket tilt angle (travel posture)

deg

49.5

49.5

Digging depth (10° dump) (with tooth)

mm

440

440

Performance

Travel speed

Max. rimpull

Dimensions

(Bucket raised)

01-8 0

WA600-3

SPECIFICATIONS

GENERAL

Machine model

WA600-3D

Serial No.

50001 – 52000

Model

SA6D170E-2

SAA6D170E-3

4-cycle, water-cooled, in-line, 6-cylinder, direct injection, with turbocharger, and after-cooler

4-cycle, water-cooled, in-line, 6-cylinder, direct injection, with turbocharger, and after-cooler

mm

6 – 170 x 170

6 – 170 x 170

Piston displacement

¬ {cc}

23.15 {23,150}

23.15 {23,150}

Flywheel horsepower

kW/rpm {HP/rpm}

328/2,000 {440/2,000}

357/2,000 {478/2,000}

Maximum torque

Nm/rpm {kgm/rpm} 2,060/1,400 {210/1,400}

Fuel consumption ratio

g/kW•h {g/HP•h}

209 {156}

221 {165}

High idle speed

rpm

2,100

2,175

Low idle speed

rpm

700

700

24V, 50A

Alternator

(12V, 200Ah) x 2

Power train

Battery

Axle, wheel

2,373/1,400 {242/1,400}

24V, 7.5kW x 2

Starting motor

Torque converter

3-element, 1-stage, single-phase (TCA45-2B)

3-element, 1-stage, single-phase (TCA43-7B)

Transmission

Planetary gear, constant-mesh multpledisc, hydraulically actuated, pressure rised lubrication, modulation type

Planetary gear, constant-mesh multpledisc, hydraulically actuated, pressure rised lubrication, modulation type

Reduction gear

Spiral bevel gear, splash lubrication

Spiral bevel gear, splash lubrication

Differential Final drive

Straight bevel gear

Straight bevel gear

Planetary gear single stage, splash lubrication

Planetary gear single stage, splash lubrication

Drive type

Front/rear-wheel drive

Front axle

Fixed-frame, full-floating

Rear axle

Center pin support type, full-floating

Tire

35/65 x 33 – 24 PR (L4)

Wheel rim Inflation pressure

28.00 x 33 WTB Front tire Rear tire

Main brake Brakes

53001 and up

No. of cylinders – bore x stroke

Performance

Engine

Type

52001 – 53000

Parking brake

WA600-3

kPa {kg/cm2} 2

kPa {kg/cm }

392 {4.0} 343 {3.5} Front/rear wheel braking, separate front/rear wheel, wet disc, hydraulically actuated Drive shaft, dry caliper type disc brake, Hydraulically released spring type

01-9 (16)

GENERAL

SPECIFICATIONS

Machine model

WA600-3D

Steering system

Serial No. Type Structure

PPC pump

¬ /min

496 (Gear type: SAR (4) 140 + 125)

492 (Gear type: SAL (4) 125 + 125)

¬ /min

187 (Gear type: SAR (3) 100)

199 (Gear type: SAL (4) 100)

¬ /min

232 (Gear type: SAR (4) 125)

246 (Gear type: SAL (4) 125)

¬ /min

59 (Gear type: SAR (1) 32)

63 (Gear type: SAL (1) 32)

Main control valve Set pressure

2-spool type MPa {kg/cm2}

Steering valve Set pressure

No. – bore x stroke

MPa {kg/cm2}

mm

Work equipment

Link type Bucket edge type

01-10 (16)

2 – 130 x 529 Reciprocating piston

mm

Bucket cylinder No. – bore x stroke

20.6 {210} Reciprocating piston

Lift cylinder No. – bore x stroke

20.6 {210} Orbitroll + spool valve type

Steering cylinder

Cylinder

53001 and up

Fully hydraulically power steering

Hydrau- Switch pump lic pump Delivery Steering pump

Control valve

52001 – 53000 Articulated type

Work equipment pump

Hydraulic system

50001 – 52000

2 – 225 x 1,130 Reciprocating piston

mm

1 – 280 x 710

Single link Flat edge with tooth

WA600-3

GENERAL

WEIGHT TABLE

WEIGHT TABLE WA600-3

¤

This weight table is a guide for use when transporting or handling components. Unit: kg Machine model

WA600-3

Machine model

WA600-3

Serial Number

50001 – 52000 52001 and up

Serial Number

50001 – 52000 52001 and up

Engine assembly

2,750

2,900

Steering and switch pump

—

39

Radiator assembly

415

545

Torque converter charging and PPC pumps

—

24

Torque converter assembly

157

220

Hydraulic pumps

—

41

Transmission assembly

1,400

1,400

Lift cylinder (1 piece)

404

404

Upper drive shaft

29.5

31

Bucket cylinder

524

524

Center drive shaft

64

64

Engine hood

116.5

116.5

Front drive shaft

64

64

Front frame

3,390

3,390

Rear drive shaft

48.2

48.2

Rear frame

3,450

3,630

Front axle assembly

2,996

2,996

Bucket link (with bushing)

147

147

Rear axle assembly

2,898

2,898

Bellcrank (with bushing)

897

897

Front differential assembly

499

499

Lift arm (with bushing)

3,262

3,262

Rear differential assembly

508

508

Bucket (with teeth)

4,250

4,250

Planetary carrier assembly (1 piece)

115

115

Counterweight

2,820

2,820

Wheel hub (1 piece)

195

195

Fuel tank

405

405

136/153

136/153

Battery (1 piece)

59

59

Wheel (1 piece)

466

466

Cab assembly

439

456

Tire (1 piece)

990

990

Air conditioner unit

23

23

Steering valve

48

48

Operator's seat

54

54

Orbit-roll valve

5.2

5.2

Floor frame

180

184

Steering cylinder (1 piece)

77

77

Hydraulic tank

414

414

Hydraulic, Steering and PPC Pumps

72

—

Torque converter charging and switch pumps

30

—

Main control valve

90

90

Axle pivot (front/rear)

WA600-3

01-11 (16)

GENERAL

WEIGHT TABLE

WA600-3D

¤

This weight table is a guide for use when transporting or handling components. Machine model Serial Number

Unit: kg

WA600-3D 50001 – 52000

52001 – 53000

53001 and up

2,750

2,900

2,900

Radiator assembly

415

545

630

Torque converter assembly

157

220

220

Transmission assembly

1,400

1,400

1,400

Upper drive shaft

29.5

31

31

Center drive shaft

64

64

64

Front drive shaft

64

64

64

Rear drive shaft

48.2

48.2

45.2

Front axle assembly

2,996

2,996

2.996

Rear axle assembly

2,898

2,898

2,898

Front differential assembly

499

499

499

Rear differential assembly

508

508

508

Planetary carrier assembly switch (1 piece)

115

115

115

Wheel hub (1 piece)

195

195

195

136/153

136/153

136/153

Wheel (1 piece)

466

466

466

Tire (1 piece)

990

990

990

Steering valve

48

48

48

Orbit-roll valve

5.2

5.2

5.2

Steering cylinder (1 piece)

77

77

77

Hydraulic tank

414

414

414

Hydraulic, Steering and PPC Pumps

72

—

—

Torque converter charging and switch pumps

30

—

—

Main control valve

90

90

90

Steering and switch pump

—

39

39

Engine assembly

Axle pivot (front/rear)

01-12 0

WA600-3

GENERAL

WEIGHT TABLE

Unit: kg Machine model Serial Number

WA600-3D 50001 – 52000

52001 – 53000

53001 and up

Torque converter charging and PPC pumps

—

24

24

Hydraulic pumps

—

41

41

Lift cylinder (1 piece)

404

404

404

Bucket cylinder

524

524

524

Engine hood

200

200

200

Front frame

3,390

3,390

3,390

Rear frame

3,450

3,630

3,670

Bucket link (with bushing)

147

147

147

Bellcrank (with bushing)

897

897

897

Lift arm (with bushing)

3,262

3,262

3,262

Bucket (with teeth)

4,250

4,250

4,250

Counterweight

2,820

2,820

2,820

Fuel tank

405

405

405

Battery (1 piece)

59

59

59

Cab assembly

439

456

456

Air conditioner unit

23

23

23

Operator's seat

54

54

54

Floor frame

180

184

184

WA600-3

01-13 (16)

GENERAL

LIST OF LUBRICANT AND COOLANT

LIST OF LUBRICANT AND COOLANT RESERVOIR

KIND OF FLUID –22 –30

AMBIENT TEMPERATURE –4 –20

14 –10

32 0

50 10

68 20

86 30

SAE 30 SAE 10W Engine oil pan

SAE 10W-30 SAE 15W-40 Engine oil SAE 30

Transmission case

CAPACITY 104 40

122°F 50°C

Specified

Refill

61 ¶

43 ¶

62 ¶

47 ¶

120 ¶

110 ¶

Serial No. : Serial No. :  50001 – 5200050001 – 52000 Serial No. : Serial No. :   52001 and up 52001 and up

SAE 10W

Hydraulic system

SAE 10W

500 ¶

345 ¶

Axle (Front and rear) (each)

See Note 1

124 ¶

124 ¶

–

–

670 ¶

–

137 ¶ Serial No. :   50001 – 52000 142 ¶ Serial No. :  52001 – 53000 160 ¶ Serial No. :  53001 and up

–

Pins

Grease

Fuel tank

Diesel fuel

Cooling system

Coolant

NLGI No. 2

ASTM D975 No. 2 ª

Add antifreeze

ª ASTM D975 No. 1

Note 1: For axle oil, use only recommended oil as follows. SHELL: DONAX TT or TD CALTEX: RPM TRACTOR HYDRAULIC FLUID CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TDH OIL MOBIL: MOBIL AND SUPER UNIVERSAL It is possible to substitute engine oil CLASS-CD SAE30 for axle oil. If noise comes from the brake, it is no problem of durability.

01-14 (16)

WA600-3

GENERAL

LIST OF LUBRICANT AND COOLANT

REMARK: • When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %.

•

•

•

•

Fuel sulphur content

Change interval of oil in engine oil pan

0.5 to 1.0 %

1/2 of regular interval

Above 1.0 %

1/4 of regular interval

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

Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute

WA600-3

01-15 (16)

10 STRUCTURE AND FUNCTION

Power train .................................................... 10- 2 Power train system ...................................... 10- 4 Radiator, hydraulic oil cooler ...................... 10- 6 Radiator, hydraulic oil cooler (with suction fan) ...................................... 10-6-4 Torque converter and transmission piping .......................................................... 10- 7 Hydraulic circuit for power train ................. 10- 8 Hydraulic circuit diagram for power train ... 10-10 Torque converter .......................................... 10-12 Torque converter regulator valve (Serial No.: 52001 and up) ...................... 10-14-4 Transmission ................................................ 10-15 Transmission control valve ......................... 10-24 Torque converter oil cooler ......................... 10-44 Torque converter oil filter ............................ 10-45 Transfer ......................................................... 10-47 Drive shaft ..................................................... 10-48 Center support .............................................. 10-49 Axle ................................................................ 10-50 Differential .................................................... 10-52 Limited slip differential ............................. 10-54-1 Final drive ..................................................... 10-55 Axle mount ................................................... 10-58 Center hinge pin ........................................... 10-60 Steering piping ............................................. 10-61 Steering column ........................................... 10-62 Steering unit (orbit-roll valve) ..................... 10-63 Steering valve ............................................... 10-66 Two-way restriction valve ............................ 10-77 Stop valve ..................................................... 10-78 Emergency steering piping ......................... 10-79 Diverter valve (for emergency steering) ..... 10-80 Brake piping .................................................. 10-84 Brake circuit diagram ................................... 10-86 Brake valve .................................................... 10-88 Charge valve ................................................. 10-93 Accumulator (for brake) ............................... 10-97 Slack adjuster ............................................... 10-98 Brake ............................................................ 10-101 Parking brake .............................................. 10-103 WA600-3

Spring cylinder ........................................... 10-105 Parking brake solenoid valve .................... 10-106 Hydraulic piping ......................................... 10-108 Work equipment hydraulic circuit diagram ..................................................... 10-110 Work equipment lever linkage .................. 10-112 Hydraulic tank ............................................. 10-113 Accumulator (for PPC valve) ..................... 10-115 PPC valve .................................................... 10-116 PPC reliev valve .......................................... 10-120 Cut-off valve ................................................ 10-121 Main control valve ...................................... 10-124 Auto grease system ................................ 10-137-1 Lubrication of work equipment ................. 10-138 Work equipment linkage ............................ 10-140 Bucket .......................................................... 10-142 Bucket positioner and boom kick-out ....... 10-143 Operation of proximity switch .................. 10-145 Rops canopy ............................................... 10-149 Cab ............................................................... 10-150 Cab heater ................................................ 10-150-1 Air conditioner ............................................ 10-151 Electric circuit diagram .............................. 10-154 Machine monitor system ........................... 10-158 Main monitor .............................................. 10-159 Maintenance monitor ................................. 10-164 Machine with joystick and automatic shift control ...................................................... 10-165-1 Engine starting circuit ................................ 10-166 Engine stop circuit ................................... 10-167-2 Auto priming system (APS) (Serial No. : 50001 – 52000) ..................... 10-169 Pre-heating circuit (Serial No. : 52001 and up) ................... 10-172-1 Electric transmission control ..................... 10-173 Kick-down, hold switch .............................. 10-176 Kick-down electrical circuit ........................ 10-177 Electric parking brake control .................... 10-183 E.C.S.S. (Electronically Controlled Suspension System) ................................ 10-192

10-1 (15)

STRUCTURE AND FUNCTION

RADIATOR, HYDRAULIC OIL COOLER

Serial No. : 52001 and up

1. 2. 3. 4. 5. 6. 7.

After cooler Coolant level sensor Upper tank Radiator core Fuel cooler Sub tank Lower tank (hydraulic oil cooler 7A, 7B)

A: B: C: D: E: F:

After cooler outlet port After cooler inlet port Coolant inlet port Hydraulic oil cooler inlet port Hydraulic oil cooler outlet port Coolant outlet port

SPECIFICATIONS Radiator • Core model: PF2-7 • Total heat dissipating area: 135.22 m2 (52001 – 53001) 166.80 m2 (53001 and up) • Cross-sectional area of water flow: 217.01 cm2 (52001 – 53001) 233.43 cm2 (53001 and up) Hydraulic oil cooler

Core type

Oil cooler 7A

Oil cooler 7B

PTO-OL

PTO-OL

Heat 1.396 m2 (52001 – 53000) dissipating 1.829 m2 (53001 and up) area

1.829 m2

After cooler (Fuel cooler) • Core type: CF40-1 • Total heat dissipating area: 6.45 m2 After cooler • Total heat dissipating area: 25.54 m2

10-6-2 (16)

WA600-3

STRUCTURE AND FUNCTION

RADIATOR, HYDRAULIC OIL COOLER

RADIATOR, HYDRAULIC OIL COOLER (with suction fan) Serial No. : 52001 and up

1. 2. 3. 4. 5. 6. 7.

After cooler Coolant level sensor Upper tank Radiator core Fuel cooler Sub tank Lower tank (hydraulic oil cooler 7A, 7B)

A: B: C: D: E: F:

After cooler outlet port After cooler inlet port Coolant inlet port Hydraulic oil cooler inlet port Hydraulic oil cooler outlet port Coolant outlet port

10-6-4 (16)

SPECIFICATIONS Radiator • Core model: PF2-7 • Total heat dissipating area: 135.22 m2 • Cross-sectional area of water flow: 217.01 cm2 Hydraulic oil cooler Oil cooler 7A

Oil cooler 7B

Core type

PTO-OL

PTO-OL

Heat dissipating area

1.396 m2

1.829 m2

After cooler (Fuel cooler) • Core type: CF40-1 • Total heat dissipating area: 6.45 m2 After cooler • Total heat dissipating area: 25.54 m2 WA600-3

STRUCTURE AND FUNCTION

WA600-3

RADIATOR, HYDRAULIC OIL COOLER

10-6-5 (15)

STRUCTURE AND FUNCTION

FINAL DRIVE

FINAL DRIVE Serial No.: 50001 – 52018

1. 2. 3. 4. 5. 6.

Axle shaft Sun gear (Teeth: 19) Ring gear (Teeth: 71) Planetary carrier Planetary gear (Teeth: 25) Wheel

WA600-3

10-55 (16)

STRUCTURE AND FUNCTION

FINAL DRIVE

Serial No.: 52019 and up

1. 2. 3. 4. 5. 6.

Axle shaft Sun gear (Teeth: 19) Ring gear (Teeth: 71) Planetary carrier Planetary gear (Teeth: 25) Wheel

10-56 (16)

WA600-3

STRUCTURE AND FUNCTION

FINAL DRIVE

OUTLINE • To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and send drive force to the tires.

OPERATION • The motive force transmitted from the differential through axle shaft (1) to sun gear (2) is transmitted to planetary gear (5). The planetary gear rotates around the inside of a fixed ring gear (3) and in this way transmits rotation at a reduced speed to the planetary carrier (4). This motive force is then sent to the wheels (6) which are installed to the planetary carriers (4).

WA600-3

10-57 (16)

BRAKE VALVE

STRUCTURE AND FUNCTION

BRAKE VALVE BRAKE VALVE (RIGHT) Serial No.: 50001 – 52018

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Brake pedal (left, right brake) Rod (right brake) Pilot piston (right brake) Spool (right brake) Upper cylinder (right brake) Spool (right brake) Lower cylinder (right brake) Rod (left brake) Spool (left brake) Cylinder (left brake)

10-88 (16)

A: B: C: D: E: F:

Pilot port (right brake) To rear brake (right brake) To front brake (right brake) Drain (left, right brake) To pilot port (left brake) From accumulator (left, right brake)

WA600-3

STRUCTURE AND FUNCTION

BRAKE VALVE

BRAKE VALVE (LEFT) Serial No.: 50001 – 52018

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 cylinder to apply the brakes. • When the left pedal is depressed, oil is sent to the right pedal to apply the brakes in the same way as when the right pedal is depressed.

WA600-3

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.

10-88-1 (16)

STRUCTURE AND FUNCTION

BRAKE VALVE

BRAKE VALVE (RIGHT) Serial No.: 52019 and up

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Brake pedal (left, right brake) Rod (right brake) Pilot piston (right brake) Spool (right brake) Upper cylinder (right brake) Spool (right brake) Lower cylinder (right brake) Rod (left brake) Spool (left brake) Cylinder (left brake)

10-88-2 (16)

A: B: C: D: E: F:

Pilot port (right brake) To rear brake (right brake) To front brake (right brake) Drain (left, right brake) To pilot port (left brake) From accumulator (left, right brake)

WA600-3

STRUCTURE AND FUNCTION

BRAKE VALVE

BRAKE VALVE (LEFT) Serial No.: 52019 and up

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 cylinder to apply the brakes. • When the left pedal is depressed, oil is sent to the right pedal to apply the brakes in the same way as when the right pedal is depressed.

WA600-3

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.

10-89 (16)

SLACK ADJUSTER

STRUCTURE AND FUNCTION

SLACK ADJUSTER Serial No.: 50001 – 52018

1

2

5

1. 2. 3. 4. 5.

Bleeder Cylinder Check valve Piston Spring

A: Inlet port B: Outlet port

10-98 (16)

3

4

B

A

SEW00121

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 Piston actuation pressure: 2 0.01 + 0.01 MPa {0.1 + 0.1 0 0 kg/cm } Check valve cracking pressure: 0.93 ± 0.05 MPa {9.5 ± 0.5 kg/cm2} Check valve closing pressure: 0.6 ± 0.05 MPa {6.0 ± 0.5 kg/cm2}

WA600-3

STRUCTURE AND FUNCTION

SLACK ADJUSTER

Serial No.: 52019 and up

1. 2. 3. 4. 5.

Cylinder Check valve Piston Spring Bleeder

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.

A: Inlet port B: Outlet port

WA600-3

10-98-1 (16)

STRUCTURE AND FUNCTION

BRAKE

BRAKE Serial No.: 50001 – 52018

1. 2. 3. 4. 5. 6. 7. 8.

Guide pin Return spring Cylinder Brake piston Outer gear (No. of teeth: 164) Hub gear (No. of teeth: 112) Plate Disc

WA600-3

10-101 (16)

STRUCTURE AND FUNCTION

BRAKE

Serial No.: 52019 and up

1. 2. 3. 4. 5. 6. 7. 8.

Guide pin Return spring Cylinder Brake piston Outer gear (No. of teeth: 164) Hub gear (No. of teeth: 112) Plate Disc

10-101-1 (16)

WA600-3

STRUCTURE AND FUNCTION

WORK EQUIPMENT LEVER LINKAGE

WORK EQUIPMENT LEVER LINKAGE

1. 2. 3. 4.

Kick-down switch Boom lever Bucket lever Work equipment lock lever

10-112 (16)

5. Solenoid valve for bucket lever 6. Solenoid valve for boom lever 7. PPC valve

WA600-3

STRUCTURE AND FUNCTION

CUT-OFF VALVE

CUT-OFF VALVE

1. 2. 3. 4.

Unload valve Check valve Cut-off relief valve Screen

C: P: T: T1:

Port C (from hydraulic pump) Port P (from steering valve) Port T (to tank) Port T1(to tank)

WA600-3

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.

10-121 (16)

STRUCTURE AND FUNCTION

MAIN CONTROL VALVE

3-SPOOL (If equipped)

A1: To attachment cylinder A2: To bucket cylinder bottom A3: To boom cylinder bottom B1: To attachment cylinder B2: To bucket cylinder head B3: To boom cylinder head

10-126 (16)

D1: D2: P: P1: P2: PA1:

Drain port Drain port From pump From PPC valve P2 From PPC valve P3 From option PPC valve

PA2: From PPC valve P4 PA3: From PPC valve P2 PB1: From option PPC valve PB2: From PPC valve P1 PB3: From PPC valve P3 T: Drain port WA600-3

STRUCTURE AND FUNCTION

MAIN MONITOR

MAIN MONITOR DISPLAY FUNCTION Display category

Symbol

Display item

Display range

Display method

Check

When there is abnormality display on maintenance monitor

Display flashes (for details, see MAINTENANCE MONITOR DISPLAY FUNCTION)

Emergency steering actuated

When actuated

Display flashes

Parking brake actuated, transmission not at neutral

Display flashes and buzzer sounds

When there is abnormality display on maintenance monitor

Display flashes (buzzer may also sound) for details, see MAINTENANCE MONITOR DISPLAY FUNCTION)

Hi beam

When operated

Display lights up

Turn signal (left, right)

When operated

Display lights up

Parking brake

When operated

Display lights up Buzzer sounds when parking brake is applied and shift lever is not at N

Emergency steering normal

When normal (oil is flowing in hydraulic circuit)

Display lights up

Preheating

When preheating

Lights up Lighting up time changes according to engine water temperature when starting switch is turned ON (for details, see PREHEATING OUTPUT FUNCTION)

Shift hold (Machine equipped with auto shift)

When shift is held

Display lights up

Speedometer

Travel speed

0 – 99 km/h

Digital display (display switches between tachometer and speedometer)

Shift indicator

Shift indicator

1–4N

Digital display

Failure action code

Failure action code

When controller detects failure and action by operator is needed, CALL is displayed, or CALL AND E B B (action code) are displayed in turn

Digital display Buzzer sounds (For details of the travel data display mode, see TROUBLE DATA DISPLAY MODE)

Shift indicator

F, R, display (when equipped with joystick steering)

F. R

Digital display

Check

Caution Caution

Pilot

10-160 (16)

WA600-3

MAINTENANCE MONITOR

STRUCTURE AND FUNCTION

MAINTENANCE MONITOR DISPLAY FUNCTION Display category

Symbol

Display item

Display range

Engine water level

Below low level

Engine oil level

Below low level

Engine water level

Below low level

Engine oil pressure

Below specified pressure

Brake oil pressure

Below specified pressure

Check

Display method Displays when engine is stopped and starting switch is ON Display when normal: OFF Display when abnormal: Flashes CHECK lamp flashes Displays when engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes Buzzer sounds

––––––––––––––––––––Engine water temperature Above 102°C

Buzzer sounds if above 105°C

––––––––––––––––––––Caution

Service meter

Torque converter oil temperature

Above 120°C

Buzzer sounds if above 130°C

Fuel level

Below low level

Displays when engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes

Battery charge

When charge is defective

Air cleaner

Above specified negative pressure

Displays when engine is running Display when normal: OFF Display when abnormal: Flashes CHECK lamp flashes

Service meter

0 – 9999.9h

Service meter indicator

Lights up when service meter is running

Fuel level

All lamps light up below applicable level Flashes when level is 1

Engine water temperature

One place lights up to show applicable level Flashes when level is 6 or 7

Torque converter oil temperature

One place lights up to show applicable level Flashes when level is 6 or 7

Gauges

WA600-3

Actuated when charge is normal Advances 1 for every hour

10-165 (16)

STRUCTURE AND FUNCTION

MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL

Table 1 Automatic shift change points table Gear speed

Travel speed (km/ h)

Gear-shift inhibition time (sec)

1→2

Min. 5.6 (5.8)

2

2→3

Min. 9.3 (9.8)

2

3→4

Min. 17.6

1

4→3

Max. 15.6

1

3→2

Max. 9.8 (9.3)

2

4→2

Max. 1.0

0

3→2

Max. 1.0

0

3. Engine speed (Below 1,450rpm → 1,450rpm or higher)

4→2

Max. 8.0

2

3→2

Max. 8.0

2

4. Shift-up operation while hold function is ON

1→2

5.6

0

2→3

9.3

0

3→4

17.6

0

2→1

No limit

5

3→1

Max. 12.7

5

4→1

Max. 12.7

5

Item 1. Basic shift change

2. Engine speed (Below 1,450rpm)

5. Shift-down operation while kickdown function is ON

6. Changeover of F and R to each other (Range I in Fig. 1) (F→)N→R (R→)N→F

4→2

Note 1)

3→2

2

1→2

7. Changeover of F and R to each other (Range II in Fig. 1) (F→)N→R (R→)N→F

→4

Min. 17.6

→3

Max. 9.3 – 17.6

8. Changeover of F and R to each other

→4

Min. 17.6

F→N→F

→3

Max. 9.3 – 17.6

R→N→R

→2

Max. 9.3

Note 2) 2

0

Note 1)The engine speed is below 1,800rpm and travel speed is below 16km/h, or travel speed is below 13km/h. Note 2)When the engine speed is 1,800rpm or higher and travel speed is 13km/h or higher, or travel speed is 16km/h or higher, the gear is not shifted immediately, but shifted down to the 2nd position as the travel speed drops.

10-165-5 (16)

WA600-3

STRUCTURE AND FUNCTION

ENGINE STARTING CIRCUIT

APS completely stopped

APS started Passage of time Glow plug preheats

Starting switch Heater switch APS water temperature sensor Glow plug Monitor pilot lamp display Fuel injection nozzle.

OFF

ON ON

OFF OFF

ON No injection

STARTING WITH APS (actuated when engine water temperature is below 20°C) 1. Open the APS fuel valve in the center of the left side of the engine. fl Leave the fuel valve open during the cold season when the temperature goes down and the APS is used. 2. Turn the starting switch ON. 3. Turn the fuel cut-off switch OFF, then turn the starting switch to the START position and crank the starting motor for approx. 10 seconds. fl Do this to lubricate the whole engine with oil. fl When the fuel cut-off switch is turned OFF, the fuel cut solenoid is turned OFF and the fuel injection pump is set to the NO INJECTION position. 4. Turn the fuel cut-off switch ON. fl Release the switch and it will automatically return to the ON position. 5. If the heater switch is set to the ON position, the monitor pilot lamp will light up and the glow lamp will preheat. fl When the monitor pilot lamp lights up, set the heater switch to AUTO.

WA600-3

Starting motor turns

Engine starts, intake air heated

START AUTO

ON OFF

ON (Max. 20°C)

OFF

ON

OFF OFF

Intermittent injection

Flashes

OFF

No injection

6. Depress the accelerator pedal half way. 7. The preheating stops after approx. 12 seconds and the monitor pilot lamp goes out. Turn the starting switch key to the START position to start the engine. fl If the starting switch is turned to the START position while the monitor pilot lamp is still lighted up, the glow plug will become wet and it will be impossible to carry out ignition. 8. When the engine starts, return the starting switch to the ON position. 9. After the engine starts, when the engine rotation becomes smooth and the exhaust gas color becomes normal, turn the heater switch OFF. fl After the engine is started and the engine water temperature reaches approx. 20°C, the monitor pilot lamp flashes to inform the operator that the afterheating has been completed. At the same time, the afterheating is automatically canceled.

10-167 (16)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE

Serial No. : 52001 and up

Category

Item

Machine model

WA600-3

Engine

SAA6D170E-3

Measurement conditions

Standard value for new machine

Service limit value

750 ± 25

750 ± 25

2,175 ± 50

2,175 ± 100

2,000

—

˚C

680

700

kPa {mmHg}

Min. 113 {850}

100 {750}

Max. 5.0

7.0

Max. 2.0

3.0

0.32

—

0.62

—

Unit

Low idle Engine speed

High idle

rpm

Rated speed Exhaust temperature

Whole speed range (ambient temperature: 20°C)

Air supply pressure (boost pressure)

At rated output At sudden acceleration

Engine related

Exhaust gas color

Bosch index At rated output

Valve clearance (normal temperature)

Intake valve

Compression pressure (SAE30 oil)

Oil temperature: 40 – 60°C 2 (Engine speed: 210 – 250 rpm) MPa {kg/cm }

Min. 2.9 {30}

2.1 {21}

Blow-by pressure (SAE30 oil)

(Coolant temperature: Green range) kPa {mmH2O} At high idle

Max. 3.9 {400}

7.9 {800}

mm Exhaust valve

(Coolant temperature: Green range) MPa {kg/cm2} 0.39–0.54 {4.0–5.5} At high idle (SAE30)

0.21 {2.1}

(Coolant temperature: Green range) MPa {kg/cm2} 0.34–0.49 {3.5–4.0} At high idle (SAE10W)

0.18 {1.8}

Oil pressure At low idle (SAE30)

MPa {kg/cm2}

Min. 0.12 {1.2}

Max. 0.07 {0.7}

At low idle (SAE10W)

MPa {kg/cm2}

Min. 0.1 {1.0}

Max. 0.05 {0.5}

°C

90 –␣ 110

120

Oil temperature

Whole speed range (inside oil pan)

Alternator belt tension

Deflection of one belt when pressed with finger force of approx. 58.8 N {approx. 6 kg.}

mm

10 – 15

10 – 15

Air conditioner compres- Deflection when pressed sor belt tension with finger force of approx. 58.8 N {approx. 6 kg.}

mm

10 – 15

10 – 15

WA600-3

20-2-1 (16)

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS Serial No. : 50001 – 52000 Machine model

Speed control lever

Directional lever

Category

Unit

Standard value for new machine

Service limit value

N {kg}

+0.5 5.88 +4.9 – 2.94 {0.6 – 0.3 }

16.7 {1.7}

mm

35 ±␣ 10

35 ±␣ 10

+0.5 5.88 +4.9 – 2.94 {0.6 – 0.3 }

16.7 {1.7}

+0.5 5.88 +4.9 – 2.94 {0.6 – 0.3 }

16.7 {1.7}

3rd – 4th

+0.5 5.88 +4.9 – 2.94 {0.6 – 0.3 }

16.7 {1.7}

1st – 2nd

35 ±␣ 10

35 ±␣ 20

35 ±␣ 10

35 ±␣ 20

35 ±␣ 10

35 ±␣ 20

Max. 23.5 {2.4}

35.3 {3.6}

Max.15.7 {1.6}

23.5 {2.4}

HOLD→LOWER

Max. 24.5 {2.5}

37.3 {3.8}

LOWER→HOLD

—

—

Max. 34.3 {3.5}

52.0 {5.3}

FLOAT→HOLD

Max. 14.7 {1.5}

22.6 {2.3}

HOLD→DUMP

Max. 23.5 {2.4}

35.3 {3.6}

HOLD→TILT

Max. 23.5 {2.4}

35.3 {3.6}

TILT→HOLD

Max. 14.7 {1.5}

22.6 {2.3}

67 ±␣ 15

67 ±␣ 30

53 ±␣ 15

53 ±␣ 30

67 ±␣ 15

67 ±␣ 30

HOLD→DUMP

60 ±␣ 15

60 ±␣ 30

HOLD→TILT

60 ±␣ 15

60 ±␣ 30

mm

Max. 40

50 –␣ 100

Item

• Engine stopped N – FORWARD, • Measure at center of lever REVERSE knob

Travel

N – FORWARD, REVERSE 1st – 2nd

Travel

2nd – 3rd

• Engine stopped • Measure at center of lever knob

2nd – 3rd

N {kg}

mm

3rd – 4th HOLD→RAISE

Operating effort

RAISE→HOLD

• Engine speed: Low idle • Hydraulic oil temperature: 45 – 55°C

Lift arm LOWER→FLOAT

Bucket

N {kg}

HOLD→RAISE

• Engine speed: Low idle • Hydraulic oil temperature: Lift arm HOLD→LOWER 45 – 55°C Travel

Work equipment control lever

Measurement conditions

Operating effort

Operating effort

WA600-3

HOLD→FLOAT

mm

Bucket • Engine stopped • Machine facing straight to front

Steering wheel

Play

Operating effort

• Flat, horizontal, straight, dry paved road surface

N {kg}

10.0 ±␣ 3.0 {1.0 ±␣ 0.3}

19.6 {2.0}

Turns

• Engine speed: High idle • Left lock - right lock

Turns

3.9 ±␣ 0.4

4.5

Max. 5.8

6.5

Max. 4.1

5.0

Operating time

Low idle High idle

WA600-3

• Engine running • Hydraulic oil temperature: 45 – 55°C • Left lock - right lock

sec.

20-3 (16)

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Machine model Category

Item

Measurement conditions

Operating angle

STD model

Accelerator pedal

• Engine speed: Low idle Operating effort (Measure at 150 mm point • Hydraulic oil temperature: 45 – 55°C from pedal fulcrum)

Standard value for new machine

Service limit value

N {kg}

68.6 ± 3.0 {7.0 ± 0.3}

78 {88}

51

—

34

—

mm

56

—

N {kg}

294 ± 29.4 {30 ± 3}

421.4 {43}

45

—

deg. Max. (α 2)

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

Operating effort (Measure at 150 mm point from pedal fulcrum) Operating angle

Unit

Neutral (α 1)

Stopper height (L)

Brake pedal

WA600-3

• Engine speed: Low idle • Hydraulic oil temperature: 45 – 55°C

Neutral (α 1) deg. Max. (α 2)

15

mm

Play

A

• Tire inflation pressure: Specified pressure

+1 0

—

5 ±␣ 0.5

—

Max. 2.5

—

Max. 4.0

—

2 – 15

—

2,070 ± 100

2,070 ± 200

2,080 ± 100

2,080 ± 200

1,670 ± 100

1,670 ± 300

Tire

Fitting of wheel lock ring B

Clearance of wheel lock ring

Engine speed

Torque converter stall

20-4 (16)

Hydraulic stall

Torque converter stall + hydraulic stall

mm

C • Engine coolant temperature: Green range • Torque converter oil temperature: 60 – 80°C • Hydraulic oil temperature: 45 – 55°C • Gearshift lever: F4 or R4

rpm

WA600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model Category

WA600-3 Standard value for new machine

Service limit value

2.94 ± 0.2 {30 ±␣ 2.0}

2.94 ± 0.2 {30 ±␣ 2.0}

3.19 ± 0.2 {32.5 ±␣ 2.0}

3.19 ± 0.2 {32.5 ±␣ 2.0}

1.76 ± 0.10 {18 ±␣ 1}

1.76 ± 0.10 {18 ±␣ 1}

1.05 ± 0.10 {10.8 ±␣ 1.0}

1.05 ± 0.10 {10.8 ±␣ 1.0}

Torque converter relief pressure (inlet port)

0.78 ± 0.1 {8 ±␣ 1}

0.78 ± 0.1 {8 ±␣ 1}

Torque converter outlet port pressure

0.34 ± 0.05 {3.5 ±␣ 0.5}

0.34 ± 0.05 {3.5 ±␣ 0.5}

0.2 ± 0.1 {2 ±␣ 1}

0.2 ± 0.1 {2 ±␣ 1}

+10 20.6 +0.98 – 0.29 {210 – 3 }

+10 20.6 +0.98 – 1.27 {210 – 3 }

3.72 +0.19 {38 +20 } 0

+4 3.72 +0.39 – 0.19 {38 – 2 }

5.88 +0.49 {60 +50 } 0

+10 5.88 +0.98 – 0.49 {60– 5 }

9.8 +0.98 {100+10 0 0 }

+15 9.8 +1.47 – 0.49 {100– 5 }

1st

7.4 ± 0.3

7.4 ± 0.3

2nd

12 ± 0.6

12 ± 0.6

3rd

21.0 ± 1.0

21.0 ± 1.0

33.5 ± 1.7

33.5 ± 1.7

1st

8.2 ± 0.4

8.2 ± 0.4

2nd

13.9 ± 0.7

13.9 ± 0.7

3rd

23.0 ± 1.1

23.0 ± 1.1

4th

35.2 ± 1.8

35.2 ± 1.8

Item Low idle

Measurement conditions

Unit

• Torque converter oil temperature: 60 – 80°C

Main relief pressure Transmission, torque converter

High idle

F2, R2 cluch pressure

• Torque converter oil temperature: 60 – 80°C • Engine speed: High idle

Pilot pressure

MPa {kg/cm2}

Accumulator

Steering

Lubrication pressure (oil cooler outlet port)

Steering relief pressure

• Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle

MPa {kg/cm2}

Orbit-roll output pressure

Charge cut-in pressure

Charge cut-out pressure

• Engine speed: Low idle • Hydraulic oil temperature: 45 – 55°C

• Point when brake oil pressure warning lamp goes out

MPa

{kg/cm2} • Point when oil pressure is going up and then starts to go down

Power train

FORWARD

4th km/h

Travel speed

REVERSE

WA600-3

20-5 (16)

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Machine model

Wheel brake

Category

Item

Measurement conditions

WA600-3 Standard value for new machine

Service limit value

4.9 ± 0.49 {50 ± 5}

4.9 ± 0.69 {50 ± 7}

Max. 0.49 {5}

0.49 {5}

m

Max. 5

5

mm

7.5 ±␣ 0.6

13.4

5.9 – 9.8 {60 – 100}

5.9 – 9.8 {60 – 100}

Max. 0.14 {Max. 1.4}

0.14 {1.4}

Stopped

Stopped

31.7 ±␣ 0.3

12.7

1.06 ±␣ 0.18

2.1

+2 3.72 +0.2 0 {38 0 }

+2 3.72 +0.2 – 0.2 {38 – 2 }

+2 3.72 +0.2 0 {38 0 }

+2 3.72 +0.2 – 0.2 {38 – 2 }

2.54 ± 0.05 {26 ± 0.5}

2.54 ± 0.05 {26 ± 0.5}

Unit

Brake oil pressure

• Hydraulic oil temperature: 45 – 55°C

Drop in brake pressure

MPa {kg/cm2} • Engine stopped • Keep brake pedal depressed at 4.9 MPa {50 kg/cm2} and measure drop in oil pressure after 5 min.

Performance

• Tire inflation pressure: Specified pressure • Flat, horizontal, straight, dry paved road surface • Speed when applying brake: 20 km/h, braking delay: 0.1 sec • Brake pedal operating effort: Specified operating effort (294±29.4 N {30±3 kg}) • Measure stopping distance • Measure piston stroke

Disc wear Parking brake inlet port pressure

Brake released

• Torque converter oil temperature: 60 – 80°C • Engine at high idle

MPa {kg/cm2}

Brake operated

Parking brake

• Tire inflation pressure: Specified pressure • Flat dry paved road with 1/5 (11°20') grade • Machine at operating condition

—

Performance

Pad thickness

Including pack metal

PPC

mm

20-6 (16)

Clearance

Total of each end

PPC valve source pressure (Orbit-roll source pressure)

• Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle

PPC valve output pressure

Lift arm RAISE, • Hydraulic oil temperature: MPa FLOAT; bucket 45 – 55°C {kg/cm2} DUMP, TILT • Engine speed: High idle • Work equipment control lever: Lift arm Operated fully LOWER

WA600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model Category

Unit

Standard value for new machine

Service limit value

MPa {kg/cm2}

20.6 +0.49 – 0.29 {210+5 –3 }

20.6 +0.49 – 1.27 {210 +5 –13 }

7.9 ± 0.5

9.0

4.8 ±␣ 0.5

6.0

3.0 ±␣ 0.3

4.0

2.1 ±␣ 0.3

3.0

Max. 40

40

Retraction of bucket cylinder rod

Max. 20

0

Clearance of bucket positioner proximity switch

3 –␣ 5

—

3 –␣ 5

—

Item Work equipment relief pressure

Work equipment speed

Lift arm RAISE

Measurement conditions • Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle • Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle • No load

Lift arm LOWER

sec.

When fully operated

• Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle • No load

Bucket tiltback

Work equipment

WA600-3

Bucket horizontal (above ground)

Proximity switch

Hydraulic drift

Retraction of lift cylinder rod

• Hydraulic oil temperature: 45 – 55°C • Leave for 5 minutes after stopping engine then measure for next 15 minutes • Bucket empty, lift arm, bucket horizontal mm

mm Clearance of boom kick out proximity switch

WA600-3

20-7 (16)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Serial No. : 52001 and up Machine model

Speed control lever

Directional lever

Category

Item Operating effort

• Engine stopped N – FORWARD, • Measure at center of lever REVERSE knob

Travel

N – FORWARD, REVERSE

Operating effort

Travel

Unit

Standard value for new machine

N {kg}

5.88 – 2.94 {0.6 – 0.3 }

16.7 {1.7}

mm

35 ±␣ 10

35 ±␣ 10 16.7 {1.7}

5.88 – 2.94 {0.6 – 0.3 }

+4.9

+0.5

16.7 {1.7}

3rd – 4th

+4.9 +0.5 5.88 – 2.94 {0.6 – 0.3 }

16.7 {1.7}

1st – 2nd

35 ±␣ 10

35 ±␣ 20

35 ±␣ 10

35 ±␣ 20

35 ±␣ 10

35 ±␣ 20

Max. 23.5 {2.4}

35.3 {3.6}

Max.15.7 {1.6}

23.5 {2.4}

HOLD→LOWER

Max. 24.5 {2.5}

37.3 {3.8}

LOWER→HOLD

—

—

Max. 34.3 {3.5}

52.0 {5.3}

FLOAT→HOLD

Max. 14.7 {1.5}

22.6 {2.3}

HOLD→DUMP

Max. 23.5 {2.4}

35.3 {3.6}

HOLD→TILT

Max. 23.5 {2.4}

35.3 {3.6}

TILT→HOLD

Max. 14.7 {1.5}

22.6 {2.3}

67 ±␣ 15

67 ±␣ 30

53 ±␣ 15

53 ±␣ 30

67 ±␣ 15

67 ±␣ 30

HOLD→DUMP

60 ±␣ 15

60 ±␣ 30

HOLD→TILT

60 ±␣ 15

60 ±␣ 30

mm

Max. 40

50 –␣ 100

2nd – 3rd

2nd – 3rd

Operating effort

RAISE→HOLD

5.88 – 2.94 {0.6 – 0.3 } N {kg}

mm

• Engine speed: Low idle • Hydraulic oil temperature: 45 – 55°C

Lift arm LOWER→FLOAT

N {kg}

• Engine speed: Low idle • Hydraulic oil temperature: 45 – 55°C Lift arm HOLD→LOWER Travel

HOLD→RAISE

HOLD→FLOAT

mm

Bucket • Engine stopped • Machine facing straight to front

Play

Steering wheel

+0.5

+0.5

• Engine stopped • Measure at center of lever knob

3rd – 4th

Bucket

+4.9

Service limit value

+4.9

1st – 2nd

HOLD→RAISE

Work equipment control lever

Measurement conditions

WA600-3

Operating effort

• Flat, horizontal, straight, dry paved road surface

N {kg}

10.0 ±␣ 3.0 {1.0 ±␣ 0.3}

19.6 {2.0}

Turns

• Engine speed: High idle • Left lock - right lock

Turns

3.9 ±␣ 0.4

4.5

Max. 5.8

6.5

Max. 4.1

5.0

Operating time

Low idle High idle

20-7-1 (16)

• Engine running • Hydraulic oil temperature: 45 – 55°C • Left lock - right lock

sec.

WA600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model Category

Item

Measurement conditions

Operating angle

STD model

Accelerator pedal

• Engine speed: Low idle Operating effort (Measure at 150 mm point • Hydraulic oil temperature: 45 – 55°C from pedal fulcrum)

Standard value for new machine

Service limit value

N {kg}

58.8 ± 2.45 {6.0 ± 0.25}

88.2 {9.0}

48

—

35

—

mm

56 ± 5

—

N {kg}

294 ± 29.4 {30 ± 3}

421.4 {43}

45

—

deg. Max. (α 2)

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

Operating effort (Measure at 150 mm point from pedal fulcrum) Operating angle

Unit

Neutral (α 1)

Stopper height (L)

Brake pedal

WA600-3

• Engine speed: Low idle • Hydraulic oil temperature: 45 – 55°C

Neutral (α 1) deg. Max. (α 2)

15

mm

Play

A

• Tire inflation pressure: Specified pressure

+1 0

—

5 ±␣ 0.5

—

Max. 2.5

—

Max. 4.0

—

2 – 15

—

2,100 ± 100

2,100 ± 200

2,130 ± 100

2,130 ± 200

1,740 ± 100

1,740 ± 300

Tire

Fitting of wheel lock ring B

Clearance of wheel lock ring

Engine speed

Torque converter stall

Hydraulic stall

Torque converter stall + hydraulic stall

WA600-3

mm

C • Engine coolant temperature: Green range • Torque converter oil temperature: 60 – 80°C • Hydraulic oil temperature: 45 – 55°C • Gearshift lever: F4 or R4

rpm

20-7-2 (16)

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Machine model Category

WA600-3 Standard value for new machine

Service limit value

2.94 ± 0.2 {30 ±␣ 2.0}

2.94 ± 0.2 {30 ±␣ 2.0}

3.19 ± 0.2 {32.5 ±␣ 2.0}

3.19 ± 0.2 {32.5 ±␣ 2.0}

1.76 ± 0.10 {18 ±␣ 1}

1.76 ± 0.10 {18 ±␣ 1}

1.05 ± 0.10 {10.8 ±␣ 1.0}

1.05 ± 0.10 {10.8 ±␣ 1.0}

Torque converter relief pressure (inlet port)

0.78 ± 0.1 {8 ±␣ 1}

0.78 ± 0.1 {8 ±␣ 1}

Torque converter outlet port pressure

0.34 ± 0.05 {3.5 ±␣ 0.5}

0.34 ± 0.05 {3.5 ±␣ 0.5}

0.2 ± 0.1 {2 ±␣ 1}

0.2 ± 0.1 {2 ±␣ 1}

22.1 +1.27 {225 +13 0 0 }

+13 22.1 +1.27 – 0.98 {225 – 10 }

3.72 +0.19 {38 +20 } 0

+4 3.72 +0.39 – 0.19 {38 – 2 }

5.88 +0.49 {60 +50 } 0

+10 5.88 +0.98 – 0.49 {60– 5 }

9.8 +0.98 {100+10 0 0 }

+15 9.8 +1.47 – 0.49 {100– 5 }

1st

6.4 ± 0.3

6.4 ± 0.3

2nd

11.1 ± 0.6

11.1 ± 0.6

3rd

18.8 ± 1.0

18.8 ± 1.0

30.3 ± 1.6

30.3 ± 1.6

1st

7.1 ± 0.4

7.1 ± 0.4

2nd

12.9 ± 0.7

12.9 ± 0.7

3rd

20.5 ± 1.1

20.5 ± 1.1

4th

32.7 ± 1.7

32.7 ± 1.7

Item Low idle

Measurement conditions

Unit

• Torque converter oil temperature: 60 – 80°C

Main relief pressure Transmission, torque converter

High idle

F2, R2 cluch pressure

• Torque converter oil temperature: 60 – 80°C • Engine speed: High idle

Pilot pressure

MPa {kg/cm2}

Accumulator

Steering

Lubrication pressure (oil cooler outlet port)

Steering relief pressure

• Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle

MPa {kg/cm2}

Orbit-roll output pressure

Charge cut-in pressure

Charge cut-out pressure

• Engine speed: Low idle • Hydraulic oil temperature: 45 – 55°C

• Point when brake oil pressure warning lamp goes out

MPa

{kg/cm2} • Point when oil pressure is going up and then starts to go down

Power train

FORWARD

4th km/h

Travel speed

REVERSE

20-7-3 (16)

WA600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model

Wheel brake

Category

Item

Measurement conditions

WA600-3 Standard value for new machine

Service limit value

4.9 ± 0.49 {50 ± 5}

4.9 ± 0.69 {50 ± 7}

Max. 0.49 {5}

0.49 {5}

m

Max. 5

5

mm

7.5 ±␣ 0.6

13.4

5.9 – 9.8 {60 – 100}

5.9 – 9.8 {60 – 100}

Max. 0.14 {Max. 1.4}

0.14 {1.4}

Stopped

Stopped

31.7 ±␣ 0.3

12.7

1.06 ±␣ 0.18

2.1

+2 3.72 +0.2 0 {38 0 }

+2 3.72 +0.2 – 0.2 {38 – 2 }

+2 3.72 +0.2 0 {38 0 }

+2 3.72 +0.2 – 0.2 {38 – 2 }

2.54 ± 0.05 {26 ± 0.5}

2.54 ± 0.05 {26 ± 0.5}

Unit

Brake oil pressure

• Hydraulic oil temperature: 45 – 55°C

Drop in brake pressure

MPa {kg/cm2} • Engine stopped • Keep brake pedal depressed at 4.9 MPa {50 kg/cm2} and measure drop in oil pressure after 5 min.

Performance

• Tire inflation pressure: Specified pressure • Flat, horizontal, straight, dry paved road surface • Speed when applying brake: 20 km/h, braking delay: 0.1 sec • Brake pedal operating effort: Specified operating effort (294±29.4 N {30±3 kg}) • Measure stopping distance • Measure piston stroke

Disc wear Parking brake inlet port pressure

Brake released

• Torque converter oil temperature: 60 – 80°C • Engine at high idle

MPa {kg/cm2}

Brake operated

Parking brake

• Tire inflation pressure: Specified pressure • Flat dry paved road with 1/5 (11°20') grade • Machine at operating condition

—

Performance

Pad thickness

Including pack metal

PPC

mm Clearance

Total of each end

PPC valve source pressure (Orbit-roll source pressure)

• Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle

PPC valve output pressure

WA600-3

Lift arm RAISE, • Hydraulic oil temperature: MPa FLOAT; bucket 45 – 55°C {kg/cm2} DUMP, TILT • Engine speed: High idle • Work equipment control lever: Lift arm Operated fully LOWER

20-7-4 (16)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model Category

Unit

Standard value for new machine

Service limit value

MPa {kg/cm2}

20.6 +0.49 – 0.29 {210+5 –3 }

20.6 +0.49 – 1.27 {210 +5 –13 }

7.9 ± 0.5

9.0

4.8 ±␣ 0.5

6.0

3.0 ±␣ 0.3

4.0

2.1 ±␣ 0.3

3.0

Max. 40

40

Retraction of bucket cylinder rod

Max. 20

0

Clearance of bucket positioner proximity switch

3 –␣ 5

—

3 –␣ 5

—

Item Work equipment relief pressure

Measurement conditions • Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle • Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle • No load

Lift arm LOWER

sec.

When fully operated

• Hydraulic oil temperature: 45 – 55°C • Engine speed: High idle • No load

Bucket tiltback

Work equipment speed

Lift arm RAISE

Work equipment

WA600-3

Bucket horizontal (above ground)

Proximity switch

Hydraulic drift

Retraction of lift cylinder rod

• Hydraulic oil temperature: 45 – 55°C • Leave for 5 minutes after stopping engine then measure for next 15 minutes • Bucket empty, lift arm, bucket horizontal mm

mm Clearance of boom kick out proximity switch

20-7-5 (16)

WA600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Starting switch terminal C

L05

L05

APS preheating signal (★) Preheating ON signal (★★)

Starting switch terminal BR

L05

L07

Measure voltage Measure voltage

Main monitor

Directional switch (N)

Measure voltage

L05

Measure voltage

Battery charge (alternator)

Measure voltage

L05

Measure voltage

Power supply

Measure voltage

Connector InpsecSystion Name of component No. tem method

Directional switch (F)

Measurement conditions

Judgement table If the condition is as shown in the table below, it is normal Between (1), (2) –␣ chassis Between (1), (2) – (3)

20 – 30 V

If the condition is as shown in the table below, it is normal Engine running (at above 1/2 throttle) Between 28 ±␣ 2 V Starting switch ON (5) – (3) Max. 1 V (Engine stopped)

Measure voltage

1) Turn starting switch OFF. 2) Insert Tadapter.

ª If the battery is old, or after starting in cold areas, the voltage may not rise for some time. If the condition is as shown in the table below, it is normal Directional lever at N Directional lever not at N

20 –␣ 30 V Between (8) – (3) Max. 1 V

If the condition is as shown in the table below, it is normal Srarting switch at START Srarting switch at OFF or ON

20 –␣ 30 V Between (4) – (3) Max. 1 V

If the condition is as shown in the table below, it is normal Preheating stopped Between Max. 1 V Preheating operated (19) – (3) 20 –␣ 30 V

If the condition is as shown in the table below, it is normal Starting switch ON

Between 20 –␣ 30 V (10) – (12) Max. 1 V Starting switch OFF

If the condition is as shown in the table below, it is normal Directional lever at F Between 20 –␣ 30V (7) – Directional lever chassis Max. 1 V not at F

L08

Directional switch (R)

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.

If the condition is as shown in the table below, it is normal Directional lever at R Between 20 –␣ 30V (8) – Directional lever chassis Max. 1 V not at R

1) Turn starting switch OFF. 2) Insert Tadapter.3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter.

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter.

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.

(★) Serial No.: 50001 – 52000 (★★) Serial No.: 52001 and up

WA600-3

20-9 (15)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

L18

Battery charge (alternator)

L18

Measure voltage

Power supply

Measure voltage

Connector InpsecSystion Name of component No. tem method

Measurement conditions

Judgement table If the condition is as shown in the table below, it is normal Between (1), (2) –␣ chassis Between (1), (2) – (3)

20 – 30 V

If the condition is as shown in the table below, it is normal Engine running (at above 1/2 throttle) Between 28 ±␣ 2 V (12) – Starting switch ON (3), (14) Max. 1 V (Engine stopped)

G01 (male)

E11 (★)

Measure resistance Measure resistance

Radiator coolant level switch

Measure resistance

Maintenance monitor

R07 (male)

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Engine started.

ª If the battery is old, or after starting in cold areas, the voltage may not rise for some time.

If the condition is as shown in the table below, it is normal

Fuel level sensor

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.

Float raised to stopper

Float lowered to stopper

Approx. 4 Ω

Approx. 85 Ω

If the condition is as shown in the table below, it is normal Coolant level normal Between Max. 1 Ω (1) – (2) Min. 1 MΩ Coolant level low

If the condition is as shown in the table below, it is normal Min. 0.07 MPa {0.7 kg/cm2} Max. 0.03 MPa {0.3 kg/cm2}

1) Turn starting switch OFF. 2) Disconnect connector. 3) Drain fuel. 4) Remove fuel level sensor. 5) Connect T-adapter.

Between Min. 1MΩ sensor terminal Max. 1Ω – Chassis

1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter. 4) Engine started.

R17 (★★)

Measure voltage

Engine oil pressure switch If the condition is as shown in the table below, it is normal Min. 0.05 MPa {0,5 kg/cm2} Max. 0.05 MPa {0,05 kg/cm2}

Between sensor 20 – 30 V R17(A) – Max. 1V Chassis

(★) Serial No.: 50001 – 52000 (★★) Serial No.: 52001 and up

20-10 (16)

WA600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Connector InpsecSystion Name of component No. tem method

Measurement conditions

Judgement table

Engine oil lever switch

Dust indicator

WA600-3

E07 (male)

E10

E13 (male) E14 (male)

Measure resistance Measure resistance

Torque converter oil temperature sensor

E04 (male)

Measure resistance

Maintenance monitor

Engine coolant temperature sensor

C03 (male) C04 (male)

Measure continuity

Brake accumulator low pressure switch

Measure resistance

If the condition is as shown in the table below, it is normal Accumlator pressure: Min 5.39 ± 0.49 MPa {5.39 ± 0.49 kg/cm2}

Max. 1 Ω

1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter.

Between Depress brake pedal (1) – (2) and lower accumlator pressure to below Min. 1 MΩ 4.41 ± 0.49 MPa {45 ± 5 kg/cm2}

If the condition is as shown in the table below, it is normal Normal temperature (25˚C) Between (1) – (2) 100 ˚C

Approx. 40 kΩ Approx. 3.7 kΩ

If the condition is as shown in the table below, it is normal Normal temperature (25˚C) Between (1) – (2) 100 ˚C

Approx. 40 kΩ Approx. 3.7 kΩ

If the condition is as shown in the table below, it is normal Between Max. 1 Ω Oil level abnormal (1) – (2) Min. 1 MΩ Oil level normal

If the condition is as shown in the table below, it is normal Air cleaner normal Between Continuity E13 (1) No Air cleaner clogged – E14 (1) Continuity

1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter.

1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter.

1) Turn starting switch OFF. 2) Disconnect terminal.

1) Turn starting switch OFF. 2) Disconnect connector. 3) Start engine. 4) Measure continuity.

20-11 (16)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

SysName of component tem

Measurement conditions

Judgement table If the condition is as shown in Table 1, the monitor panel is normal Table 1 Connec- Monitor item tor No. (input connector)

CHECK items CAUTION items L18 (male)

Engine coolant level ((8)–(3),(14)) Engine oil level ((13)–(3),(14)) Engine oil pressure ((10)–(3),(14)) Brake oil pressure ((11)–(3),(14))

Measurement conditions

Display

Sensor signal

Engine stopped, starting switch ON

Flashing OFF Flashing OFF Flashing OFF Flashing OFF Flashing OFF Flashing OFF

15 – 20 V Max. 1 V 15 – 20 V Max. 1 V 15 – 20 V Max. 1 V 15 – 20 V Max. 1 V Max. 10 V Min. 12 V 15 – 20 V Max. 1 V

Engine stopped, starting switch ON Engine running Engine running

Battery charge Engine running ((12)–(3),(14)) Air cleaner ((15)–(3),(14))

Engine running

Table 2 Display level according to sensor resistance

Maintenance monitor

Gauge display (Starting switch ON)

E Red

Flash-  ing ←→  67



20-12 (16)

ON

102130°C

 

Min. Red 2 0.24 – 3.47 Red 1 3.13 – 3.75 Green 4 3.39 – 4.26  Green 3 3.85 – 5.14 Green 2 4.65 – 6.94 E F Green 1 6.27 –10.26 White Green Max. White →  Red 9.29 – ON Flashing ←→   (1 place) (kΩ) (1 place) 50



120130°C

 

Min. Red 2 0.24 – 1.90 Red 1 1.68 – 2.40 Green 5 2.15 – 3.05  Green 4 2.74 – 5.14 Green 3 4.65 – 9.39 E F Green 2 8.43 –18.18 Max. Geeen 1 15.88 – Green Red   (kΩ) ON ←→ →  Flashing (1 place) (1 place) Green 1 Green 2 Green 3 Green 4 Green 5 Red 1 Red 2

Torque converter oil temperature gauge L18 (male) Measure resistance between (5) – (3), (14)

Green

0 – 15.7 12.6 – 24.0 20.5 – 30.6 26.7 – 39.6 35.2 – 51.6 46.5 – 80.6 73.8 –

1) Turn starting switch OFF, then insert dummy resistance or measure resistance of sensor. 2) Turn starting switch ON and check display.

White Green 1 Green 2 Green 3 Green 4 Red 1 Red 2

Gauge

Engine coolant temperature gauge L18 (male) Measure resistance between (4) – (3), (14)

Min. Green 6 Green 5 Green 4  Green 3 F Green 2 Green 1  Max. Red ← (Ω)

Red Green 1 Green 2 Green 3 Green 4 Green 5 Green 6

Fuel level gauge L18 (male) Measure resistance between (6) – (3), (14)

(Starting switch OFF)

1) Turn starting switch OFF. 2) Insert Tadapter.

WA600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Connector InpsecSystion Name of component No. tem method

Measurement conditions

Judgement table

E02 (male)

APS nozzle

—

L71 L72

APS contoller

Power source

APS coolant temperature sensor

L71

L72 L71

Glow plug 1

(★)

20-14 (16)

Measure resistance Measure resistance

APS contoller system (★)

Glow plug

Measure resistance

E05 (male)

Measure voltage

APS coolant temperature sensor

Measure voltage

L74

Measure voltage

APS switch

Measure continuity

If the condition is as shown in the table below, it is normal ON AUTO OFF

Between (1) – (2)

Continuity

Between (3) – (4)

Continuity

1) Turn starting switch OFF. 2) Disconnect connectors. 3) Connect T-adapter.

Between (1) – (2) No continuity Between (3) – (4)

Continuity

Between (1) – (2) No continuity Between (3) – (4) No continuity

If the condition is as shown in the table below, it is normal Between terminal – chassis

Up tp 20˚C

Max. 0.5 Ω

20˚C and up Min. 1 MΩ

If the condition is as shown in the table below, it is normal No.1 glow plug

Between (1) –␣ chassis

No.2 glow plug

Between (4) –␣ chassis

Between nozzle terminals

1.5 – 2.5 Ω

If the condition is as shown in the table below, it is normal Between L72 (1) – L71 (1)

20 – 30 V

If the condition is as shown in the table below, it is normal Up tp 20˚C

Max. 1 V

20˚C and up

7 – 10 V

If the condition is as shown in the table below, it is normal Between L72 (2) – L71 (1)

1) Turn starting switch OFF. 2) Disconnect connector.

0.8 –␣ 1.3 Ω

If the condition is as shown in the table below, it is normal

Between (1) – (2)

1) Turn starting switch OFF. 2) Disconnect connector.

ASP stopped

Max. 1 V

ASP operating

4 – 12 V

1) Turn starting switch OFF. 2) Disconnect terminals.

1) Turn starting switch ON. 2) Insert T-adapter.

1) Turn starting switch ON. 2) Insert T-adapter.

1) Turn starting switch ON. 2) Insert T-adapter.

Serial No.: 50001 – 52000

WA600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

L71

L71

Measure voltage Measure voltage

APS contoller

Measurement conditions

Judgement table If the condition is as shown in the table below, it is normal Between L72 (3) – L71 (1)

ASP stopped

Max. 1 V

ASP operating

4 – 12 V

If the condition is as shown in the table below, it is normal Between L72 (4) – L71 (1)

ASP stopped

Max. 1 V

ASP operating

0.4 – 5 V

If the condition is as shown in the table below, it is normal Between (3) – (1)

10 – 24 V

If the condition is as shown in the table below, it is normal Between (4) – (1)

ASP stopped

Max. 1 V

Pre-heat power

HEAT

1) Turn starting switch ON. 2) Insert T-adapter.

1) Turn starting switch ON. 2) Insert T-adapter.

1) Turn starting switch ON. 2) Insert T-adapter.

1) Turn starting switch ON. 2) Insert T-adapter.

ASP operating 12 – 20 V ª

ª Voltage is kept 12 –␣ 20 V for 12 seconds after starting switch ON, then goes down to below 1V. If the condition is as shown in the table below, it is normal

Measure voltage

APS contoller system (★)

Engine starting signal of starting switch

Monitor lamp signal of preheating

Pre-heat system (★★)

L72 L71

APS nozzle

Measure voltage

L72 L71

Glow plug 2

Measure voltage

Connector InpsecSystion Name of component No. tem method

Between (2) –␣ chassis

20 – 30 V

ª When coolant temperature is maintained at lower than 0ºC for more than 30 seconds.

1) Turn starting switch OFF. 2) Connect T-adapter. 3) Turn starting switch ON.

(★) Serial No.: 50001 – 52000 (★★) Serial No.: 52001 and up

WA600-3

20-15 (16)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

FOR MACHINE WITH JOYSTICK AND AUTMATIC SHIFT CONTROL Only specific items are described for machine with joystick and automatic shift control.

Solenoid (1st)

Solenoid (2nd)

Solenoid (3rd)

Solenoid (4th)

Solenoid (F)

20-16 (15)

T01 (male)

T01 (male)

T01 (male)

T01 (male)

T01 (male)

Measure voltage Measure voltage Measure voltage

L01

Between C1(7), (13) – chassis Between C2(1), (12) – chassis Between C1(7), (13) – (6), (12)

20 – 30 V

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.

Between C2(1), (12) – (11), (21) If the condition is as shown in the table below, it is normal. Between (6) – (17) Between (6) – chassis

20 – 30 V

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 4) Turn parking brake switch ON

If the condition is as shown in the table below, it is normal. Turn parking brake 20 – 30 V switch ON Between Turn parking brake (1) – (3) Max. 1 V switch OFF

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Disconnect connectors. 3) Connect Tadapter.

Measure resistance

Parking brake switch

C3A

If the condition is as shown in the table below, it is normal.

If the condition is as shown in the table below, it is normal.

Measure resistance

Transmission & Joystick steering control

Power supply (for signal)

C1 C2

Measurement conditions

Judgement table

If the condition is as shown in the table below, it is normal.

Measure resistance

Power supply

Connector Inspection No. method

If the condition is as shown in the table below, it is normal.

Measure resistance

Name of component

If the condition is as shown in the table below, it is normal.

Measure resistance

System

If the condition is as shown in the table below, it is normal.

Between (H) – (B)

50 – 70 Ω

Between (H), (B) – chassis

Min. 1 MΩ

Between (G) – (B)

50 – 70 Ω

Between (G), (B) – chassis

Min. 1 MΩ

Between (F) – (B)

50 – 70 Ω

Between (F), (B) – chassis

Min. 1 MΩ

Between (E) – (B)

50 – 70 Ω

Between (E), (B) – chassis

Min. 1 MΩ

Between (D) – (A)

50 – 70 Ω

Between (D), (A) – chassis

Min. 1 MΩ

1) Turn starting switch OFF. 2) Disconnect connectors. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connectors. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connectors. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connectors. 3) Connect Tadapter.

WA600-3

TESTING AND ADJUSTING

50 – 70 Ω

Between (C), (A) – chassis

Min. 1 MΩ

If the condition is as shown in the table below, it is normal. Between (1) – (2) Between (1), (2) – chassis

500 – 1000 Ω Min. 1 MΩ

Measure voltage

—

Adjust

Speed control lever (1st)

Speed control lever (2nd)

Speed control lever (3rd)

Speed control lever (4th)

C3B

Adjust

—

Between (2) – (9)

Min. 0.5 V

1) Screw in until the tip of sensor contacts gear, then turn back 1 turn. 2) It works normally by adjustment above. If the condition is as shown in the table below, it is normal. Between (1) – (2) Between (1), (2) – chassis

500 – 1000 Ω Min. 1 MΩ

1) Screw in until the tip of sensor contact gear, then turn back 3/4 –1 turn. 2) Sensor should work normally when adjusted as above.

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.

— 1) Turn starting switch OFF. 2) Disconnect connectors. 3) Connect Tadapter.

—

Measure voltage

T05 (male)

Measure resistance

C4

1) Turn starting switch OFF. 2) Disconnect connectors. 3) Connect Tadapter.

If the condition is as shown in the table below, it is normal. Speed control lever Between 20 – 30 V at 1st (7) – Speed control lever chassis Max. 1 V not at 1st

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.

Measure voltage

Speed

Controller

Between (C) – (A)

1) Turn starting switch OFF. 2) Disconnect connectors. 3) Connect Tadapter.

If the condition is as shown in the table below, it is normal. Speed control lever Between 20 – 30 V at 2nd (15) – Speed control lever chassis Max. 1 V not at 2nd

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.

Measure voltage

Engine speed

Speed

WA600-3

If the condition is as shown in the table below, it is normal.

Measure in AC range

Engine speed Transmission & Joystick steering control

E06 (male)

Measurement conditions

Judgement table

If the condition is as shown in the table below, it is normal. Speed control lever Between 20 – 30 V at 3rd (8) – Speed control lever chassis Max. 1 V not at 3rd

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.

Measure voltage

Controller

Engine speed sensor

T01 (male)

Measure resistance

Solenoid (R)

Connector Inspection No. method

Measure resistance

Name of component

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

If the condition is as shown in the table below, it is normal. Speed control lever Between 20 – 30 V at 4th (8) – Speed control lever chassis Max. 1 V not at 4th

1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.

20-17 (15)

TESTING AND ADJUSTING Table of tools for testing, adjusting, and troubleshooting ................................................................... 20-102 Measuring engine speed ..................................................................................................................... 20-103-2 Measuring exhaust gas color .............................................................................................................. 20-105-1 Adjusting valve clearance .................................................................................................................... 20-105-2 Testing and adjusting injector lift (Serial No. : 52001 and up) .......................................................... 20-106-1 Measuring compression pressure ......................................................................................................... 20-107 Measuring blow-by pressure ................................................................................................................. 20-108 Measuring engine oil pressure .............................................................................................................. 20-109 Testing and adjusting fuel injection timing (Serial No. : 50001 – 52000) ............................................ 20-110 Replacing fan belt adjusting auto-tensioner ......................................................................................... 20-112 Testing and adjusting alternator belt tension ....................................................................................... 20-113 Testing and adjusting belt tension for air conditioner compressor ................................................. 20-113-1 Handling eqipment in fuel circuit (Serial No. : 52001 and up) .......................................................... 20-113-2 Measuring fuel pump output port pressure (Serial No. : 52001 and up) ......................................... 20-113-2 Bleeding air from fuel circuit (Serial No. : 52001 and up) ................................................................. 20-113-3 Measuring exhaust temperature ............................................................................................................ 20-114 Measuring air supply pressure (boost pressure) .................................................................................. 20-115 Adjusting speed sensor .......................................................................................................................... 20-116 Adjusting fuel control cable (Serial No. : 50001 – 52000) .................................................................... 20-117 Method for adjusting engine stop motor cable (Serial No. : 50001 – 52000) ..................................... 20-118 Testing and adjusting torque converter, transmission oil pressure .................................................... 20-120 Procedure for flushing torque converter, transmission hydraulic circuit ........................................... 20-125 Procedure for moving machine when transmission valve fails .......................................................... 20-126 Testing and adjusting steering oil pressure .......................................................................................... 20-128 Testing and adjusting steering stop valve ............................................................................................. 20-130 Testing brake oil pressure ....................................................................................................................... 20-131 Measuring wear of brake disc ................................................................................................................ 20-132 Measuring brake performance ............................................................................................................... 20-133 Testing and adjusting parking brake ...................................................................................................... 20-134 Testing and adjusting accumulator charge cut-in and cut-out pressure ............................................ 20-136 Testing and adjusting PPC oil pressure ................................................................................................. 20-137 Measuring work equipment hydraulicpressure .................................................................................... 20-139 Adjusting work equipment lever linkage .............................................................................................. 20-141 Testing and adjusting of bucket positioner ........................................................................................... 20-143 Testing and adjusting of boom kick-out ................................................................................................ 20-144 Testing proximity switch actuation pilot lamp ...................................................................................... 20-145 Adjusting main monitor (speedometer module) .................................................................................. 20-146 Bleeding air .............................................................................................................................................. 20-147 Releasing remaining pressure in hydraulic circuit ............................................................................... 20-148 Pm clinic inspection table ....................................................................................................................... 20-149 WA600-3

20-101 (11)

TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TESTING AND ADJUSTING

TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Serial No. : 50001 – 52000 Test, measurement item Symbol

Part No.

Part Name

Remarks

Engine speed

A

799-205-1100

Tachometer kit

Digital display: 6.0 – 99,999.9 rpm

Coolant, oil, exhaust temperatures

B

799-101-1502

Digital temperature gauge

–99.9 to + 1,299°C

799-101-5002

Analog hydraulic tester

Pressure gauge:

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic gauge

1.0 MPa {10 kg/cm2}

Adapter

Both male and female 14 × 1.5 (female PT 1/8) Both male and female 18 × 1.5 (female PT 1/8)

1 Oil pressure

C

2

790-261-1311 3 790-261-1321 Compression pressure

Blow-by pressure

Operating effort

795-502-1590

Compression gauge

2

795-502-1350

Adapter

1

799-201-1504

Blow-by checker

2

799-201-1590

Gauge

Commercially available

Feeler gauge

1

799-201-9001

Handy smoke checker

2

Commercially available

Smoke meter

799-201-2202

Pressure gauge

1

793-520-1805

Brake test kit

—

2

• 793-520-1851

Nipple

—

3

790-301-1230

Elbow

1

79A-264-0020

F

G

H

I

Stroke, hydraulic drift

K

Work equipment speed

L

Measuring brake disc wear Measuring voltage, resistance value Adjusting fuel injection timing

M N

79A-264-0211

(16)

0 – 98 kPa {0 – 1,000 mmH2O}

Bosch index: 0 – 9

–101.3 to + 199.9 kPa {–760 to + 1,500 mmHg}

Kit part No. : 799-101-5002 0 – 294.2N {0 – 30 kg}

79A-264-0090 Commercially available Commercially available Commercially available

20-102

—

Push-pull scale

J 2

Troubleshooting of wiring harness, sensors

0 – 6.9 MPa {0 – 70 kg/cm2} Kit part No. : 795-502-1205

E

Air supply pressure (boost pressure)

Brake oil pressure

1 D

Valve clearance

Exhaust color

2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

0 – 490.3N {0 – 50 kg} Scale Stopwatch

—

Caliper gauge

—

Tester

795-471-1200

Gauge assembly

1

799-601-7400

T-adapter assembly

2

799-601-3460

3

799-601-7360

4

799-601-7370

P

—

 Dial gauge is commercially   available  — MS 10P

Q Adapter

Relay 5P Relay 6P

WA600-3

TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TESTING AND ADJUSTING

Serial No. : 52001 and up Test, measurement item Symbol

Coolant, oil, exhaust temperatures

799-205-1100

A

Engine speed

Part No.

1

799-101-1502

2

—

B

Part Name Tachometer kit Digital temperature gauge Heat gun (surface temperature gauge)

C

2

Digital hydraulic tester

799-401-2320

Hydraulic gauge

1.0 MPa {10 kg/cm2}

Adapter

Both male and female 14 × 1.5 (female PT 1/8) Both male and female 18 × 1.5 (female PT 1/8)

790-261-1321

Valve clearance

Exhaust color

Operating effort

795-502-1590

Compression gauge

2

795-502-1350

Adapter

799-201-1504

Blow-by checker

799-201-1590

Gauge

1

6162-23-4500

Barring device

2

Commercially available

Feeler gauge

1

799-201-9001

Handy smoke checker

2

Commercially available

Smoke meter

799-201-2202

Pressure gauge

1

793-520-1805

Brake test kit

—

2

• 793-520-1851

Nipple

—

3

790-301-1230

Elbow

1

79A-264-0020

F

G

H

I

0 – 98 kPa {0 – 1,000 mmH2O}

Bosch index: 0 – 9

–101.3 to + 199.9 kPa {–760 to + 1,500 mmHg}

Kit part No. : 799-101-5002 0 – 294.2N {0 – 30 kg}

Push-pull scale

J 79A-264-0090

0 – 490.3N {0 – 50 kg} Scale

M

Commercially available Commercially available Commercially available

N P

Stroke, hydraulic drift

K

Work equipment speed

L

WA600-3

0 – 6.9 MPa {0 – 70 kg/cm2} Kit part No. : 795-502-1205

E

2

Measuring brake disc wear Measuring voltage, resistance value Adjusting fuel injection timing

Pressure gauge:

1 D

Air supply pressure (boost pressure)

Brake oil pressure

2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

3

Blow-by pressure

–99.9 to + 1,299°C

Analog hydraulic tester

790-261-1311

Compression pressure

Digital display: 6.0 – 99,999.9 rpm

799-101-5002 1 Oil pressure

Remarks

Stopwatch

—

Caliper gauge

—

79A-264-0211

Tester

—

795-471-1200

Gauge assembly

 Dial gauge is commercially   available 

20-103 (16)

TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TESTING AND ADJUSTING

Test, measurement item Symbol

Troubleshooting of wiring harness, sensors

Q

Part No.

Part Name

Remarks

1

799-601-7400

—

2

799-601-3460

3

799-601-7360

4

799-601-7370

5

795-799-5460

Cable (cummins No.: 3824774)

6

795-799-5470

Cable (cummins No.: 3824775)

7

795-799-5480

Cable (cummins No.: 3824776)

8

795-799-5520

Socket (S)

For speed sensor 1 and 2

9

795-799-5530

Socket (C)

For fuel temperature sensor For coolant temperature sensor

10

795-799-5540

Socket (A)

For intake air temperature sensor

12

799-601-9020

DT 2P

13

799-601-9050

DT 6P

14

799-601-9270

T-adapter assembly MS 10P Adapter

Relay 5P Relay 6P Atmospheric pressure Fuel rail pressure sensor Timing rail pressure actuator Fuel pump actuator Fuel rail actuator Timing rail actuator Engine oil pressure sensor Boost pressure sensor Fuel pump pressure sensor

HD30 – 24 – 21P Adapter

20-103-1 (14)

15

799-601-9290

HD30 – 24 – 31P

16

799-601-9350

DRC26 – 40P

17

799-601-9360

DRC26 – 24P

WA600-3

TESTING AND ADJUSTING

MEASURING ENGINE SPEED

MEASURING ENGINE SPEED Serial No. : 50001 – 52000

¤ ¤

Put blocks securely under the tires.

When removing or installing the measuring equipment, be careful not to touch any high temperature parts. ¤ Before starting measurement, check that there is no one in the surrounding area. fl Measure the engine speed under the following conditions. • Coolant temperature: Within green range • Hydraulic temperature: 45°C – 55°C • Power train oil temperature: 70°C – 90°C 1. Measuring engine speed (low idle and high idle) 1) Remove plug (1) from the engine speed pickup port. 2) Install nut of tachometer kit A, then connect bracket [1], probe and tachometer. 3) Start the engine and measure the engine speed at high idle and low idle. 2. Measuring torque converter stall speed 1) Install the tool same as procedure 1. 2) Start the engine. 3) Turn the transmission cut-off selector switch (2) OFF and depress the left brake securely. (Check that the transmission cut-off selector pilot lamp is OFF.) 4) Place the gearshift lever at F4 or R4. • For machines equipped with automatic transmission, turn the main monitor manual switch ON and place the speed lever at F4 or R4. 5) Release the parking brake. 6) Depress the accelerator pedal gradually to raise the engine speed to high idle, then measure the engine speed when the torque conver ter stalls. fl Avoid stalling more than 20 seconds and prevent the torque converter oil temperature from going above 120˚C.

WA600-3

20-103-2 (16)

TESTING AND ADJUSTING

MEASURING ENGINE SPEED

3. Measuring hydraulic stall speed 1) Install the tool same as procedure 1. 2) Start the engine and run at high idle. 3) Extend the lift cylinder or bucket cylinder and measure the engine speed when the circuit is relieved. 4. Measuring torque converter stall + hydraulic stall (full stall) speed 1) Install the tool same as procedure 1. 2) Start the engine. 3) Turn the transmission cut-off selector switch OFF and depress the left brake securely. (Check that the transmission cut-off selector pilot lamp is OFF.) 4) Place the gearshift lever at F4 or R4. • For machines equipped with automatic transmission, turn the main monitor manual switch ON and place the speed lever at F4 or R4. 5) Release the parking brake. 6) Run the engine at high idle and stall the torque converter, and at the same time, extend the lift cylinder or bucket cylinder and measure the engine speed when the circuit is relieved.

20-103-3 (16)

WA600-3

TESTING AND ADJUSTING

MEASURING ENGINE SPEED

Serial No. : 52001 and up

¤ ¤

Put blocks securely under the tires.

When removing or installing the measuring equipment, be careful not to touch any high temperature parts. ¤ Before starting measurement, check that there is no one in the surrounding area. fl Measure the engine speed under the following conditions. • Coolant temperature: Within green range • Hydraulic temperature: 45°C – 55°C • Power train oil temperature: 70°C – 90°C 1. Measuring engine speed (low idle and high idle) 1) Stick the reflective tape of tachometer kit A to crankshaft pully. 2) Set the probe of tachometer kit A by stand to the front of reflective tape, then connect to tachometer. 3) Start the engine and measure the engine speed at high idle and low idle. 2. Measuring torque converter stall speed 1) Set the tool same as procedure 1. 2) Start the engine. 3) Turn the transmission cut-off selector switch (2) OFF and depress the left brake securely. (Check that the transmission cut-off selector pilot lamp is OFF.) 4) Place the gearshift lever at F4 or R4. • For machines equipped with automatic transmission, turn the main monitor manual switch ON and place the speed lever at F4 or R4. 5) Release the parking brake. 6) Depress the accelerator pedal gradually to raise the engine speed to high idle, then measure the engine speed when the torque conver ter stalls. fl Avoid stalling more than 20 seconds and prevent the torque converter oil temperature from going above 120˚C.

20-104 (16)

WA600-3

TESTING AND ADJUSTING

MEASURING ENGINE SPEED

3. Measuring hydraulic stall speed 1) Set the tool same as procedure 1. 2) Start the engine and run at high idle. 3) Extend the lift cylinder or bucket cylinder and measure the engine speed when the circuit is relieved. 4. Measuring torque converter stall + hydraulic stall (full stall) speed 1) Set the tool same as procedure 1. 2) Start the engine. 3) Turn the transmission cut-off selector switch OFF and depress the left brake securely. (Check that the transmission cut-off selector pilot lamp is OFF.) 4) Place the gearshift lever at F4 or R4. • For machines equipped with automatic transmission, turn the main monitor manual switch ON and place the speed lever at F4 or R4. 5) Release the parking brake. 6) Run the engine at high idle and stall the torque converter, and at the same time, extend the lift cylinder or bucket cylinder and measure the engine speed when the circuit is relieved.

WA600-3

20-105 (16)

TESTING AND ADJUSTING

ADJUSTING MAIN MONITOR

ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) •

•

•

The speedometer on the main monitor is a common part for all machines, and the input signal for the travel speed differs according to the machine, so it is necessary to adjust the monitor for use with the particular model. In addition, the tire diameter also differs according to the type of tire fitted, so it is necessary to adjust to give the correct travel speed. It is also necessary to change the switches if the optional E.C.S.S. (Electronically Controlled Suspension System) is installed.

Adjustment procedure • Turn off the power, then remove the machine monitor and adjust the switches at the back of the speedometer. 1. Setting machine model 1) Remove the rubber caps from dipswitches (1), (2) and (3) at the back of the speedometer. 2) When the rubber cap is removed, a rotary switch can be seen inside. Using a flat-headed screwdriver, turn this switch to adjust it to the settings in the table below. DIP SW 2 DIP SW 3 (speed(tachomometer cor- eter input rection) selection)

Tire size

DIP SW 1 (model selection)

35-65-33-24PR (STD)

6

7

0

29.5-29-28PR (OPT)

6

A

0

3) When the cap is removed from dipswitch (4) at the back of the speedometer, an ON/OFF switch can be seen. Adjust the setting if the E.C.S.S. (Electronically Controlled Suspension System) is installed. DIP SW 4 Switch No. Without With E.C.S.S. E.C.S.S. ON

ON

2

ON

ON

3

ON

OFF

Switch position

4

ON

ON

Amount of correction (%)

4) After completing the adjustment, fit the rubber caps securely and install the main monitor. fl Before installing the main monitor, check again that its setting is matched to the specification of the machine.

20-146 (11)

Reference Amount of correction for switch (2)

1

0

1

2

3

4

5

6

7

+14 +12 +10 +8 +6 +4 +2 +0

Switch position

8

9

A

Amount of correction (%)

0

–2

–4 –6 –8 –10 –12 –14

B

C

D

E

F

WA600-3

Pm CLINIC INSPECTION TABLE

WA600-3 # 52001 and up Machine Serial No. Mounted Engine

HOUR INSPECTION Work instruction No.

Date of execution Year: Month:

# SAA6D170E-3

Service meter

Inspector

Day: hours

INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK Is there abnormality before starting inspection? .............................................................................................................................................................................................................................................

Ambient temperature Max.: ˚C

.............................................................................................................................................................................................................................................

Min.:

˚C

.............................................................................................................................................................................................................................................

Height:

m

What is maximum level of coolant temperature? (During work)

What is maximum level of torque converter and transmission oil temperature? (During work)

White Green Green Green Green Red Red 1 2 3 4 5 6 7

Green Green Green Green Green Red Red 1 2 3 4 5 6 7

fl AFTER STARTING ENGINE Item

Condition

Unit

Low idle

675 – 725

Torque converter stall

rpm

Engine

Full stall

Boost pressure Exhaust temperature

T/C

kPa {mmAq}

Engine: Full throttle SAE30 Engine: Low idle SAE10W

Inlet pressure Outlet pressure

—

2,000 – 2,200 1,900 – 2,300

1,640 – 1,840 1,440 – 2,040

Torque converter stall

Engine pressure

Bad

2,030 – 2,230 1,930 – 2,330

Hydraulic stall

Blow-by pressure

Measurement Good result

2,125 – 2,225 2,075 – 2,275

High idle Engine speed

Service Standard value for new machine limit value

MPa {kg/cm2}

Engine: Low idle

Torque converter stall with engine at full throttle

kPa {mmHg}

Ambient temperature Torque converter stall with engine at full throttle 1 Engine: Full throttle Torque converter oil temperature: 60 – 80˚C 2 Transmission: Neutral

Max. 3.9 {Max. 400} 0.39 – 0.54 {4.0 – 5.5} Min. 0.12 {Min. 1.2} Min. 0.1 {Min. 1.0} Min. 113 {Min. 850}

Max. 7.9 {Max. 800} Min. 0.21 {Min. 2.1} Min. 0.07 {Min. 0.7} Min. 0.07 {Min. 0.7} Min. 100 {Min. 750}

-–-

-–-

Max. 680

Max. 700

˚C

MPa {kg/cm2}

0.68 – 0.88 {7.0 – 9.0} 0.29 – 0.39 {3.0 – 4.0}

0.68 {7.0 0.29 {3.0

– 0.88 – 9.0} – 0.39 – 4.0}

Transmission

fl WHEN THE TRANSMISSION IS IN THE SPEED RANGE, APPLY THE BRAKE FULLY Main relief pressure P6 Transmission: Neutral

2.74 – 3.14 {28.0 – 32.0}

2.74 – 3.14 {28.0 – 32.0}

Modulating pressure in Directional lever: Neutral Gearshift lever: N and 1st P1 2nd → 1st

2.74 – 3.14 {28.0 – 32.0}

2.74 – 3.14 {28.0 – 32.0}

Directional lever: Neutral Modulating pressure P3 Gearshift lever: Engine: 1st → 2nd Low idle Oil MPa Modulating pressure in Directional lever: Neutral Gearshift lever: {kg/cm2} N & 3rd P1 2nd → 3rd temperature: (SAE30) Modulating pressure in Directional lever: Neutral 70 – 90˚C Gearshift lever: N & 4th P1 3rd → 4th Modulating pressure in Directional lever: Neutral → F F & 4th P1 Gearshift lever: 4th Modulating pressure in Directional lever: Neutral → R R & 4th P1 Gearshift lever: 4th

1.66 – 1.86 {17.0 – 19.0}

1.66 – 1.86 {17.0 – 19.0}

2.74 – 3.14 {28.0 – 32.0}

2.74 – 3.14 {28.0 – 32.0}

2.74 – 3.14 {28.0 – 32.0}

2.74 – 3.14 {28.0 – 32.0}

2.74 – 3.14 {28.0 – 32.0}

2.74 – 3.14 {28.0 – 32.0}

2.74 – 3.14 {28.0 – 32.0}

2.74 – 3.14 {28.0 – 32.0}

WA600-3

20-149 (16)

WA600-3 # 52001 and up

Steering

Item Operating time of steering wheel

Condition Right lock Engine: Low idle (Left lock) Left lock (Right lock) Engine: Full throttle

Unit Oil temperature: 45 – 55˚C

Service Standard value for new machine limit value Max. 5.8

Max. 6.5

Max. 4.1

Max. 5.0

20.3 – 21.6 {207 – 220}

19.3 – 21.6 {197 – 220}

31.4 – 32.0

12.7

0.88 – 1.24

2.1

mm

6.9 – 8.1

Max. 13.4

MPa {kg/cm2}

5.9 – 6.4 {60 – 65} 9.8 – 10.8 {100 – 110}

5.4 – 6.9 {55 – 70} 9.3 – 11.3 {95 – 115}

Measurement Good result

Bad

sec

APPLY THE WORK EQUIPMENT LOCK LEVER TO THE FRAME Relief pressure

Engine: Full throttle Oil temperature: 45 - 55˚C

MPa {kg/cm2}

Pad thickness (including backing) sec

Parking brake Clearance between pad and disc

Brake

Front right Wheel brake

Wear of brake disc (Measured by piston stroke)

Front left Rear right Rear left

Hydraulic equipment

Accumulator charge pressure

Charge cut-in pressure Charge cut-out pressure

Engine: Low idle

Hydraulic oil temperature Work equipment valve Engine: Full throttle relief pressure Oil temperature: 45 – 55˚C Raising with engine at full throttle Lift arm speed Lowering with engine at full throttle Bucket speed

Tilting back with engine and full throttle

Full stroke

˚C MPa {kg/cm2}

sec

Bucket: Horizontal

—

—

20.3 – 21.1 {207 – 215} 7.4 – 8.4

19.3 – 21.1 {197 – 215} Max. 9.0

4.3 – 5.3

Max. 6.0

2.7 – 3.3

Max. 4.0

1.8 – 2.4

Max. 3.0

SET THE LIFT ARM AND BUCKET IN THE MEASURING POSITION AND STOP THE ENGINE Hydraulic drift of work equipment

Lift arm and bucket: Horizontal

Bucket cylinder Lift cylinder

mm/15 minutes

Max. 20

Max. 20

Max. 40

Max. 40

Axle

REPLACE PLUG WITH SPARE Visual check of differential drain plug

Engine: Stopped fully

Front axle Rear axle

Must be free from extremely much metal dust

MEMO: Write a phenomenon, information, etc. detected by the check of today. ...................................................................................................................................................................................................................................................................................... ............................................................................................................................... ............................................................................................................................... ....................... ............................................................................................................................... ............................................................................................................................... ....................... ............................................................................................................................... ............................................................................................................................... ....................... ............................................................................................................................... ............................................................................................................................... ....................... ............................................................................................................................... ............................................................................................................................... ....................... ............................................................................................................................... ............................................................................................................................... ....................... ............................................................................................................................... ............................................................................................................................... ....................... ............................................................................................................................... ............................................................................................................................... ....................... ............................................................................................................................... ............................................................................................................................... ....................... ............................................................................................................................... ............................................................................................................................... .......................

20-150 (16)

WA600-3

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING Judgement standard

Remedy

1. Check fuel level, type of fuel

—

Add fuel

2. Check for impurities in fuel

—

Clean, drain

3. Check hydraulic oil level

—

Add oil

4. Check hydraulic filter . (Torque converte, Transmission hydraulic oil)

—

Clean, drain

5. Check brake oil level

—

Add oil

6. Check engine oil level

—

Add oil

7. Check coolant level

—

Add water

8. Check dust indicator for clogging

—

Clean or replace

9. Check for looseness, corrosion of battery terminal, wiring

—

Tighten or replace

10. Check for looseness, corrosion of alternater terminal, wiring

—

Tighten or replace

11. Check for looseness, corrosion of starting motor terminal, wiring

—

Tighten or replace

12. Check operation of instruments

—

Repair or replace

13. Check for abnormal noise,smell

—

Repair

14. Check for oil leakage

—

Repair

15. Carry out air bleeding

—

Bleed air

16. Check effect of parking brake, wheel brake

—

Repair or replace

24 – 26 V

Replace

18. Check battery electrolyte level

—

Add or replace

19. Check for discolored, burnt, exposed wiring

—

Replace

20. Check for missing wiring clamps, hanging wiring

—

Repair

21. Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals)

—

Disconnect connector and dry

22. Check for blown, corroded fuses

—

Replace

28.5 – 29.5 V

Replace

—

—

Hydtaulic, mechanical equipments

Electrical equipments

Lubricating oil, engine coolant

Item

Electrics, eiectrical equipment

17. Check battery voltage (engine stopped)

23. Check alternator voltage (engine runing at 1/2 throttle or above) (If the battery charge is low, the voltage may be approx. 25V immediately after starting.) 24. Sound of actuation of battery relay (when starting switch is turned ON, OFF)

20-212 (16)

WA600-3

TROUBLESHOOTING

CONNECTOR TYPES AND MOUNTING LOCATIONS

CONNECTOR TYPES AND MOUNTING LOCATIONS Serial No. : 50001 – 52000 fl The Address column in the table below shows the address in the connector arrangement drawing (3-dimensional drawing). Connector No.

Type

No. of pins

A02

Connector

1

A03

Terminal

A04

Address

Connector No.

Type

No. of pins

Battery relay (BR)

L3

B08

KES 1

2

Window washer (rear)

1

Battery relay (E)

L3

BR1

SWP

6

Intermediate connector (bulk head) J2

Connector

1

Battery relay (BR)

L4

C01

X

2

Low pressure switch (emergency)

H1

A4

X

2

Air conditioner air servo motor

P6

C01

SWP

6

Front wiper motor

B7

A05

Terminal

1

Battery relay (E)

L4

C02

X

2

Lift arm proximity switch

H1

A5

M

2

Air conditioner thermistor

R5

C02

Yazaki

9

Cassette stereo

B7

A6

SWP

6

Air conditioner air mixing motor

R5

C03

X

2

Low pressure switch (brake)

G1

A7

M

6

Air conditioner blower motor

R5

C03

M

2

Front working lamp (R.H.)

C8

A8A

S

10

Intermediate connector (air conditioner) R4

C04

X

2

Low pressure switch (brake)

G1

A8B

S

8

Intermediate connector (air conditioner) R4

C04

M

2

Front working lamp (L.H.)

D8

A9

Yazaki

4

Air conditioner blower relay (M)

R2

C05

—

4

Beacon lamp switch

D8

A10

Yazaki

4

Air conditioner blower relay (Hi)

Q1

C06

KES 1

2

Room lamp

E9

A11

Yazaki

4

Air conditioner blower relay (M2)

R2

C07

M

4

Rear wiper motor

H9

A12

Yazaki

4

Air conditioner condenser relay

Q2

C08

Connector

1

Cigar lighter

B7

A13

Yazaki

4

Air conditioner blower relay (M1)

R2

C09

Connector

1

Cigar lighter

C7

A14

X

2

Air conditioner switch

R5

C11

Connector

1

Door switch (R.H.)

E8

A14

Yazaki

4

Air conditioner condenser relay

Q2

C12

Connector

1

Door switch (L.H.)

G9

A15

Yazaki

2

Air conditioner switch

R5

C13

KES 0

2

Speaker switch (L.H.)

G9

A15

Yazaki

4

Air conditioner condenser relay

R2

C14

KES 0

2

Speaker switch (R.H.)

F9

A16

Yazaki

4

Air conditioner compressor relay

Q2

C15

Connector

1

Beacon lamp

D8

A16

AMP

12

Air conditioner controller

P1

C16

M

2

Side working lamp (L.H.)

G9

A17

AMP

16

Air conditioner controller

P1

C17

M

2

Side working lamp (R.H.)

E8

A18

SWP

8

Air conditioner air servo motor (L.H.) P1

CL1

A19

SWP

8

Air conditioner air servo motor (R.H.) M4

CL2

S

10

Intermediate connector (air conditioner) M3

AL1

MiC

21

ECSS (controller)

M5

CL3

M

6

Intermediate connector (air conditioner) M3

AL2

AMP040 20

ECSS (controller)

M5

CL4

M

6

Intermediate connector (power window) M3

AL3

AMP040 16

ECSS (controller)

R6

CL18 Connector

1

Power window motor (L.H.)

E1

Place of use

S (blue) 12

Address

Place of use

H9

Intermediate connector (cab harness) M3

AL4

M

6

ECSS (machine selection)

P1

CL19 Connector

1

Power window motor (L.H.)

E1

ASS

X

2

Air suspension

R5

CL20 Connector

1

Power window motor (R.H.)

C7

B01

X

1

Air conditioner condenser

I2

CL21 Connector

1

Power window motor (R.H.)

C7

B02

X

2

Air conditioner condenser

J2

CR1

X

4

Low pressure switch (brake)

I1

B03

X

1

Air conditioner condenser

L6

E01

Terminal

1

Slow blow fuse (80A)

B04

X

2

Air conditioner condenser

L5

E02

X

4

Intermediate connector (glow plug) S6

B05

KES 1

2

Diode (window washer)

I9

E03

SWP

8

Engine stop motor

T2

B06

KES 1

2

Diode (window washer)

I9

E04

X

2

Coolant temperature sensor

T7

B07

KES 1

2

Window washer (front)

H9

E05

Connector

2

APS coolant temperature sensor

S5

W3

ECSS : Electronically controlled suspension system

WA600-3

20-213 (16)

TROUBLESHOOTING

Connector No.

Type

No. of pins

E06

X

2

E07

X

E08

CONNECTOR TYPES AND MOUNTING LOCATIONS

Address

Connector No.

Type

Engine speed sensor

S4

FS1

L

2

Torque converter temperature sensor

S3

FS2

X

2

Starting motor

U2

FS3

M

E09

X

2

Starting motor

T2

FS4

E10

X

1

Engine oil level switch

S2

E11

Terminal

1

Engine oil pressure switch

E12

X

1

E13

Connector

E14

Place of use

No. of pins

Place of use

Address

2

Fuse I

R6

S (blue) 12

Fuse I

Q6

6

Fuse I

Q6

L

2

Fuse II

Q6

FS5

M

6

Fuse II

Q6

S5

FS6

M

4

Fuse II

P6

Air conditioner compressor switch

V7

G01

X

2

Coolant level switch

K9

1

Dust indicator

U7

G02

M

2

Working lamp (R.H.)

J9

Connector

1

Dust indicator

U7

G03

M

2

Working lamp (L.H.)

L8

E15

Terminal

1

Alternator (B)

X5

G04

M

6

Rear combination lamp

L8

E16

Terminal

1

Alternator (R)

X7

G05

M

6

Rear combination lamp

L6 L7

E17

Terminal

1

Alternator (E)

X6

GR1

SWP

6

Intermediate connector (radiator harness)

E18

Terminal

1

GND

L3

GRE

SWP

6

Auto-grease (OP)

R3

E19

KES 1

2

Diode (starting motor)

X4

L01

SWP

6

Parking brake switch

N2

E20

KES 1

2

Diode (starting motor)

V3

L02

SWP

6

Light & dimmer switch

N2

E21

KES 1

2

Diode (starting motor)

V3

L03

SWP

6

Turn signal switch

N2

E22

KES 1

2

Diode (starting motor)

V2

L04

SWP

14

Transmission switch

N1

E23

KES 1

2

Diode (Air conditioner compressor) V7

L05

AMP040 20

Main monitor

M4

ECSS

SWP

14

Intermediate connector (ECSS)

R4

L06

AMP040 16

Main monitor

M3

ER1

SWP

14

Intermediate connector (engine harness) U2

L07

AMP040 12

Main monitor

M4

ER2

SWP

12

Intermediate connector (engine harness) V2

L08

AMP040

8

Main monitor

M2

F01

M

3

L09

M

6

Starting switch

M2

F02

M

3

L10

S

10

Wiper switch

O1

F03

M

3

Intermediate connector (head lamp R.H.) A6 Intermediate connector A6 (combination lamp R.H.) Intermediate connector E1 (combination lamp L.H.)

L12

X

2

Transmission cut off switch

O1

F04

M

3

Intermediate connector (head lamp L.H.)

D1

L15

M

4

Kick-down switch

M5

F05

X

3

Bucket positioner proximity switch A2

L15

KES 1

2

Boom kick-out solenoid

M5

F06

X

3

Boom kick-out proximity switch

A1

L17

KES 1

2

Bucket positioner solenoid

M4

F07

Connector

1

Horn (L.H.)

A1

L18

AMP040 16

Maintenance monitor

N6

F08

Connector

1

Horn (R.H.)

A5

L19

AMP040

8

Maintenance monitor

N6

F09

Connector

1

Horn (R.H.)

A4

L21

KES 1

2

Maintenance monitor

N6

F10

Connector

1

Horn (L.H.)

B1

L22

KES 1

2

Maintenance monitor

O6

F13

Terminal

1

GND (front frame)

C1

L40

Yazaki

7

Power window switch (R.H.)

N6

F14

X

2

Parking brake solenoid

D1

L41

Yazaki

7

Power window switch (L.H.)

M5

F15

X

2

Parking caution (monitor)

C1

L42

Connector

1

Caution buzzer

O6

FR1

S

10

Intermediate connector (front lamp)

D8

L43

Connector

1

Caution buzzer

O6

Intermediate connector (boom• bucket switch)

F1

L44

KES 0

6

Wiper relay

O6

FR2

SWP

20-214 (16)

6

WA600-3

TROUBLESHOOTING

Connector No.

Type

Address

Connector No.

Type

L46

KES 1

4

Flasher unit

O7

LR5

X

4

Intermediate connector (GND)

L48

—

5

Bucket relay

N7

LR6

L

2

Intermediate connector (power supply) R3

L49

—

5

Lift arm relay

N7

R01

X

2

Emergency steering switch

H1

L51

—

6

Side working lamp relay

O8

R03

KES 1

2

Diode (battery relay)

K2

L52

—

5

Hazzard relay

M7

R04

KES 1

2

Diode (battery relay)

K3

L53

—

5

Stop lamp relay

M8

R05

KES 1

2

Fuel level sensor

J2

L55

—

5

Horn relay

O8

R06

Terminal

1

Slow blow fuse (30A)

X4

L56

—

5

ECSS relay

M9

R07

Terminal

1

Slow blow fuse (30A)

W3

L57

—

5

Neutral relay

M8

R08

Terminal

1

Slow blow fuse (80A)

W3

L58

—

5

Neutralizer relay

M8

R09

Terminal

1

Slow blow fuse (80A)

W3

L59

—

5

Parking brake safety relay

M9

R10

Terminal

1

GND

K3

L60

—

6

Front working lamp relay

N9

R11

Terminal

1

Battery relay (M)

L4

L61

—

6

Rear working lamp relay

O9

R12

Terminal

1

Battery relay (B)

L5

L62

—

5

Engine stop relay

N9

R13

Terminal

1

Back buzzer

L6

L63

Connector

8

Horn switch

O1

R14

Terminal

1

Back buzzer

L6

L64

—

5

Engine oil pressure switch

M8

RA1

X

2

Intermediate connector (battery relay)

L5

L65

—

5

Transmission cut off relay

N9

T01

MS

10

Transmission control valve

E9

L66

—

6

Traveling FORWARD relay

O7

T02

KES 1

2

Diode (transmission control valve) F9

L67

—

6

Traveling REVERSE relay

O8

T03

KES 1

2

Diode (transmission control valve) F1

L68

—

6

Kick down relay

O8

T04

KES 1

2

Diode (transmission control valve) F9

L71

SWP

6

APS controller

M5

T05

X

2

Speed sensor

A2

L72

X

2

APS controller

M4

TL1

SWP

2

Intermediate connector

R3

L73

KES 1

2

Engine stop switch

N1

L74

KES 1

4

Preheating switch

M2

L75

KES 1

2

ECSS (Switch)

P6

L76

—

5

2nd – 1st selector relay

N7

L80

—

5

Dust indicator relay

M8

L81

X

2

Stop lamp switch

O1

L91

—

5

Power window relay (left rise)

O9

L92

—

5

Power window relay (left lower)

O8

L93

—

5

Power window relay (right rise)

N9

L94

—

5

Power window relay (right lower)

O9

S (blue) 12

R4

LR1

No. of pins

CONNECTOR TYPES AND MOUNTING LOCATIONS

Place of use

LR2

SWP

14

Intermediate connector (lamp, horn) Intermediate connector (air conditioner, washer)

LR3

SWP

12

Intermediate connector (engine)

R3

LR4

SWP

14

Intermediate connector (engine)

R4

No. of pins

Address

Place of use

R3

R4

ECSS : Electronically controlled suspension system

WA600-3

20-215 (16)

TROUBLESHOOTING

No. of pins

CONNECTOR TYPES AND MOUNTING LOCATIONS

Connector No.

Type

CL20

Connector

1

Power window regulator (R.H.)

C7

ER3

X

3

CL21

Connector

1

Power window regulator (R.H.)

C7

F01

M

3

Place of use

Address

Connector No.

Type

No. of pins

Place of use

Address

Intermediate connector

V1

Intermediate connector (head lamp R.H.) A6

CLTP

Connector

2

Engine coolant temperature sensor T8

F02

M

3

CR1

X

4

Low pressure switch (brake)

F03

M

3

Intermediate connector (combination lamp R.H.) Intermediate connector (combination lamp L.H.)

I1

A6 E1

E01

Terminal

1

Slow blow fuse (80A)

W2

F04

M

3

Intermediate connector (head lamp L.H.)

E04

X

2

Water temperature sensor

X4

F05

X

3

Bucket positioner proximity switch A2

E06

X

2

Engine speed sensor

T2

F06

X

3

Boom kick-out proximity switch

A1

E07

X

2

Torque converter temperature sensor(monitor)

T2

F07

Connector

1

Horn (L.H.)

A1

E08

X

2

Starting motor

U1

F08

Connector

1

Horn (R.H.)

A5

E09

X

2

Starting motor

T1

F09

Connector

1

Horn (R.H.)

A4

E10

X

1

Engine oil level switch

T5

F10

Connector

1

Horn (L.H.)

B1

E12

X

1

Air conditioner compressor switch U9

F13

Terminal

1

GND (front frame)

C1

E13

Connector

1

Dust indicator

T3

F14

X

2

Parking brake solenoid

D1

E14

Connector

1

Dust indicator

T2

F15

X

2

Parking caution (monitor)

C1

E15

Terminal

1

Alternator (B)

S7

FLTP

Connector

2

Fuel temperature sensor

U9

E16

Terminal

1

Alternator (R)

S6

FR1

S

10

Intermediate connector (front lamp)

D8

E17

Terminal

1

Alternator (E)

S7

FR2

SWP

6

E18

Terminal

1

GND

L3

FSO-

Terminal

1

Fuel shutoff valve (-)

S7

E19

KES 1

2

Diode (starting motor)

X3

FSO+ Terminal

1

Fuel shutoff valve (+)

S8

E20

KES 1

2

Diode (starting motor)

X3

FS1

2

Fuse I

Q6

E21

KES 1

2

Diode (starting motor)

T1

FS2

S (blue) 12

Fuse I

Q6

E22

KES 1

2

Diode (starting motor)

T1

FS3

6

Fuse I

Q6 Q6

L

M

D1

F1

E23

Connector

2

Diode (air conditioner compressor)

U9

FS4

L

2

Intermediate connector (lift arm, bucket switch)

E24

Terminal

1

Heater relay

V9

FS5

M

6

Fuse II

P6

E25

Terminal

1

Heater relay

W9

FS6

M

4

Fuse II

P6

E26

Terminal

1

Heater relay

U9

G01

X

2

Radiator water level sensor

K9

E27

Terminal

1

Heater relay

W9

G02

M

2

Working lamp (R.H.)

J9

E31

Terminal

1

Slow blow fuse

W2

G03

M

2

Working lamp (L.H.)

L8

E32

Terminal

1

Slow blow fuse

V1

G04

M

6

Rear combination lamp

L8

E33

Terminal

1

Heater relay

W9

G05

M

6

Rear combination lamp

L6 L7

ECMA DRC26

40

Engine controller

T5

GR1

SWP

6

Intermediate connector (radiator harness)

ECMB

DRC26

40

Engine controller

V9

GRE

SWP

6

Auto-grease (OP)

R3

ECB2

DT

2

S6

GND

Terminal

1

GND (OP)

M2

ECSS

SWP

6

Intermediate connector (ECSS) (OP) R4

GND

Terminal

1

Engine block GND

M2

ER1

SWP

14

Intermediate connector (engine harness) V1

GND

Terminal

1

GND

S6

ER2

SWP

14

Intermediate connector (engine harness) V1

GND

Terminal

1

GND

S7

WA600-3

—

20-219-2 (16)

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

(Pin No. is printed on connector (wire insertion side), too.)

Type (Shell size code)

HD30 series connector Body (Plug)

Body (Receptacle)

Pin (male terminal)

Pin (female terminal)

Part No. of T-adapter

799-601-9270

24-21 (7)

Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206

Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106

Pin (female terminal)

Pin (male terminal)

799-601-9270

Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206

Part No.: 08191-73101, 08191-73102 08191-73105, 08191-73106

Pin (male terminal)

Pin (female terminal)

799-601-9280

24-23 (8)

Part No.:08191-81201,08191-81202,08191-81203, 08191-81204,08191-81205,08191-80206

Pin (female terminal)

Part No.: 08191-84101,08191-84102,08191-84103, 08191-84104,08191-84105,08191-84106

Pin (male terminal)

799-601-9280

Part No.:08191-82201,08191-82202,08191-82203, 08191-82204,08191-82205,08191-82206

20-228-4 (11)

Part No.:08191-83101,08191-83102,08191-83103, 08191-83104,08191-83105,08191-83106

WA600-3

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

(Pin No. is printed on connector (wire insertion side), too.)

DT series connector c Body (Plug)

Body (Receptacle)

Part No. of T-adapter

8GR :799-601-9060 8B :799-601-9070 8G :799-601-9080 8BR :799-601-9090

8

Part No.: 08192-18200 (Normal type) 08192-28200 (Fine wire type)

Part No.: 08192-18100 (Normal type) 08192-28100 (Fine wire type)

12GR :799-601-9110 12B :799-601-9120 12G :799-601-9130 12BR :799-601-9140

12

Part No.: 08192-19200 (Normal type) 08192-29200 (Fine wire type)

WA600-3

Part No.: 08192-19100 (Normal type) 08192-29100 (Fine wire type)

20-228-7 (11)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

(Pin No. is printed on connector (wire insertion side), too.)

Type (Shell size code)

DTM series connector Body (Plug)

Body (Receptacle)

2

Part No. of T-adapter

799-601-9010

Part No.: 08192-02200

Part No.: 08192-02100

(Pin No. is printed on connector (wire insertion side), too.)

Type (Shell size code)

DTHD series connector Body (Plug)

Body (Receptacle)

2

Part No. of T-adapter

—

Part No.: 08192-31200 (Contact size #12) 08192-41200 (Contact size #8) 08192-51200 (Contact size #4)

20-228-8 (14)

Part No.: 08192-31100 (Contact size #12) 08192-41100 (Contact size #8) 08192-51100 (Contact size #4)

WA600-3

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 type connector Male (female housing)

Female (male housing)

10

799-601-7510

—

Part No.: 7821-92-7330

12

799-601-7520

—

Part No.: 7821-92-7340

14

799-601-7530

—

Part No.: 7821-92-7350

18

799-601-7540

—

Part No.: 7821-92-7360

20

799-601-7550

—

WA600-3

T-adapter Part No.

Part No.: 7821-92-7370

20-228-9 (14)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins

DRC26 Series connector Body (plug)

Body (receptacle)

24

T-adapter Part No.

799-601-9360

—

Part No.: 7821-93-3110

40 (A)

799-601-9350

—

Part No.: 7821-93-3120

40 (B)

799-601-9350

—

20-228-10 (14)

Part No.: 7821-93-3130

WA600-3

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

T-BRANCH BOX AND T-BRANCH TABLE

799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340 799-601-7140

WA600-3

Measurement box Measurement box Measurement box Measurement box Plate Plate Plate BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) Case MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Additional cable Case X X X X SWP SWP SWP SWP SWP M M M M M M S

—

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

799-601-2800

Connector type or No. of pins part name

799-601-2700

Part No.

799-601-2500

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of Harness Checker assembly.

Econo-21P MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P 5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P

1P 2P 3P 4P 6P 8P 12P 14P 16P 1P 2P 3P 4P 6P 8P 8P

20-228-11 (14)

TROUBLESHOOTING

799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410 799-601-9420 799-601-9430

20-228-12 (14)

S S S S S AMP040 AMP040 AMP040 AMP040 Short connector Case Case 070 070 070 070 070 Relay connector Relay connector JFC connector DTM DT DT DT DT DT DT DT DT DT DT DT DT HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 Plate Measurement box Case Case DRC26 DRC26 For NE, G sensor For fuel, boost press. PVC socket

—

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

799-601-2800

799-601-2700

Connector type or No. of pins part name

799-601-2500

Part No.

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

10P-White 12P-Blue 16P-Blue 16P-White 12P-White 8P 12P 16P 20P X-2

10P 12P 14P 18P 20P 5P 6P 2P 2P 2P 3P 4P 6P 8P-Gray 8P-Black 8P-Green 8P-Brown 12P-Gray 12P-Black 12P-Green 12P-Brown 18-8 18-14 18-20 18-21 24-9 24-16 24-21 24-23 24-31 For HD30 For DT, HD

40P 24P 2P 3P 2P

WA600-3

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

Method of using troubleshooting charts ............................................................................................... 20-302 S- 1 Starting performance is poor (starting always takes time) ....................................................... 20-306 S- 2 Engine does not start (1) Engine does not turn ............................................................................................................. 20-308 (2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ..................... 20-309 (3) Exhaust gas smoke comes out but engine does not start (fuel is being injected) ........... 20-310 S- 3 Engine does not pick-up smoothly (follow-up is poor) ............................................................. 20-311 S- 4 Engine stops during operations .................................................................................................. 20-312 S- 5 Engine does not rotate smoothly (hunting) ............................................................................... 20-313 S- 6 Engine lacks output (no power) .................................................................................................. 20-314 S- 7 Exhaust smoke is black (Incomplete combustion) .................................................................... 20-315 S- 8 Oil comsumption is excessive (or exhaust smoke is blue) ....................................................... 20-316 S- 9 Oil becomes contaminated quickly ............................................................................................. 20-317 S-10 Fuel consumption is excessive .................................................................................................... 20-318 S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down ..................................... 20-319 S-12 Oil pressure lamp lights up (drop in oil pressure) ..................................................................... 20-320 S-13 Oil level rises ................................................................................................................................. 20-321 S-14 Coolant temperature becomes too high (overheating) ............................................................. 20-322 S-15 Abnormal noise is made .............................................................................................................. 20-323 S-16 Vibration is excessive ................................................................................................................... 20-324

WA600-3

20-301 (16)

S-1

TROUBLESHOOTING

General causes why exhaust gas comes out but engine does not start. • Defective electrical system • Insufficient dupply of fuel • Insufficient intake of air • Improper selection of fuel (At ambient temperature of – 10°C or below, use ASTEM D975 No. 1) fl Battery charging rate Ambient temperature

Charging rate

20°C 0°C –10°C • •

100 %

90 %

80 %

75 %

70 %

1.28 1.29 1.30

1.26 1.27 1.28

1.24 1.25 1.26

1.23 1.24 1.25

1.22 1.23 1.24

The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold weather the specific gravity must be for the charging rate of at least75% in the above table.

Causes

Wor np Defe iston ri ng ctive cont , cylind Clog er act o ged f val air c Clog v l e, v e a ged ner fuel elem alve se Clog at filte ent ged r, st fee ra Defe ctive d pump iner APS s Defe devi trainer cti ce Defe ve regu lato ctive r alt Defe ctive ernator or Defe ctive deterio rate injec Defe db tion tive nozz attery injec Defe l e t i o tive injec n timing tion pum p (ra ck, p lung er st uc k )

S-1 Starting performance is poor (starting always takes time)

Questions

Confirm recent repair history Degree of use

Operated for long period

Ease of starting

Gradually became worse Starts when warm

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

Check items

Engine does not pick up smoothly, and combustion is irregular Blow-by gas is excessive Match marks on fuel injection pump are out of alignment Mud is stuck to fuel tank cap When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular) When compression pressure is measured, it is found to be low When air cleaner element is inspected directly, it is found to be clogged

Troubleshooting

When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged APS combustion portion does not become warm Voltage is 26–30V between alternator terminal B and terminal E with engine at low idle

Yes No

Either specific gravity of electrolyte or voltage of battery is low Some cylinders does not change engine speed when operating on reduced cylinders When check is made using delivery method, injection timing is found to be incorrect When control rack is pushed, it is found to be heavy or does not return (when blind plug at rear of pump is removed, it can be seen that plunger control sleeve does not move) When fuel cap is inspected directly, it is found to be clogged

20-306 (16)

Remedy

Replace Repair Clean Clean Clean Replace Replace Replace Replace Replace Adjust Replace

When overflow valve is inspected, it is found to be stiff, or always stays open Legend : Possible cause (jugding from Questions and Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

WA600-3

TROUBLESHOOTING

S-2

S-2 Engine does not start (1)

Engine does not turn

General causes why engine does not turn Causes

Defe

ctive wiri ng o Defe f sta ctive rting o Defe circu ctive r deteri it o rate Brok star d ba ting en r ttery mot ing Defe gea or r ct Defe ive safe ty r cti Defe ve batte elay or s afe ry re ctive ty s w lay ba Defe itch ctive ttery te rmin adju Defe al c o stm ctive e nne nt o en Defe ctio f en ctive gine st n op m gine st star op m ting otor otor swit ch wire

• Internal parts of engine seized fl If internal parts of the engine are seized, carry out troubleshooting for "Engine stops during operations". • Failure in power train • Defective electrical system

Questions

Confirm recent repair history Degree of use

Operated for long period

Condition of horn when start- Horn does not sound ing switch is turned ON Horn sound level is low Rotating speed is slow When starting switch is turned to START, pinion moves out, but

Makes grating noise Soon disengages again Makes rattling noise and does not turn

When starting switch is turned to ON, there is no clicking sound Battery terminal is loose When starting switch is turned to ON, linkage does not move When battery is checked, battery electrolyte is found to be low

Carry out troubleshooting for defective wiring of starting circuit

Check items

When starting switch is turned to START, pinion does not move out

20-308 (16)

Replace Replace Replace Replace Replace Replace Adjust Replace Replace

When ring gear is inspected directly, tooth surface is found to be chipped Does not move even when engine stop mtoro linkage is disconnected Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

Carry out troubleshooting for defective wiring of starting circuit

For the following conditions 1) – 5), turn the starting switch OFF, connect the cord, and carry out troubleshooting at ON 1) When terminal B and terminal C of starting switch are connected, engine starts 2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal C of safety relay are connected, engine starts 4) When terminal of safety switch and terminal B of starting motor are connected, engine starts 5) There is no 24V voltage between terminal B and terminal E of battery relay

—

Troubleshooting

Specific gravity of electrolyte, voltage of battery is low

WA600-3

S-3

TROUBLESHOOTING

S-3 Engine does not pick-up smoothly (follow-up is poor) General causes why engine does not pick up smoothly Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Use of improper fuel Defective fuel injection pump

Clog ged air c Clog lean ged er e fuel lem Clog ent filte ged r , str f e aine ed p Clog r ump ged stra inje Defe ctio iner ctiv n n e fe Wor ed p ozzle, d n pi ef ec ump ston tive Seiz spra ring ed t , y cylin urbo d Imp e c r harg rope e r , r inte valv Clog rfer e cle ge enc aran e Clog d fuel t ce ank ged air b , lea Defe king reat her ctiv fuel e co hole pipi Imp ntac ng rope t of r v adju alve Bro stm , va k ent lve diap en inje of in seat hrag ction j ectio m, b pum n pu roke p bo mp n ai stop r pu ost com leve mp pen r sato r

• • • • •

Causes

Confirm recent repair history

Questions

Degree of use

Operated for long period

Replacement of filters has not been carried out according to operation manual Non-specified fuel has been used Engine oil must be added more frequently Rust and water are found when fuel is drained Dust indicator is red Noise of interference is heard from around turbocharger Engine pick-up suddenly became poor Color of exhaust gas

Blue under light load Black

Check items

Clanging sound is heard from around cylinder head Mud is stuck to fuel tank cap There is leakage from fuel piping High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Blow-by gas is excessive When air cleaner element is inspected directly, it is found to be clogged

Troubleshooting

When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Some cylinders does not change engine speed when operating on reduced cylinders Inspect feed pump When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy When valve clearance is checked directly, it is found to be outside standard value When fuel cap is inspected directly, it is found to be clogged When feed pump is operated, operation is too light or too heavy

WA600-3

Replace

Adjust

Replace

Repair

Clean

Adjust

Replace

Replace

Replace

Repair

Clean

Clean

Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

Clean

When starting switch is turned ON, there is a clearance between stop lever and stopper bolt When boost compensator diaphragm is inspected it is found to be broken, or pipe is crushed

20-311 (16)

S-4

TROUBLESHOOTING

S-4 Engine stops during operations General causes why engine stops during operations

Causes

Bro

ken , sei zed Bro pist ken on, , sei con zed Bro nec ken cran ting valv ksha rod Bro e ft be syst ken arin em , sei g ( v Bro z a ed g lve, ken ear rock pum train er le Bro p au ver, ken xilia etc. fuel r y ) Lack equ pum ipm p dr of fu ent ive el Clog sha ged ft, k ey fuel Clog f i l ter, ged stra feed Bro iner pum ken p st , sei rain Clog zed er feed ged , lea pum Clog k i p n pist g fu ged on el p fuel Defe ipin tank g ctiv a i e in r bre ject Fail ath ion ure pum er hole in c has p (r a sis p ck, p owe lung r tra er s in tuck )

• Internal parts of engine seized • Insufficient supply of fuel • Overheating fl If there is overheating and the engine stops, carry out troubleshooting for overheating. • Failure in power train fl If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.

Questions

Confirm recent repair history Degree of use

Operated for long period Abnormal noise was heard and engine stopped suddenly

Condition when engine stopped

Engine overheated and stopped Engine stopped slowly There was hunting and engine stopped

Fuel gauge lamp lights up Fuel tank is found to be empty Replacement of filters has not been carried out according to operation manual Non-specified fuel has been used When feed pump is operated, there is no response or it is heavy Mud is stuck to fuel tank cap Engine turns, but stops when transmission control lever is operated

Try to turn by hand using barring tool

Carry out troubleshooting in chassis volume

Check items

Does not turn at all Turns in opposite direction Moves amount of backlash Shaft does not turn Rust and water are found when fuel is drained Metal particles are found when oil is drained

20-312 (16)

Replace

Clean

Replace

Repair

Clean

Clean

Add

Replace

Replace

Replace

Replace

Inspect feed pump directly When control rack is pushed, it is found to be heavy or does not return Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

Replace

Turns when pump auxiliary equipment is removed When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged

Replace

Troubleshooting

When gear train is inspected, it does not turn

—

Carry out troubleshooting in chassis volume

Remove oil pan and inspect directly Remove head cover and inspect directly

WA600-3

S-5

TROUBLESHOOTING

S-5 Engine does not rotate smoothly (hunting) General causes why engine does not rotate smoothly

Defe ctiv e op erat Defe ino ctiv of g e adju Defe ove stm rnor ctiv ent e op of g Low erat ove ion spe rnor ed i of c Lack s to ontr o lo of fu ol ra w ck el Clog ged feed Clog pum ged p st fuel rain Clog f i lter, er ged, stra air in iner Clog c ircui ged t bet , air wee Clog in ci n fu rcui ged el ta t be f uel nk a Defe twee tank nd f ctiv n fe eed air b e fu ed p pum el fe reat um p ed p her and hole ump nozz le

• Air in fuel system • Defective governor mechanism

Causes

Confirm recent repair history Degree of use

Operated for long period Occurs at fixed speed range

Questions

Condition of hunting

Occurs at low idle Occurs even when speed is raised Occurs on slopes

Fuel tank is found to be empty Replacement of filters has not been carried out according to operation manual Rust is found when fuel is drained Leakage from fuel piping

Troubleshooting

Check items

When feed pump is operated, 1) No response, light, return is quick 2) No response, light, return is normal Engine speed sometimes changes greatly Sometimes difficult to stop engine Seal on injection pump has come off When governor lever is moved it is found to be stiff When injection pump is tested, governor is found to be improperly adjusted When control rack is pushed, it is found to be heavy or does not return When fuel cap is inpsected directly, it is found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged

WA600-3

Replace

Clean

Repair

Repair

Clean

Clean

Add

Adjust

Adjust

Adjust

Adjust

Check fuel feed pump Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

20-313 (16)

TROUBLESHOOTING

S-6

S-6 Engine lacks output Causes

• • • •

Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Use of Improper fuel (If non-specified fuel is used, output drops) • Lack of output due to overheating fl If there is overheating and lack of output, carry out troubleshooting for overheating

Clog ged air c Seiz lean ed t er e u r lem boc Wor harg ent n pi er, i s t on r nter Clog ing, fere ged cylin nce fuel Clog der filte ged r , s f t eed r Clog pum ainer ged p st inje Seiz rain c tion ed i er noz njec Imp zle, t i o n pu rope defe ctiv mp r va e sp Defe plun lve clea ray ctiv ger r e a con nce Ben tact t fue of v l lev alve Clog er li and ged nka , ge, valv l e Clog akin defe e se g fu ged ctiv e f e ad at l u pipi el ta Brok just n nk a en i men ir br g t Inco njection e a ther rrec pum t po hole p bo Oil l sitio ost c eve no om l too high f stop le pensato r dia ver phr

General causes why engine lacks output

ag m

Carry out troubleshooting to decide if the cause is in the enginer or in the machine. (Measure engine stall speed).

Confirm recent repair history Degree of use

Questions

Power was lost

Operated for long period Suddenly Gradually

Engine oil must be added more frequently Replacement of filters has not been carried out according to operation manual Non-specified fuel has been used Dust indicator is red Color of exhaust gas

Black Blue under light load

Noise of interference is heard from around turbocharger Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular High idle speed under no load is normal, but speed suddenly drops when load is applied When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low There is hunting from engine (rotation is irregular) Clanging sound is heard from around cylinder head High idle speed of engine is low Leakage from fuel piping When injection pipe is held between fingers, there is no pulse, or there are cylinders with a weak pulse

When turbocharger is rotated by hand, it is found to be heavy Troubleshooting

When compression pressure is measured, it is found to be low When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Some cylinders does not change engine speed when operating on reduced cylinders When control rack is pushed, it is found to be heavy or does not return When valve clearance is checked directly, it is found to be outside standard value When lever is placed at FULL position, it does not contact stopper When feed pump is operated, operation is too light or too heavy

20-314 (16)

Clean

Repair

Adjust

Replace

Adjust

Replace

Repair

Clean

Clean

Replace

Replace

Clean

When fuel cap is inspected directly, it is found to be clogged Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

Go to S-3 Engine does not pick up smoothly

When air cleaner element is inspected directly, it is found to be clogged

WA600-3

S-8

TROUBLESHOOTING

S-8 Oil comsumption is excessive (or exhaust smoke is blue) fl To prevent the oil from leaking up or down, do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)

Brok en p isto n rin Wor g n pi ston Clog r i n g, c ged ylin brea der Lea ther kag line or b e fro r r Lea eath mo kag il fil er h e fro ter, ose Lea mo oil c kag il pi oole e fro p r i n Lea g mo kag il dr e fro a i n Bro mo plug ken il pa oil c n, c Wor oole ylin der n se r hea al a d, e Wor t tur tc. bine n se a e l at n Wor d blow n, b er e roke nd Dus Turb nr t su och cked ear sea arge l Wor , i s n fro eal r n va surf m in l v ace e (s t a Brok k tem e sy en in , gu stem jecti ide) Oil l on p , bro eve ump ken l too boos seal high t c om pens ator diap hrag m

Causes

General causes why oil consumption is excessive • Abnormal combustion of oil • External leakage of oil • Wear of lubrication system

Questions

Confirm recent repair history Degree of use

Operated for long period

Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Exhaust gas is blue under light load Amount of blow-by gas

Abnormally excessive None

Area around engine is dirty with oil

Check items

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

Troubleshooting

Inside of joint bolt of injection pump and boost compensator pipe is wet with oil When compression pressure is measured, it is found to be low When breather element is inspected, it is found to be clogged with dirty oil There is external leakage of oil from engine Pressure-tightness test of oil cooler shows there is leakage Excessive play of turbocharger shaft Check rear seal directly When intake manifold is removed, dust is found inside

20-316 (16)

Adjust

Replace

Repair

Repair

Repair

Replace

Replace

Replace

Repair

Repair

Repair

Repair

Clean

Replace

Replace

When intake manifold is removed, inside is found to be dirty with oil Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

WA600-3

S-9

TROUBLESHOOTING

S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly Intake of exhaust gas due to internal wear Clogging of lubrication passage Improper combustion Use of improper oil Operation under excessive load Interval between oil change too long

Causes

Wor n pi ston Clog ring , cyl ged inde brea r ther Clog , bre ged athe oil f r tub ilter Wor e n va lve, Clog valv ged e gu oil c ide Clog oole r ged turb Defe och arge ctiv e se r dr ain a Defe l at pipe turb ctiv e sa och a f e r t g y va Exh er tu lve aus rbin t ga e en s is d blac Oil l k eve l too high

• • • • • •

Questions

Confirm recent repair history Degree of use

Operated for long period

Engine oil must be added more frequently Non-specified fuel has been used Color of exhaust gas

Blue under light load Abnormally excessive None

When oil filter is inspected, metal particles are found When exhaust pipe is removed, inside is found to be dirty with oil Engine oil temperature rises quickly

Carry out troubleshooting also for "Exhaust gas is black".

When oil level is checked with dipstic, it is found to be above H mark

When oil filter is inspected directly, it is found to be clogged When oil cooler is inspected directly, it is found to be clogged Turbocharger drain tube is clogged

WA600-3

Replace

Replace

Clean

Clean

Replace

Replace

Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

Clean

Excessive play of turbocharger shaft When safety valve is inspected directly, spring is found to be catching or broken Replace

Troubleshooting

When compression pressure is measured, it is found to be low When breather element is inspected directly, it is found to be clogged with dirty oil, or hose is broken

Adjust

Check items

Oil filter caution lamp stays on even when oil pressure rises

—

Amount of blow-by gas

Carry out troubleshooting also for "Exhaust gas is black".

Black

20-317 (16)

S-10

TROUBLESHOOTING

S-10 Fuel consumption is excessive General causes why fuel consumption is excessive Causes Defe ctiv e in ject Defe ion ctiv pum e in p (e ject Defe xces i on n ctiv sive ozzl e in e sp inje ject Imp ctio ray ion rope n) p ump r fue Exte p l l i u n nge ject rnal ion r leak timi age Defe ng from ctiv e oi fuel l sea Defe pipi l ins ctiv ng, ide e ad fuel feed just Defe filte men pum r ctiv t of e in p (pis fuel ject t o ion n l eve ) noz r lin zle ( kag loos e e re tain ing cap )

• Leakage of fuel • Improper condition of fuel injection • Excessive injection of fuel

Questions

Confirm recent repair history Degree of use

Operated for long period More than for other machines of same model

Condition of fuel consumption

Exhaust gas color

Gradually increased Suddenly increased Black White

Seal on injection pump has come off Check items

There is irregular combustion When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match mark on injection pump is misaligned There is external leakage of fuel from engine Engine oil level rises and smells of diesel fuel Engine low idle speed is high

Troubleshooting

Injection pump test shows that injectin amount is too high Some cylinders does not change engine speed when operating on reduced cylinders When control rack is pushed, it is found to be heavy or does not return When check is made using delivery method, injection timing is found to be incorrect Remove nozzle holder and inspect directly Remove feed pump and inspect direclty

20-318 (16)

Repair

Adjust

Repair

Repair

Adjust

Replace

Replace

Adjust

When engine speed is measured, low idle speed is found to be high Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

WA600-3

S-11

TROUBLESHOOTING

S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down General causes why oil is in coolant Causes Bro ken oil c oole Bro ken r co re, O cylin -ring der Insu hea ffici d , cyl ent inde prot Bro r he rusi ken ad g on o oil c aske f cy oole Brok lind t r for en c e r ylin p l i o n w e der r Inte e r line train rnal O-ri crac ng, ks in Brok hole en s c s ca ylin eal o der used n wa bloc by p ter p k ittin ump g (bre athe r ho le cl ogg ed)

• Internal leakage in lubrication system • Internal leakage in cooling system

Questions

Confirm recent repair history Degree of use Increase in oil level

Operated for long period Suddenly increased Gradually increased

Engine oil level has risen, oil is cloudy white Excessive air bubbles inside radiator, water spurts back Hydraulic oil, torque converter, transmission oil is cloudy white When hydraulic oil, torque converter, transmission oil is drained, water comes out Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage Remove cylinder head and inspect directly Remove oil pan and inspect directly

WA600-3

Replace

Replace

Replace

Replace

Replace

Replace

Inspect water pump

Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

Replace

Troubleshooting

Check items

Hard water is being used as coolant (corrosion resistor valve is closed)

20-319 (16)

S-12

TROUBLESHOOTING

S-12 Oil pressure lamp lights up (drop in oil pressure) General causes why oil pressure lamp lights up. • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Used of improper oil (improper viscosity) • Deterioration of oil due to overheating

ged oil f ilter n be a ring Clog jour ged nal stra Clog iner ged insi , de o brok Bro il pa en o ken n il pi suct pe i Defe ion nsid pipe ctiv eo e oi b razi Insu l pu ng p il pan mp ffici o e rtion nt o Defe il le ctiv vel e i n oi regu Defe l pa lato ctiv n r va e re lve Lea l i ef v king alve , crus Defe hed ctiv hyd e oi raul Defe l lev ic p el se ctiv ipin e oi nso g l r pres Wat er, f sure uel s e in o nso Clog il r ged oil c oole r

Causes

★ Standards for engine oil selection AMBIENT TEMPRATURE KIND 0 10 20 30 OF FLUID -20 –10

40 50°C

SAE 30CD SAE 10WCD Engine oil SAE 10W-30CD

Clog

Wor

Clean

Clean

SAE 15W-40CD

Questions

Confirm recent repair history Operated for long period Degree of use Replacement of filters has not been carried out according to operation manual Caution lamp lights up Non-specified fuel has been used Lights up at low idle

Check items

Condition when oil pressure lamp lights up

Lights up at low, high idle Lights up on slopes Sometimes lights up

Crushed piping, leakage from hydraulic piping (external) Oil level sensor lamp lights up When oil level in oil pan is checked, it is found to be low Metal particles are found when oil is drained Metal particles are stuck to oil filter element

Oil pump rotation is heavy, there is play There is catching of relief valve, regulator valve, or spring, valve guide is broken When oil level sensor is replaced, oil pressure sensor lamp goes out

20-320 (16)

Replace

Replace

Repair

Adjust

Adjust

Add

Replace

Repair

Clean

Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

Clean

When oil pressure is measured, it is found to be within standard value Check oil cooler

Replace

Carry out troubleshooting for "Oil level rises".

When oil filter is inspected directly, it is found to be clogged Remove oil pan and inspect directly

—

Troubleshooting

Oil is cloudy white or smells of diesel oil

WA600-3

S-13

TROUBLESHOOTING

S-13 Oil level rises fl If there is oil in the coolant, carry out troubleshooting for "Oil is in coolant".

Questions

Bro

• Water in oil (cloudy white) • Fuel in oil (diluted, and smells of diesel fuel) • Entry of oil from other component

ken oil c oole Defe r co ctiv re, O e no -ring zzle Bro ken h o l der prec cylin s omb leev d e usti er hea Clog on c d, h ged ham ead g wat b aske er) er p Wor t (in ump n, d clud b ama reat ing Defe ged her h ctiv r o e ar s le, d e se eal efec al o Lea surf tive f pu kag ace seal mp e of o f r uel Defe a u xilia from ct in ry e noz side quip zle h inje Defe m en olde ctio ctiv t n r ret e th p u mp aini erm Dam ng c osta aged ap t se cylin at Crac der liner ks in O-rin side Bro g, ho cylin ken les m der afte bloc ade r-co k by p oler ittin core g

Causes

General causes why oil level rises

Confirm recent repair history Degree of use

Operated for long period

There is oil in radiator coolant Exhaust gas is white

Check items

When engine is first started, drops of water come from muffler Leave radiator cap open. When engine is run at idle, an abnormal number of bubbles appear, or water spurts back Water pump breather hole is clogged with mud When water pump breather hole is cleaned, water comes out Oil level does down in TORQFLOW transmission, or damper case Oil level does down in hydraulic tank Engine oil smells of diesel fuel Fuel is added more frequently Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage

Troubleshooting

When compression pressure is measured, it is found to be low Remove water pump and inspect directly Inspect rear seal directly When pump auxiliary equipment is removed, seal is found to be broken Remove nozzle holder and inspect directly Remove injection pump and inspect directly There is improper contact of thermostat seat valve Remove oil pan and inspect directly

WA600-3

Replace

Replace

Replace

Repair

Replace

Repair

Replace

Repair

Replace

Replace

Replace

Replace

Pressure-tightness test of after-cooler core shows there is leakage Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

20-321 (16)

S-14

TROUBLESHOOTING

S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high Causes

Lack of cooling air (deformation, damage of fan) Drop in heat dissipation efficiency Defective cooling circulation system Rise in oil temperature of power train fl Carry out troubleshooting for chassis

Bro ken Clog water p ge ump Clog d, crush ed r ged adia radi Defe tor f ator ctiv in core e , lea ther Defe mos kag ctiv e tat ( ew doe ater Insu s no ffici tem t op e p nt c erat Fan en) ooli ure belt ng w g aug s lipp a e Clog t e r ing, ged wor , bro n Defe f an p ken cti oil c ulle y oole Bro ve pres ken r sure c y valv lind Dam e er h aged ead cylin , he Rise der ad g in to liner aske rque O-rin Crac t con g, ho k in v e c les m rter ylin Defe oil t der ade ctive em p bloc by p fan erat ittin pum k g ure pm otor (D47 5A-1 )

• • • •

Condition of overheating

Suddenly overheated Always tends to overheat

Water temperature gauge

Rises quickly Does not go down from red range

Carry out troubleshooting for chassis

Questions

Confirm recent repair history Operated for long period Degree of use

Radiator coolant level sensor lights up Fan belt whines under sudden load

Check items

Cloudy white oil is floating on coolant Coolant flows out from overflow hose Excessive air bubbles inside radiator, water spurts back Engine oil level has risen, oil is cloudy white Radiator shroud, inside of underguard are clogged with dirt or mud When light bulb is held behind radiator, no light passes through Water is leaking because of cracks in hose or loose clamps Belt tension is found to be slack Power train oil temperature enters red range before engine coolant temperature

When measurement is made with radiator cap tester, set pressure is found to be low When compression pressure is measured, it is found to be low Remove oil pan and inspect directly

Carry out troubleshooting for chassis

When coolant temperature is measured, it is found to be normal When oil cooler is inspected directly, it is found to be clogged

Replace —

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

Carry out troubleshooting for chassis

Troubleshooting

Temperature difference between top and bottom radiator tanks is too small

—

Temperature difference between top and bottom radiator tanks is excessive

20-322 (16)

Replace

Replace

Replace

Replace

Repair

Add

Replace

Replace

Repair

Repair

Replace

Pressure-tightness test of cylinder head shows there is leakage Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

WA600-3

S-16

TROUBLESHOOTING

S-16 Vibration is excessive fl If there is abnormal noise together with the vibration, carry out troubleshooting for "Abnormal noise is made" General causes why vibration is excessive

Questions

• Defective parts (abnormal wear, breakage) • Improper alignment • Abnormal combustion

Confirm recent repair history Degree of use Condition of vibration

Wor n, s eize Wor d co n ca nne mb ctin Wor ush g ro n su i ng d, m ppo ain Loo r t bea pilo se e ring t ngin Bro e mou ken part ntin g bo Mis insi alig de o l nme utpu ts, brok Imp n en c t sh t be rope ush aft ( twe r ge ion en e dam Valv a r tra ngin per) e sy i e n s a bac tem nd p Defe k lash (val owe ctive ve, r tra rock Defe injectio in er le n pu ctiv m v e p er, e vibr (exce Clog tc.) atio ged stuc n da ssive inje inje k mpe ction ctio , plu r n no nger zzle seize

d)

Causes

Operated for long period Suddenly increased Gradually increased

Non-specified fuel has been used Metal particles are found in oil filter

Check items

Metal particles are found when oil is drained Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed Exhaust gas is black Seal on injection pump has come off Remove oil pan and inspect directly

Troubleshooting

Remove side cover and inspect directly Check directly for worn support pilot, play Inspect directly for loose engine mounting bolts, broken cushion Check inside of output shaft (damper) directly When radial runout, face runout are measured, they are found to be outside standard Remove front cover, and inspect directly Remove head cover and inspect directly

20-324 (16)

Replace

Replace

Adjust

Replace

Repair

Repair

Replace

Replace

Replace

Replace

Replace

Injection pump test shows that injection amount is incorrect Legend : Possible cause (jugding from Questions and Remedy Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items confirm the cause

WA600-3

TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE) Serial 52001 and up Method of error code display ...................................................................................................................... 20-353 Action taken by controller and condition of machine when error code is displayed .................................... 20-356 Schematic diagram for engine control system ............................................................................................ 20-364 EA-1 Error code [111] (Abnormality in controller memory)....................................................................... 20-366 EA-2 Error code [112] (Abnormality in timing rail actuator ....................................................................... 20-366 EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system) ......................... 20-367 EA-4 Error code [115] (Abnormality in engine speed sensor 2 system) .................................................. 20-368 EA-5 Error code [116] (Abnormality in timing rail pressure sensor system high level) ............................ 20-370 EA-6 Error code [117] (abnormality in timing rail pressure sensor system low level) .............................. 20-371 EA-7 Error code [118] (Abnormality in fuel pump pressure sensor system high level) ............................ 20-372 EA-8 Error code [119] (Abnormality in fuel pump pressure sensor system low level) ............................. 20-373 EA-9 Error code [121] (Abnormality in engine speed sensor 1 system) .................................................. 20-374 EA-10 Error code [122] (Abnormality in boost pressure sensor system high level)................................... 20-375 EA-11 Error code [123] (Abnormality in boost pressure sensor system low level) .................................... 20-376 EA-12 Error code [131] (Abnormality in accelerator sensor system high level)......................................... 20-377 EA-13 Error code [132] (Abnormality in accelerator sensor system low level) .......................................... 20-378 EA-14 Error code [135] (Abnormality in oil pressure sensor system high level) ........................................ 20-379 EA-15 Error code [141] (Abnormality in oil pressure sensor system low level) ......................................... 20-380 EA-16 Error code [143] (Abnormal drop in oil pressure (level 1)) .............................................................. 20-381 EA-17 Error code [144] (Abnormality in coolant temperature sensor system high level) .......................... 20-382 EA-18 Error code [145] (Abnormality in coolant temperature sensor system low level) ............................ 20-383 EA-19 Error code [151] (Abnormal rise in coolant temperature)................................................................ 20-383 EA-20 Error code [153] (Abnormality in intake air temperature sensor system high level)........................ 20-384 EA-21 Error code [154] (Abnormality in intake air temperature sensor system low level) ......................... 20-384 EA-22 Error code [221] (Abnormality in atmospheric pressure sensor system high level) ........................ 20-385 EA-23 Error code [222] (Abnormality in atmospheric pressure sensor system low )................................. 20-386 EA-24 Error code [234] (Overspeed) ......................................................................................................... 20-388 EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage).............................................. 20-389 EA-26 Error code [259] (Abnormality in fuel shut-off valve)....................................................................... 20-390 EA-27 Error code [261] (Abnormal rise in fuel temperature) ..................................................................... 20-390 EA-28 Error code [263] (Abnormality in fuel temperature sensor system high level) ................................ 20-391 EA-29 Error code [265] (Abnormality in fuel temperature sensor system low level).................................. 20-391 EA-30 Error code [316] (Abnormality in fuel pump actuator system current) ............................................ 20-392 EA-31 Error code [318] (Abnormality in fuel pump actuator) ..................................................................... 20-393 EA-32 Error code [343] (Abnormality in controller internal communication) .............................................. 20-393 EA-33 Error code [346] (Abnormality in controller power down)................................................................ 20-394 EA-34 Error code [384] (Abnormality in preheating heater control system) .............................................. 20-395 EA-35 Error code [415] (Abnormal drop in oil pressure (level 2)) .............................................................. 20-396 EA-36 Error code [423] (Abnormality in timing rail pressure sensor system in range) .............................. 20-397

WA600-3

20-351 (16)

EA-37 EA-38 EA-39 EA-40 EA-41 EA-42 EA-43 EA-44 EA-46 EA-47 EA-48 EA-49

Error code [431] (Abnormality 1 in idling validation switch system) ................................................ 20-399 Error code [432] (Idle validation process error)............................................................................ 20-399-2 Error code [441] (Abnormality in battery voltage low level).......................................................... 20-399-4 Error code [442] (Abnormality in battery voltage high level) ........................................................ 20-399-4 Error code [451] (Abnormality in fuel rail pressure sensor system high level) ............................. 20-399-5 Error code [452] (Abnormality in fuel rail pressure sensor system low level) .............................. 20-399-6 Error code [455] (Abnormality in fuel rail actuator system current) .............................................. 20-399-7 Error code [467] (Abnormality in timing rail actuator control)....................................................... 20-399-8 Error code [514] (Abnormality in fuel rail actuator) ...................................................................... 20-399-8 Error code [527] (Abnormality in dual output solenoid A system) ................................................ 20-399-9 Error code [551] (Abnormality 2 in idle validation switch system) ................................................ 20-399-9 Error code [554] (Abnormality in fuel rail pressure sensor in range).......................................... 20-399-10

20-352 (16)

WA600-3

TROUBLESHOOTING

Action by controller

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Problem that appears on machine

Probable cause

• Red lamp lights up

• Engine cannot be started

• Defective engine controller

• Red lamp lights up • Limits engine speed to 1,500 rpm

• Engine speed goes down

• Excessive negative pressure at inlet port of fuel pump • Defective timing rail actuator or clogged screen • Broken injector O-ring • Defective engine controller

• Yellow lamp lights up

• Engine output goes down • Engine emits white smoke

• Defective timing rail actuator • Defective wiring harness and connector of timing rail actuator circuit • Defective engine controller

• Red lamp lights up • Outputs speed signal 0 rpm

• Engine stops

• Defective engine speed sensor • Defective wiring harness and connector of engine speed sensor circuit • Defective engine controller

• Red lamp lights up • Carries out open control of timing rail • Limits engine speed to 1,500 rpm

• Engine makes abnormal explosion sound or emits white smoke, then engine speed becomes 1,500 rpm

• Defective timing rail pressure sensor • Defective wiring harness and connector of timing rail pressure sensor circuit • Defective engine controller

• Red lamp lights up • Carries out open control of timing rail • Limits engine speed to 1,500 rpm

• Engine makes abnormal explosion sound or emits white smoke, then engine speed becomes 1,500 rpm

• Defective timing rail pressure sensor • Defective wiring harness and connector of timing rail pressure sensor circuit • Defective engine controller

• Yellow lamp lights up • Carries out open control of fuel pump —

• Yellow lamp lights up • Carries out open control of fuel pump

—

• Yellow lamp lights up —

• Defective fuel pump pressure sensor • Defective wiring harness and connector of fuel pump pressure sensor circuit • Defective engine controller

• Defective fuel pump pressure sensor • Defective wiring harness and connector of fuel pump pressure sensor circuit • Defective engine controller

• Defective engine speed sensor • Defective wiring harness and connector of engine speed sensor circuit • Defective engine controller

• No lamps light up

• Exhaust gas color is poor when accelerating • Engine output increases

• Defective boost pressure sensor • Defective wiring harness and connector of boost pressure sensor circuit • Defective engine controller

• No lamps light up

• Engine output goes down

• Defective boost pressure sensor • Defective wiring harness and connector of boost pressure sensor circuit • Defective engine controller

WA600-3

20-357 (16)

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

User code

System with abnormality

131

Abnormality in throttle sensor system high level

• Abnormality has occurred in throttle sensor circuit ECMB (29): 4.80 V or more detected

• Resistance of throttle sensor Between L13(3) – (2) (power source): 2,000 – 3,000 z Between L13(1) – (2) (signal): 200 – 3,000 z

132

Abnormality in throttle sensor system low level

• Abnormality has occurred in throttle sensor circuit ECMB (29): 0.30 V or less detected

• Resistance of throttle sensor Between L13 (3) and (2) (power source): 2,000 – 3,000 z Between L13 (1) and (2) (signal): 200 – 3,000 z

135

Abnormality in oil pressure sensor system high level

• Abnormality has occurred in oil pressure sensor circuit ECMB (24): 4.88 V or more detected

• Voltage of oil pressure sensor Between ECMA (6) and (17) (power source): 4.75 – 5.25 V Between ECMA (24) and (17) (signal): 0.42 – 0.58 V (engine stopped)

141

Abnormality in oil pressure sensor system low level

• Abnormality has occurred in oil pressure sensor circuit ECMA (24): 0.31 V or less detected

• 14. Voltage of oil pressure sensor Between ECMA (6) and (17) (power source): 4.75 – 5.25 V Between ECMA (24) and (17) (signal): 0.42 – 0.58 V (engine stopped)

Nature of abnormality

• Oil pressure sensor detected pressure lower than set oil pressure (level 1) Level 1 judgment value (reference) At 600 rpm Max. 0.05 MPa { 0.5 kg/cm2} At 1,000 rpm Max. 0.09 MPa { 0.9 kg/cm2} At 1,500 rpm Max. 0.15 MPa { 1.5 kg/cm2} At 1,800 rpm Max. 0.18 MPa {1.85 kg/cm2} At 2,000 rpm Max. 0.21 MPa { 21 kg/cm2}

Condition when normal

143

Abnormal drop in oil pressure (level 1)

144

Abnormality in coolant temperature sensor system high level

145

Abnormality in coolant temperature sensor system low level

151

Abnormal rise in coolant temperature

• Coolant temperature sensor has detected temperature higher than set temperature Judgment value (reference): Min. 105°C

Abnormality in intake air temperature sensor system high level

• Abnormality has occurred in intake air temperature sensor circuit ECMA (23): 4.88 V or more detected

• Resistance of intake air temperature sensor Between IMTP (A) and (B): 36 – 600 z

Abnormality in intake air temperature sensor system low level

• Abnormality has occurred in intake air temperature sensor circuit ECMA (23): 0.08 V or less detected

• Resistance of intake air temperature sensor Between IMTS (A) and (B): 36 – 600 z

• Abnormality has occurred in atmospheric pressure sensor circuit ECMA (34): 4.78 V or more detected

• Voltage of atmospheric temperature sensor Between ECMA (6) and (17) (power source): 4.75 – 5.25 V Between ECMA (34) and (17) (signal): 0.42 – 0.58 V (engine stopped)

• Abnormality has occurred in atmospheric pressure sensor circuit ECMA (34): 0.20 V or less detected

• Voltage of atmospheric pressure sensor Between ECMA (6) and (17) (power source): 4.75 – 5.25 V Between ECMA (34) and (17) (signal): 0.42 – 0.58 V (engine stopped)

153

154

221

Abnormality in atmospheric pressure sensor system high level

222

Abnormality in atmospheric pressure sensor system low level

234

20-358 (16)

Overspeed

—

• Abnormality has occurred in coolant temperature sensor circuit ECMA (22): 4.95 V or more detected

• Resistance of coolant temperature sensor Between CLTP (A) and (B): 600 – 36k z

• Abnormality has occurred in coolant temperature sensor circuit ECMA (22): 0.21 V or less detected

• Resistance of coolant temperature sensor Between CLTP (A) and (B): 600 – 36k z

• Engine speed sensor has detected speed higher than set speed Judgment value (reference): D375A :2,400 rpm or more WA600 :2,500 rpm or more PC1100 :2,400 rpm or more Morita :2,550 rpm or more

—

WA600-3

TROUBLESHOOTING

Action by controller

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Problem that appears on machine

Probable cause

• Red lamp lights up • Holds engine at constant speed

• Engine output and speed suddenly go down

• Defective throttle sensor • Defective wiring harness and connector of throttle sensor circuit • Defective engine controller

• Red lamp lights up • Holds engine at constant speed

• Engine output and speed suddenly go up

• Defective throttle sensor • Defective wiring harness and connector of throttle sensor circuit • Defective engine controller

• Yellow lamp lights up —

• Yellow lamp lights up —

• Orange lamp lights up • After 10 seconds limits injection amount to 50%

• Defective oil pressure sensor • Defective wiring harness and connector of oil pressure sensor circuit • Defective engine controller

• Defective oil pressure sensor • Defective wiring harness and connector of oil pressure sensor circuit • Defective engine controller

• Defective engine • Defective oil pressure sensor —

• Yellow lamp lights up —

• Defective coolant temperature sensor • Defective wiring harness and connector of coolant temperature sensor circuit • Defective engine controller

—

• Defective coolant temperature sensor • Defective wiring harness and connector of coolant temperature sensor circuit • Defective engine controller

• Yellow lamp lights up

• Orange lamp lights up • After 10 seconds limits injection amount to 50%

—

• Yellow lamp lights up —

• Defective intake air temperature sensor • Defective wiring harness and connector of intake air temperature sensor circuit • Defective engine controller

—

• Defective intake air temperature sensor • Defective wiring harness and connector of intake air temperature sensor circuit • Defective engine controller

• Yellow lamp lights up

• Yellow lamp lights up —

• Yellow lamp lights up —

• Red lamp lights up • Shut off common rail actuator (fuel cut-off). —

WA600-3

• Defective engine • Defective coolant temperature sensor

• Defective atmospheric pressure sensor • Defective wiring harness and connector of atmospheric pressure sensor circuit • Defective engine controller

• Defective atmospheric pressure sensor • Defective wiring harness and connector of atmospheric pressure sensor circuit • Defective engine controller

• Defective engine • Defective engine speed sensor • Defect on machine

20-359 (16)

TROUBLESHOOTING

User code

System with abnormality

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Nature of abnormality

Condition when normal

254

Abnormality in fuel shutoff valve system voltage

• Abnormality has occurred in fuel shut-off valve circuit Between ECMA (30) and (8): Voltage of 6.0 V or less or resistance of 20 z or less detected

259

Abnormality in fuel shutoff valve

• Fuel shut-off valve remains open and does not close (even when electric power is turned off, engine does not stop)

—

261

Abnormal rise in fuel temperature

• Fuel temperature sensor has detected temperature higher than set temperature Judgment value (reference): 76°C or more

—

263

Abnormality in fuel temperature sensor system high level

• Abnormality has occurred in fuel temperature sensor circuit ECMA (26): 4.95 V or more detected

• Resistance of fuel temperature sensor Between FLTP (A) and (B): 600 – 36k z

265

Abnormality in fuel temperature sensor system low level

• Abnormality has occurred in fuel temperature sensor circuit ECMA (26): 0.21 V or less detected

• Resistance of fuel temperature sensor Between FLTP (A) and (B): 600 – 36k z

Abnormality in fuel pump actuator system current

• Abnormality has occurred in fuel pump actuator circuit Between ECMA (11) and (40) (reference value): Detected value outside range of 0.40±0.35A (engine stopped)

• Resistance of fuel pump actuator Between PUMP (A) and (C): 7 – 9 z

318

Abnormality in fuel pump actuator

• Excessive difference between fuel pump command pressure value and actual pressure Judgment value (reference): Difference more than ±2.11 MPa {2.1 kg/ cm2} (when coolant temperature is 38°C or above)

343

Abnormality in controller internal communication

346

Abnormality in controller power down

384

Abnormality in preheating heater control system

• Abnormality has occurred in preheating heater control circuit ECMB (2): Circuit open or short circuit in circuit detected

415

Abnormal drop in oil pressure (level 2)

• Oil pressure sensor detected pressure lower than set oil pressure (level 2) Level 1 judgment value (reference) At 600 rpm Max. 0.04 MPa {0.4 kg/cm2} At 1,000 rpm Max. 0.08 MPa {0.8 kg/cm2} At 1,500 rpm Max. 0.13 MPa {1.3 kg/cm2} At 1,800 rpm Max. 0.16 MPa {1.6 kg/cm2} At 2,000 rpm Max. 0.18 MPa {1.8 kg/cm2}

—

423

Abnormality in timing rail pressure sensor system in range

• Timing rail pressure sensor detected abnormal pressure Judgment value (reference) when starting switch is ON: 2.42 MPa {24.65 kg/cm2} or more

—

431

Abnormality 1 in idle validation switch system

• Simultaneous detection of voltage from both ON signal and OFF signal of idle validation switch ECMB (12): Idle OFF signal ECMB (13): Idle ON signal

316

20-360 (16)

• Microprocessor error inside controller • Error in data recorded in power-down internal memory of controller

• Resistance of fuel shut-off valve Between FSO (+) and (-): 23 – 40 z

—

—

—

• Resistance of heater relay Between relay coils: 200 – 400 z

• Resistance of idle switch Between L14(1) – (2): Max. 125 z (pedal released) Between L14(1) – (3): Max. 125 z (pedal depressed)

WA600-3

TROUBLESHOOTING

Action by controller

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Problem that appears on machine

Probable cause

• No lamps light up • Shuts off power supply to fuel shut-off valve

• Engine stops

• Defective fuel shut-off valve • Defective wiring harness and connector of fuel shut-off valve circuit • Defective engine controller

• Red lamp lights up • Shuts off power supply to fuel shut-off valve

• Engine cannot stop

• Defective fuel shut-off valve • Defective injector • Defective engine controller

• Orange lamp lights up • After 30 seconds limits engine speed to 800 rpm

—

• Defective engine • Defective fuel temperature sensor • Defect on machine

—

• Defective fuel temperature sensor • Defective wiring harness and connector of fuel temperature sensor circuit • Defective engine controller

—

• Defective fuel temperature sensor • Defective wiring harness and connector of fuel temperature sensor circuit • Defective engine controller

• Yellow lamp lights up

• Yellow lamp lights up

• Yellow lamp lights up —

• Yellow lamp lights up

• Yellow lamp lights up • Yellow lamp lights up

• Engine speed becomes unstable

— • Loss of power-down data (maintenance data, present controller data, engine operating time, etc.)

• Yellow lamp lights up —

• Orange lamp lights up • After 10 seconds limits injection amount to 50%

• Defective fuel pump actuator • Defective wiring harness and connector of fuel pump actuator circuit • Defective engine controller

• Defective fuel pump actuator • Excessive negative pressure at inlet port of fuel pump • Defective fuel temperature sensor • Defective injector • Defective engine controller

• Defective controller • Defective battery • Blown fuse • Defective wiring harness and connector of controller power source circuit • Defective engine controller • Defective heater relay • Defective wiring harness and connector of heater relay circuit • Defective engine controller • Defective engine • Defective oil pressure sensor

—

• Yellow lamp lights up • Limits high idle speed to 1,500 rpm

—

• Red lamp lights up —

WA600-3

• Defective timing rail pressure sensor • Defective wiring harness and connector of timing rail pressure sensor circuit • Defective engine controller • Excessive suction resistance of fuel filter • Defective idle validation switch • Defective wiring harness and connector of idling validation switch • Defective engine controller

20-361 (16)

TROUBLESHOOTING

User code

System with abnormality

432

Idle validation process error

441

Abnormality in battery voltage low level

442

Abnormality in battery voltage high level

451

Abnormality in fuel rail pressure sensor system high level

452

Abnormality in fuel rail pressure sensor system low level

455

Abnormality in fuel rail actuator system current

467

468

Abnormality in timing rail actuator control

Abnormality in fuel rail actuator control

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Nature of abnormality

Condition when normal

• Throttle sensor signal and idle validation ON signal, OFF signal do not match ECMB (12): Idle OFF signal ECMB (13): Idle ON signal

• Resistance of idle switch Between L14(1) – (2): Max. 125 z (pedal released) Between L14(1) – (3): Max. 125 z (pedal depressed)

• Abnormality has occurred in controller power source circuit ECMB (3)(4)(5): 12 V or less detected

• Voltage of controller power source Between ECMB (3)(4)(5) and ECMA (7)(8): 17.3 – 34.7 V (When starting switch is OFF)

• Abnormality has occurred in controller power source circuit ECMB (3)(4)(5): 38 V or less detected

• Voltage of controller power source Between ECMB (3)(4)(5) and ECMA (7)(8): 17.3 – 34.7 V (When starting switch is OFF)

• Abnormality has occurred in fuel rail pressure sensor circuit ECMA (31): 4.78 V or more detected

• Voltage of fuel rail pressure sensor Between ECMA (5) and (18) (power source): 4.75 – 5.25 V Between ECMA (31) and (18) (signal): 0.42 – 0.58 V (engine stopped)

• Abnormality has occurred in fuel rail pressure sensor circuit ECMA (31): 0.15 V or less detected

• Voltage of fuel rail pressure sensor Between ECMA (5) and (18) (power source): 4.75 – 5.25 V Between ECMA (31) and (18) (signal): 0.42 – 0.58 V (engine stopped)

• Abnormality has occurred in fuel rail actuator circuit Between ECMA (1) and (20) (reference value): 0.40 ± 0.35 A (engine stopped)

• Resistance of fuel rail actuator Between RAIL (A) and (C): 7 – 9 z

• Excessive difference between timing rail command fuel value and actual timing fuel, does not reach target value

—

• Excessive difference between fuel rail command injection amount value and actual injection amount, does not reach target value

—

514

Abnormality in fuel rail actuator

• Excessive difference between fuel rail command injection amount value and actual injection amount Fuel rail judgment value (reference): Difference ±600 mm3/st or more for ±50 msec or difference ±250 mm3/st or more for ± 200 msec

527

Abnormality in dual output solenoid A system

• Abnormality has occurred in dual output solenoid A circuit ECMB (1): Circuit open or short circuit detected

• Resistance of dual output solenoid A Between R17(female)(A) – chassis: 28 – 32 z

529

Abnormality in dual output solenoid B system

• Abnormality has occurred in dual output solenoid B circuit ECMB (9): Circuit open or short circuit detected

• Resistance of dual output solenoid B Between solenoid pins: 28 – 32 z

• Simultaneous detection of no voltage from both ON signal and OFF signal of idle validation switch ECMB (12): Idle OFF signal ECMB (13): Idle ON signal

• Resistance of idle switch Between IVS (A) and (B): Max. 125 z (pedal released) Between IVS (A) and (C): Max. 125 z (pedal depressed)

551

Abnormality 2 in idle validation switch system

554

Abnormality in fuel rail pressure sensor in range

20-362 (16)

• Fuel rail pressure sensor detected abnormal pressure Judgment value (reference): When starting switch is ON: 0.17 MPa {1.76 kg/cm2} or more

—

—

WA600-3

TROUBLESHOOTING

Action by controller • Red lamp lights up • Recognizes throttle signal as 0%

—

—

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Problem that appears on machine

—

• Defective idle validation switch • Defective wiring harness and connector of idling validation switch • Defective engine controller

—

• Defective battery • Blown fuse • Defective wiring harness and connector of controller power source circuit • Defective engine controller

—

• Defective battery • Blown fuse • Defective wiring harness and connector of controller power source circuit • Defective engine controller

• Red lamp lights up • Carries out open control of fuel rail —

• Red lamp lights up • Carries out open control of fuel rail —

• Red lamp lights up • Sets current to fuel rail actuator to 0 A

• Yellow lamp lights up • Limits maximum injection amount to 217 mm3/st

—

• Excessive negative pressure at inlet port of fuel pump • Defective timing rail actuator or clogged screen • Broken injector O-ring • Defective engine controller

—

• Excessive negative pressure at inlet port of fuel pump • Defective fuel rail actuator or clogged screen • Broken injector O-ring • Defective engine controller

—

WA600-3

• Excessive negative pressure at inlet port of fuel pump • Defective fuel rail actuator or clogged screen • Broken injector O-ring • Defective engine controller

—

• Defective dual output solenoid A • Defective wiring harness and connector of dual output solenoid A circuit • Defective engine controller

—

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

• Yellow lamp lights up

• Yellow lamp lights up • Limits maximum injection amount to 270 mm3/st

• Defective fuel rail pressure sensor • Defective wiring harness and connector of fuel rail pressure sensor circuit • Defective engine controller

• Defective fuel rail actuator • Defective wiring harness and connector of fuel rail actuator circuit • Defective engine controller

• Yellow lamp lights up

• Red lamp lights up • Recognizes throttle signal as 0%

• Defective fuel rail pressure sensor • Defective wiring harness and connector of fuel rail pressure sensor circuit • Defective engine controller

—

• Yellow lamp lights up • Limits engine speed to 1500 rpm

• Yellow lamp lights up • Limits maximum injection amount to 217 mm3/st

Probable cause

—

—

• Defective idle validation switch • Defective wiring harness and connector of idling validation switch circuit • Defective engine controller • Defective fuel rail pressure sensor • Defective wiring harness and connector of fuel rail pressure sensor circuit • Defective engine controller • Excessive suction resistance of fuel filter

20-363 (16)

TROUBLESHOOTING

EA-1, EA-2

EA-1 Error code [111] (Abnormality in controller memory) Cause

Remedy

1 • Turn starting switch OFF and wait for 5 minutes. • Run engine at low idle.

NO

Is error code [111] re-enacted?

YES Defective engine controller

Replace

It has probably been reset, so operate for a short time and watch for any change in symptoms

—

Defective engine controller

Replace

2 Has error code [111] already been NO generated 3 or more times?

YES

EA-2 Error code [112] (Abnormality in timing rail actuator  






     

         



  

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20-366 (16)



*%(     %'
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WA600-3

TROUBLESHOOTING

EA-17

EA-17 Error code [144] (Abnormality in coolant temperature sensor system high level) Cause

Remedy

1 • Turn starting switch OFF. • Disconnect CLTP.

Is resistance between CLTP (male) (A) and (B) 600 – 36kΩ?

NO

Defective coolant temperature sensor

Replace

YES

2 • Turn starting switch OFF. • Disconnect ECMA and CLTP.

Is resistance between ECMA (female) (22) and CLTP (female) (A), and between ECMA (female) (22) and surrounding wiring harnesses as shown in Table 1?

NO

Defective contact, disconnection, or short circuit in wiring harness between Repair or ECMA (female) (22) and CLTP (fereplace male) (A)

YES

3 • Turn starting switch OFF. • Disconnect ECMA and CLTP.

Is resistance between ECMA (female) (17) and CLTP (female) NO (B), and between ECMA (female) (17) and surrounding wiring harnesses as shown in Table 2?

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (17) and CLTP (female) (B)

Repair or replace

Defective engine controller

Replace

YES

Table 1 ECMA (female), CLTP (female) Between ECMA (22) and CLTP (A) Between ECMA (22) and surrounding wiring harnesses

Table 2 Resistance value Max. 10 Ω Min. 1 MΩ

ECMA (female), CLTP (female) Between ECMA (17) and CLTP (B) Between ECMA (17) and surrounding wiring harnesses

Resistance value Max. 10 Ω Min. 1 MΩ

EA-17 Related electrical circuit diagram

20-382 (16)

WA600-3

TROUBLESHOOTING

EA-18, EA-19

EA-18 Error code [145] (Abnormality in coolant temperature sensor system low level) a Carry out troubleshooting for error code [144].

EA-19 Error code [151] (Abnormal rise in coolant temperature)  





      


-     '  
   (

        !"##$  !"#%$     &   '       (



WA600-3






+   ,   *   ' 

) * 

-*     , '     

) *       ', '      ' 

20-383 (16)

TROUBLESHOOTING

EA-38

EA-38 Error code [432] (Idle validation process error) Cause

Remedy

1 Is resistance between L14 NO (female) (1) and (3), and between (2) and (3) as shown in Table 1?

• Turn starting switch OFF. • Disconnect L14.

Defective idle validation switch

Replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (21) and L14 (male) (1)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (13) and L14 (male) (2)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (12) and L14 (male) (3)

Repair or replace

Defective engine controller

Replace

YES

2 Is resistance between ECMB (female) (21) and L14 (male) (1), NO and between ECMB (female) (21) and surrounding wiring harnesses as shown in Table 2?

• Turn starting switch OFF. • Disconnect ECMB and L14.

YES

3 Is resistance between ECMB (female) (13) and L14 (male) (2), NO and between ECMB (female) (13) and surrounding wiring harnesses as shown in Table 3?

• Turn starting switch OFF. • Disconnect ECMB and L14.

YES

4 Is resistance between ECMB (female) (12) and L14 (male) (3), and between ECMB (female) (12) NO and surrounding wiring harnesses as shown in Table 4?

• Turn starting switch OFF. • Disconnect ECMB and L14.

YES

Table 2

Table 1

Resistance value

Pedal

Between (1) and (3)

Released or depressed

2,000 – 3,000 Ω

Between ECMA (21) and L14 (1)

Max. 10 Ω

Released (idling ON)

1,500 – 3,000 Ω

Between ECMB (21) and surrounding wiring harnesses

Min. 1 MΩ

Between (2) and (3)

Resistance value

ECMB (female), L14 (male)

L14 (male)

Depressed (idling OFF)

Table 4

Table 3 ECMB (female), L14 (male) Between ECMB (13) and L14 (2) Between ECMB (13) and surrounding wiring harnesses

WA600-3

200 – 1,500 Ω

Resistance value

ECMB (female), L14 (male)

Resistance value

Max. 10 Ω

Between ECMB (12) and L14 (3)

Max. 10 Ω

Min. 1 MΩ

Between ECMB (12) and surrounding wiring harnesses

Min. 1 MΩ

20-399-2 (16)

TROUBLESHOOTING

EA-38

EA-38 Related electrical circuit diagram

20-399-3 (16)

WA600-3

TROUBLESHOOTING

EA-47, EA48

EA-47 Error code [527] (Abnormality in dual output solenoid A system)

Cause

Remedy

1 • Turn starting switch OFF. • Disconnect L64.

Is resistance of relay L64 (male) (1) and (2) 200 – 400 Ω?

NO

Defective engine oil pressure relay

Replace

NO

Defective contact or disconnection in wiring harness between ECMB (female) (1) and L64 (female) (1)

Repair or replace

NO

There is a disconnection or connection fault in the wiring harness between L64 Repair or replace (female) (2) and the chassis.

YES

2 • Turn starting switch OFF. • Disconnect ECMB and L64.

Is resistance between ECMB (female) (1) and L64 (female) (1) less than 1 Ω?

YES

3 • Turn starting switch OFF. • Disconnect L64.

Is the resistance value between L64(frmale) (2) and the chassis less than 1 Ω?

YES

4 • Turn starting switch OFF. • Disconnect ECMB and L64.

Is resistance between ECMB (female) (1) and surrounding wiring harnesses more than 100 kΩ?

NO

Short circuit in wiring harness between Repair or ECMB (female) (1) and L64 (female) replace (1)

YES Defective engine controller

Replace

EA-47 Related electrical circuit diagram

EA-48 Error code [551] (Abnormality 2 in idle validation switch system) a Carry out troubleshooting for error code [431].

20-399-9 (16)

WA600-3

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

20-402 (16)

WA600-3

TROUBLESHOOTING

M-2

M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up fl Before disconnecting or connecting connectors, always turn starting switch OFF. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

1 YES Is voltage between L05 (4) and chassis ground normal?

• 20 – 30 V NO • Turn starting switch to START.

Defective main monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L05 (female) (4) replace and L57 (female) (3)

M-2 Related electrical circuit diagram

20-408 (16)

WA600-3

TROUBLESHOOTING

M-4

M-4 Abnormality in shift indicator fl fl fl fl

Before disconnecting or connecting connectors, always turn starting switch 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. Check that the transmission shifts normally.

a) Displays N even when directional lever is at F

Cause

1 YES Is voltage between L08 (7) and chassis ground normal?

• 20 – 30 V NO • Turn starting switch ON. • Directional lever: F

Defective main monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L08 (female) (7) replace and L04 (female) (2)

b) Displays N even when directional lever is at R Cause

1 YES Is voltage between L08 (8) and chassis ground normal?

• 20 – 30 V NO • Turn starting switch ON. • Directional lever: R

Defective main monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L08 (female) (8) replace and L04 (female) (4)

c) Does not display N even when directional lever is at N Cause

1 YES Is voltage between L05 áG and chassis ground normal?

• 20 – 30V NO • Turn starting switch ON. • Directional lever: N

20-410 (16)

Remedy

Defective main monitor

Replace

Defective contact or disconnection in wiring harness between L05 (female) (8) and L04 (female) (3)

Repair or replace

WA600-3

TROUBLESHOOTING

M-5

M-5 High beam display does not light up fl fl fl fl

Before disconnecting or connecting connectors, always turn starting switch 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. Before starting troubleshooting, check that the lamp bulbs of night lighting are not blown.

Cause

2 YES Is resistance betYES ween L06 (female) 1 (13) and chassis ground normal? Is voltage between L06 (12) and • Max. 1 Ω NO chassis ground • Turn starting switch OFF. normal? • Disconnect L06.

• 20 – 30 V • Turn starting switch ON.

• Dimmer switch: Hi beam

NO

Defective main monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L06 (female) (13) replace and L02 (female) (3) Defective contact or disconRepair or nection in wiring harness replace between L06 (female) (12) and FS2 (female) (2)

M-5 Related electrical circuit diagram

WA600-3

20-413 (16)

TROUBLESHOOTING

M-6

M-6 Turn signal display does not light up fl fl fl fl

Before disconnecting or connecting connectors, always turn starting switch 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. Check the bulb of the turn signal display for breakage.

a) L.H. turn signal display does not light up

1 YES Is voltage between L06 (14) and chassis ground normal?

• Repeats 0V and NO 20 – 30V. • Turn starting switch ON. • Turn L.H. turn signal ON.

b) R.H. turn signal display does not light up

1 YES Is voltage between L06 (15) and chassis ground normal?

• Repeats 0V and NO 20 – 30V. • Turn starting switch ON. • Turn R.H. turn signal ON.

Cause

Defective main monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L06 (female) (14) replace and L03 (female) (4)

Cause

Defective main monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L06 (female) (15) replace and L03 (female) (3)

M-6 Related electrical circuit diagram

20-414 (16)

WA600-3

TROUBLESHOOTING

M-8

M-8 Abnormality in preheating display Serial No. : 50001 – 52000 fl fl fl fl

Before disconnecting or connecting connectors, always turn starting switch 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. If there is abnormality in APS system, carry out troubleshooting according to E-4, then carry out troubleshooting according to M-8.

a) Preheating display does not light up

YES 1 Is voltage between L05 (19) and chassis ground normal?

2 YES

Is voltage • 20 – 30V between L71 (4) • Turn starting NO and (1) normal? switch ON. • Turn APS switch • 20 – 30V NO to AUTO. • Turn starting switch ON. • Water temperature • Turn APS switch to AUTO. is below 20°C. • Water temperature is below 20°C.

b) Preheating display stays lighted up 2 YES Is voltage

YES between L71 (4) 1

Cause

Remedy

Defective main monitor (monitor module)

Replace

Defective contact or disconnection in wiring harness between L71 (female) (4) and L05 (female) (19)

Repair or replace

Defective APS controller

Replace

Short circuit with power source in wiring harness between L71 (female) (4) and L05 (female) (19)

Repair or replace

Defective APS controller

Replace

Defective main monitor (monitor module)

Replace

and (1) normal?

Does preheating stop when L05 is disconnected?

• 20 – 30V NO • Turn starting switch ON. • Turn APS switch to AUTO. • Water temperature is below 20°C.

• Disconnect L05. • Turn starting NO switch ON. • Turn APS switch to AUTO. • Water temperature is below 20°C.

M-8 Related electrical circuit diagram

20-416 (16)

WA600-3

TROUBLESHOOTING

M-9

M-9 Night lighting of monitor does not light up fl fl fl fl

Before disconnecting or connecting connectors, always turn starting switch 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. Before starting troubleshooting, check that the lamp bulbs of night lighting are not blown. Cause

1 YES Is voltage between L05 (16) and chassis ground normal?

• 20 - 30 V NO • Turn starting switch ON. • Turn small lamp switch ON.

Remedy

Defective main monitor

Replace

Defective contact or disconnection in wiring harness between L05 (female) (16) and FS2 (5)

Repair or replace

M-9 Related electrical circuit diagram

WA600-3

20-417 (16)

TROUBLESHOOTING

M-10

M-10 Abnormality in front working lamp fl fl fl fl

Before disconnecting or connecting connectors, always turn starting switch 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. Before starting troubleshooting, check that the monitor lighting is lighted up.

a) Neither monitor display nor front working lamp light up Cause

YES

Remedy

Defective contact or disconnection in wiring harness between L60 (female) (1), L05 (female) (17) and CL1 (female) (7)

Repair or replace

Defective front working lamp relay

Replace

Defective main monitor or defective contact or discon -nection in wiring harness between L60 (female) (6) and L06 (female) (1)

Repair or replace

Defective contact or discon -nection in wiring harness between L60 (female) (2), (5) and FS5 (female) (1)

Repair or replace

1 3 YES

Is voltage between L60 (1) and chassis ground normal? •0–3V • Turn starting switch ON.

Is voltage YES between L60 (1) and chassis 2 ground normal? Is voltage between L60 (2), (5) and NO chassis ground normal?

• 20 – 30 V • Turn starting switch ON.

NO •0–3V • Turn starting switch ON. • Turn working lamp switch ON. NO

b) Working lamp lights up but monitor display does not light up

Cause

1 YES Is voltage between L05 (17) and chassis ground normal?

• 20 – 30 V NO • Turn starting switch ON.

Defective main monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L05 (female) (17) replace and L60 (female) (1)

c) Monitor display lights up but working lamp does not light up Cause

Remedy

Defective contact or disconnection in wiring harness between L60 (1) – CL1 (7) – Repair or C03 (female) (1), C04 replace (female) (1), or blown working lamp bulb

20-418 (16)

WA600-3

TROUBLESHOOTING

M-11

M-11 Abnormality in rear working lamp fl fl fl fl

Before disconnecting or connecting connectors, always turn starting switch 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. Before starting troubleshooting, check that night lighting of monitor is lighted up.

a) Neither monitor display nor rear working lamp light up Cause

YES

Remedy

Defective contact or discon -nection in wiring harness between L61 (female) (1) and L05 (female) (18), CR1 (female) (12)

Repair or replace

Defective front working lamp relay

Replace

Defective main monitor or defective contact or discon -nection in wiring harness between L61 (female) (6) and L06 (female) (2)

Repair or replace

Defective contact or discon -nection in wiring harness between L61 (female) (2), (5) and FS5 (female) (2)

Repair or replace

1 3 YES

Is voltage between L61 (1) and chassis ground normal? •0–3V • Turn starting switch ON.

Is voltage YES between L06 (2) and chassis 2 ground normal? Is voltage between L61 (2), (5) and NO chassis ground normal?

• 20 – 30 V • Turn starting switch ON.

b)

NO •0–3V • Turn starting switch ON. • Turn working lamp switch ON. NO

Working lamp lights up but monitor display does not light up Cause

1 YES Is voltage between L05 (18) and chassis ground normal?

• 20 – 30 V NO • Turn starting switch ON.

Defective main monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L05 (female) (18) replace and L61 (female) (1)

c) Monitor display lights up but working lamp does not light up Cause

Remedy

Defective contact or disconnection in wiring harness Repair or between L61 (1) – LR1 (12) – G02 (female) (1), G03 replace (female) (1), or blown working lamp bulb

20-420 (16)

WA600-3

TROUBLESHOOTING

M-11

M-11 Related electrical circuit diagram

WA600-3

20-421 1

TROUBLESHOOTING

M-12

M-12 Abnormality in transmission cut-off fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not change Cause

Defective main monitor

Remedy

Replace

b) When transmission cut-off switch is turned OFF, cut-off function is always actuated

Cause

YES

Defective main monitor

Remedy

Replace

Defective contact or discon

4 YES -nection in wiring harness

1 Is voltage YES between L65 (5) and chassis 3 ground normal?

Is voltage between L06 (3) and chassis ground normal? Is voltage

• 20 – 30 V • Turn cut-off switch ON.

YES between L65 (1) and chassis 2 Is resistance between L06 (female) NO (3) and L65 (female) (2) normal?

ground normal?

• 20 – 30 V • Turn starting switch ON. • Disconnect L65

• Max. 1 Ω • Turn starting NO switch OFF. • Disconnect L06 and L65.

20-422 (16)

between L65 (female) (5) and L66 (female) (1)

Defective transmission • 20 – 30 V NO cut-off relay • Turn starting switch ON. Defective contact or discon • Turn packing switch -nection in wiring harness OFF

NO

between L65 (female) (1), FS2 (female) (8) and fuse I (9)

Defective contact or discon -nection in wiring harness between L06 (female) (3) and L65 (female) (2)

Repair or replace

Replace

Repair or replace

Repair or replace

WA600-3

TROUBLESHOOTING

M-16

M-16 Condition of monitor switches is not stored in memory fl Before disconnecting or connecting connectors, always turn starting switch OFF. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

1 YES Is voltage between L07 (10) and chassis ground normal?

• 20 – 30 V NO • Turn starting switch ON.

Defective main monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L07 (female) (10) replace and L09 (female) (2)

M-16 Related electrical circuit diagram

WA600-3

20-427 (16)

TROUBLESHOOTING

M-17

M-17 Abnormality in failure display mode fl Before disconnecting or connecting connectors, always turn starting switch OFF. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. a) Failure display mode does not work

1 YES Is voltage between L05 (5) and chassis ground normal?

•0–5V NO • Turn starting switch ON.

b) Count for time elapsed since failure in failure display mode does not advance

1 YES Is voltage between L05 (5) and chassis ground normal?

• 20 – 30 V • Start engine.

NO

Cause

Remedy

Defective main monitor

Replace

Short circuit with power source in wiring harness between L05 (female) (5) – LR4 (6) – ER1 (9) – alternator terminal R, or defective alternator

Repair or replace

Cause

Defective main monitor

Remedy

Replace

Defective contact or disconnection in wiring harness Repair or between L05 (female) (5) – replace LR4 (6) – ER1 (9) – alternator terminal R, or defective alternato

M-17 Related electrical circuit diagram

20-428 (16)

WA600-3

TROUBLESHOOTING

M-19

d) Monitor display flashes slowly (1 time/sec) Confirm that grease is not empty.

e) Monitor display goes out

YES 1 Is voltage between L07 (11) and chassis ground normal?

• Max. 3 V • Turn starting switch ON.

2 YES

Is voltage between GRE (female) (2) NO and chassis ground normal?

•2–3V NO • Turn starting switch ON. • Disconnect GRE.

Cause

Remedy

See “Handling auto-greasing system” in Operation and Maintenance Manual

—

Cause

Remedy

Defective main monitor

Replace

Hot short in wiring harness between L07 (female) (11) and GRE (female) (2)

Repair or replace

See “Handling auto-greasing system” in Operation and Maintenance Manual

—

Table 1 (Relationship between input signal and display) L07(11) L08(5) Display L

L

Rapid flashing (2 times/sec)

H

L

Slow flashing (1 time/sec)

H

H

OFF

L

H

ON

M-19 Related electrical circuit diagram

WA600-3

20-431 (16)

TROUBLESHOOTING

M-20

M-20 Abnormality in ECSS system Serial No. : 50001 – 52000 fl fl fl fl

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. Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that DIP switch 4 on the back side of the main monitor is set correctly.

a) Display does not change when switch is pressed

Cause

Defective main monitor

Remedy

Replace

b) Monitor display lights up but ECSS function does not work Cause

2 YES Is voltage between YES AL2 (15) and chassis 1 ground normal? Is voltage between • Max. 3 V NO L06 (7) and chassis • Turn starting switch ground normal?

ON. • Max. 3 V • Turn starting switch NO ON.

c) Monitor lamp does not light up

Go to Troubleshooting for ECSS controller system (D MODE)

—

Defective contact or disconnection in wiring harness between L06 (7) and AL2 (15)

Repair or replace

Defective main monitor

Replace

Cause

Defective main monitor

20-432 (11)

Remedy

Remedy

Replace

WA600-3

TROUBLESHOOTING

M-20

M-20 Related electrical circuit diagram

WA600-3

20-432-1 (11)

TROUBLESHOOTING

M-20

Serial No. : 52001 and up fl fl fl fl

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. Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that DIP switch 4 on the back side of the main monitor is set correctly.

a) Display does not change when switch is pressed

Cause

Defective main monitor

Remedy

Replace

b) Monitor display lights up but ECSS function does not work Cause

2 YES Is voltage between YES AL2 (15) and chassis 1 ground normal? Is voltage between • Max. 3 V NO L06 (7) and chassis • Turn starting switch ground normal?

ON. • Max. 3 V • Turn starting switch NO ON.

c) Monitor lamp does not light up

Remedy

Go to Troubleshooting for ECSS controller system (D MODE)

—

Defective contact or disconnection in wiring harness between L06 (7) and AL2 (15)

Repair or replace

Defective main monitor

Replace

Cause

Defective main monitor

Remedy

Replace

M-20 Related electrical circuit diagram

WA600-3

20-433 (11)

TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)

Electrical circuit diagram for maintenance monitor ............................................................................. 20-502 K- 1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds Maintenance monitor does not work .......................................................................................... 20-504 a) No lamps on maintenance monitor light up ....................................................................... 20-504 b) Some lamps do not light up ................................................................................................. 20-504 K- 2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out even after 3 seconds ............................................................................................ 20-505 K- 3 When engine is started immediately after starting switch is turned ON within 3 seconds, no lamps on maintenance monitor go out .................................................. 20-506 K- 4 When engine is stopped and starting switch is turned ON, CHECK item display flashes ..... 20-507 a) Engine oil level display flashes ............................................................................................. 20-507 b) Engine coolant level display flashes .................................................................................... 20-508 K- 5 When engine is stopped and starting switch is turned ON, CAUTION item display flashes ........................................................................................................................................... 20-509 a) Engine oil pressure display flashes ...................................................................................... 20-509 b) Battery charge display flashes .............................................................................................. 20-510 c) Brake oil pressure display flashes ........................................................................................ 20-511 d) Air cleaner clogged display flashes ...................................................................................... 20-512 K- 6 CAUTION item display is flashing, but caution buzzer does not sound .................................. 20-513 K- 7 No monitor display lights up, but caution buzzer sounds ........................................................... 20-514 K- 8 CAUTION item display is flashing, but central CHECK lamp or central CAUTION lamp does not flash ............................................................................................................................... 20-515 a) CHECK lamp ........................................................................................................................... 20-515 b) CAUTION lamp ....................................................................................................................... 20-515 K- 9 No maintenance monitor display lights up, but central CHECK lamp or central CAUTION lamp lights up ............................................................................................................. 20-516 a) CHECK lamp ........................................................................................................................... 20-516 b) CAUTION lamp ....................................................................................................................... 20-516 K-10 Only night lighting of monitor does not light up when lamp switch is turned ON ................ 20-517 K-11 Night lighting of monitor lights up even when lamp switch is OFF ........................................ 20-518 K-12 Service meter does not work ....................................................................................................... 20-519 K-13 Service meter is running even when engine is stopped ........................................................... 20-519 K-14 Abnormality in gauges ................................................................................................................. 20-520 a) Abnormality in fuel gauge .................................................................................................... 20-520 b) Abnormality in engine coolant temperature gauge ............................................................ 20-521 c) Abnormality in torque converter oil temperature gauge ................................................... 20-522

WA600-3

20-501 (16)

TROUBLESHOOTING

K-4

b) Engine coolant level display flashes fl Before starting troubleshooting, check the engine coolant level again. (Check that the engine coolant level is correct.)

Cause

3 YES

Is resistance between G01 (male) (2) and (1) normal?

Is resistance betYES ween L18 (female) (8) and chassis 2 ground normal? Is resistance betYES ween G01 (female) • Max. 1 Ω NO (1) and chassis • Turn starting switch 1 ground normal? OFF.

• Disconnect L18. • Max. 1 Ω • Turn starting switch NO OFF. • Disconnect G01.

• Max. 1 Ω • Turn starting switch NO OFF. • Disconnect G01.

Defective monitor module of maintenance monitor

Remedy

Replace

Defective contact or disconnection in wiring harness Repair or between L18 (female) (8) – replace LR3 (2) – GR1 (3) – G01 (female) (1) Defective contact or disconRepair or nection in wiring harness between G01 (female) (2) – replace GR1 (2) – chassis ground

Defective coolant level sensor

Replace

K-4 b) Related electrical circuit diagram

20-508 (16)

WA600-3

TROUBLESHOOTING

K-14

b) Abnormality in engine coolant temperature gauge (1) Nothing is displayed Cause

YES 1 Does engine coolant temperature gauge show minimum level when E04 is disconnected?

2 YES

Is resistance bet• Disconnect E04. ween E04 (female) • Turn starting NO (1) and chassis ground normal? switch ON.

• Min. 1 MΩ NO • Turn starting switch OFF. • Disconnect L18 and E06.

(2) Display shows lowest level

Defective engine coolant temperature sensor

Replace

Defective monitor module of maintenance monitor

Replace

Short circuit with chassis ground in wiring harness between E04 (female) (1) – ER1 (6) – LR4 (1) – L18 (female) (4) (contact with chassis ground)

Repair or replace

Cause

YES

Remedy

Remedy

Defective engine coolant temperature sensor

Replace

Defective monitor module of maintenance monitor

Replace

1 When short connector is connected to E04 (female), does engine coolant temperature gauge display area rise one stage at a time, and finally do all lamps go out?

3 YES YES 2

Is resistance bet• Disconnect E04. ween E04 (female) • Connect short (2) and chassis connector to E04 NO ground normal?

(female). • Turn starting switch ON.

• Turn starting switch OFF. • Disconnect E04. • Max. 1 Ω

Is resistance between L18 (female) (4) and chassis ground normal when short connector is connected to E04 (female)?

• Max. 1 Ω NO • Turn starting switch OFF. • Connect short connector to E04 (female). • Disconnect L18.

NO

Defective contact or disconnection in wiring harness Repair or between E04 (female) (1) – replace ER1 (6) – LR4 (1) – L18 (female) (4) Defective contact or disconRepair or nection in wiring harness replace between E04 (female) (2) – ER1 (7) – chassis ground

K-14 b) Related electrical circuit diagram

WA600-3

20-521 (16)

TROUBLESHOOTING

E-1

b) Starting motor turns

YES

4 YES Is resistance YES between E03 (female) (8) and chassis normal?

1 3 Does engine stop motor work?

Is voltage

YES between E03 (7)

NO

• Max. 1 Ω • Turn starting switch OFF. • Disconnect E03.

YES

and chassis normal?

• Turn starting switch ON ↔ OFF and check visually.

• 20 – 30 V • Connect T-adapter to E03. • Turn starting switch ON.

5

Does engine stop motor work when NO engine stop relay is replaced?

2 Is voltage between E03 (female) (4) NO and chassis normal?

• Replace engine stop relay (L62) with stop lamp relay (L53). • Turn starting switch ON ↔ OFF NO and check visually.

• 20 – 30 V • Turn starting switch OFF. • Disconnect E03.

YES 7 Is resistance

YES between L62 6 Is voltage between L62 (female) (1) and chassis normal?

• 20 – 30 V • Disconnect L62. • Turn starting switch ON. • Turn kill switch ON.

(female) (2) and chassis normal?

• Max. 1 Ω • Turn starting switch ON. • Disconnect L62.

NO

NO

NO

20-614 (16)

WA600-3

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)

POWER TRAIN H- 1 Machine does not start ................................................................................................................ 20-702 H- 2 Travel speed is slow, or lacks power in all speed ranges ......................................................... 20-703 H- 3 Excessive time lag when starting machine or shifting gear ..................................................... 20-704 H- 4 Torque converter oil temperature is high ................................................................................... 20-705 STEERING SYSTEM H- 5 Steering wheel does not turn ...................................................................................................... 20-706 H- 6 Steering does not turn [machine with joystick] ......................................................................... 20-707 H- 7 Turning, response of steering is poor ......................................................................................... 20-708 H- 8 Turning, response of steering is poor [machine with joystick] ................................................. 20-710 H- 9

Steering is heavy .......................................................................................................................... 20-712

H-10 Joystick is heavy [machine with joystick] .................................................................................. 20-712 H-11 Steering wheel shakes or jerks .................................................................................................... 20-713 H-12 Steering shakes or there is excessive shock [machine with joystick] ...................................... 20-714 H-13 Turning radius is different between left and right at maximum steering ................................ 20-714 BRAKE SYSTEM H-14 Wheel brakes do not work or braking effect is poor ................................................................. 20-716 H-15 Wheel brakes are not released or brakes drag .......................................................................... 20-718 H-16 Parking brake does not work or braking effect is poor ............................................................. 20-719 H-17 Parking brake is not released or brake drags (including emergency release system) ........... 20-720 WORK EQUIPMENT H-18 Neither lift arm nor bucket move ................................................................................................ 20-721 H-19 Both lift arm and bucket are slow or lack power ....................................................................... 20-722 H-20 Lift arm does not move ................................................................................................................ 20-723 H-21 Lift arm does not move [machines with remote lift arm control] ............................................ 20-724 H-22 Lift arm is slow or lift arm lacks power ...................................................................................... 20-725 H-23 Lift arm is slow or lift arm lacks power [machines with remote lift arm control] ................... 20-726 H-24 Lift arm cannot be set to FLOAT or cannot be released from FLOAT ...................................... 20-727 H-25 Lift arm drops momentarily when control lever is operated from HOLD to RAISE ................ 20-727 H-26 Remote lift arm control does not work [machines with remote lift arm control] ................... 20-728 H-27 Excessive hydraulic drift of lift arm ............................................................................................ 20-729 H-28 Bucket does not move .................................................................................................................. 20-730 H-29 Bucket is slow or lacks power ..................................................................................................... 20-731 H-30 Excessive hydraulic drift of bucket ............................................................................................. 20-732 H-31 ECSS does not work, and there is pitching and bouncing [machines with ECSS] [*] ............ 20-733 * : Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that DIP switch 4 on the back side of the main monitor is set correctly. WA600-3

20-701 (16)

H-1

TROUBLESHOOTING

H-1 Machine does not start Air blow n in Defe Cau at b ctiv low ses e pu end Defe mp of p ctiv ump e ope Defe ratio ctiv n of e op Fati mod erat gue ion o of m ulating r defe Defe r odu ctiv ctiv latin elief va e op e tra lve g Seiz e v n r alve atio smi ure n of ssio spo n cl ol p Defe of tran i l o utch smi t pre ctiv ssio seal e ro ssur Defe n cl tary e re r i ng o utch ctiv duc clut r gr e sh ing ch ( Brea o a o valv f f o ve t se r kag 2 e sp n al ri d e s i ring nsid ng i pee Defe d) (d n ro e tra ctiv t e e a n f r s e o y mis ctiv Defe pera clut sion e oi ctive ch c tion l-tig ircu oper of s htne it (fo olen ation ss) r 2n oid of co d sp v alve ntro eed l val ) ve s pool (Suc tion of fo reign matt ers, seizu re, e t

c.)

Ask the operator the following questions. • Did the problem suddenly start? Yes → Internal part seized, broken Was there any abnormal noise when this happened? Yes → Part broken Checks before troubleshooting • Does the main monitor function properly? • Is the transmission oil level correct? Is the type of oil correct? • Is the transmission filter or strainer clogged? • Does the electrical transmission control circuit work normally? • Is the transmission oil deteriorated? Does the oil smell of burning? • Is there any damage or leakage of oil that can be seen externally? • Is the drive shaft broken? • Is the wheel brake or parking brake locked?

Tank – Pump

a

No.

Remedy Problems

1

Abnormal noise comes from circuit between pump and filter

2

Does not start in any transmission range (Item 1 is normal)

3

Does not start in certain transmission ranges

4

Machine does not start when transmission oil temperature rises

5 7

Modulation pressure of transmission is low

8

Pilot pressure is insufficient

6

Transmission

b c

×

d e

×

f

g

h

i

j

k

× × × × × ×

l

×

Pressure is low in all speed ranges Pressure is low in certain speed ranges Gauge fluctuates, oil pressure is not stable.

Note 1) When the valve spool does not move even if the solenoid valve and oil pressure are normal, the cause of this trouble is “¬”. Note 2) When the transmission clutch pressure is low and the cause of this problem is not found in the above table, the valve or transmission may be cracked.

20-702 (16)

WA600-3

H-5

TROUBLESHOOTING

H-5 Steering wheel does not turn Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?

Defe ctiv e st Defe eeri Cau ng a ctiv ses e PP nd s Defe C pu w i t c ctiv mp h pu e mp cha Defe rge cti valv Defe ve Orbi e t-ro ctiv ll e st Defe op v ctiv alve e actu Defe atio ctiv n of e ac dem Defe tuat and ion ctiv e of s spo safe Defe teer ol ty-s ing ctiv ucti s e pi poo on v ston l alve seal

Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct? • Is the steering shaft broken? • Is the stop valve stopper properly adjusted? • Has the safety bar been removed from the frame?

Hydraulic Charge Orbit- Stop valve roll valve pump

a

No.

Remedy Problems

1

Steering wheel does not turn in both directions (left and right)

2

Steering wheel turns only in one direction (left or right)

3

Steering wheel is heavy in both directions (left and right)

4

Work equipment moves

5

Work equipment does not move

6

Abnormal noise comes from around PTO

7

Abnormal noise comes from around PPC pump or hydraulic tank

8

When steering relief pressure is measured

9 10 11 12

×

b c

×

d e

Steering valve

f

× × × × ×

g

h

Cylinder

i

× ×

Oil pressure is low or there is no pressure in both directions (left and right) Oil pressure is low or there is no pressure in one direction (left or right)

When Orbit-roll output pressure is measured, oil pressure is found to be low or there is no oil pressure When PPC valve (Orbit-roll) basic pressure is measured

Oil pressure is low There is no oil pressure

fl There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also.

20-706 (16)

WA600-3

H-6

TROUBLESHOOTING

H-6 Steering does not turn [machine with joystick] Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?

Defe ctiv eP Air Cau suck TO ses Defe ed in at suct ctiv e PP ion Defe end C pu ctiv of p mp e ch ump Defe arge ctiv valv e Or e Clog bit-r ged oll filte Defe r ctiv Defe e actua tion ctiv e ac of jo Defe tuat ysti ctiv ion ck s e of s olen actu Defe t op v oid a t ctiv ion alve valv e of d actu e Defe e m a t a ctiv ion n d e of s spo safe Defe teer ol ty-s ctiv ing ucti spo on v Defe e 2-wa o l a y lve ctiv res e pi ston trictor v alve seal

Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct? • Is the steering shaft broken? • Is the stop valve stopper properly adjusted? • Has the safety bar been removed from the frame? • Is the operation of the steering and the steering mode switch correct?

Hydraulic pump

a

No.

Remedy Problems

3

When steering Steering does not move (steering wheel mode only) mode switch Steering does not move (joystick mode only) is switched Steering does not move in either mode

4

Steering wheel does not turn in both directions (left and right)

5

Steering wheel turns only in one direction (left or right)

6

Steering wheel is heavy in both directions (left and right)

7

Steering wheel is heavy in one direction (left or right)

8

Work equipment moves

9

Work equipment does not move

10

Abnormal noise comes from around PTO

11

Abnormal noise comes from around PPC pump or hydraulic tank

12

When steering relief pressure is measured

1 2

13

f C

× × ×

g

×

Steering valve

Stop valve

h

i

× × ×

k

j

×

×

Valve

Cylinder

l m

×

Oil pressure is low, or there is no pressure in one direction (left or right)

When Orbit-roll output pressure is measured, oil pressure is found to be low or there is no oil pressure

15

When joystick solenoid valve output pressure is measured, oil pressure is found to be low or there is no oil pressure

17

×

d e

Joystick

Oil pressure is low, or there is no pressure in both directions (left and right)

14

16

×

b c

Charge Orbitvalve roll

When PPC valve (Orbit-roll) basic pressure is measured

Oil pressure is low There is no oil pressure

fl There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also.

WA600-3

20-707 (16)

TROUBLESHOOTING

H-7

H-7 Turning, response of steering is poor Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal

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

Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct?

Hydraulic pump

a

No.

Remedy Problems

1

Turning, response of steering is poor in both directions (left and right)

2

Turning, response of steering is poor in one direction (left or right)

3

Steering wheel is heavy in both directions

4

Steering wheel is heavy in one direction (left or right)

5

Work equipment moves

6

Work equipment does not move

7

Abnormal noise comes from around PTO

8

Abnormal noise comes from around steering pump or hydraulic tank

9

Abnormal noise comes from around switch pump or hydraulic tank

10

When steering relief pressure is measured

11

×

b c

d e

× × ×

Charge Orbit- Stop valve roll valve

f

g

h

Steering valve

i

j

× × × × × ×

k

Cylinder

l m

×

×

Oil pressure is low or there is no pressure in both directions (left and right) Oil pressure is low or there is no pressure in one direction (left or right)

12

When Orbit-roll output pressure is measured, oil pressure is found to be low

13

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

fl There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also.

20-708 (16)

WA600-3

TROUBLESHOOTING

H-8

H-8 Turning, response of steering is poor [machine with joystick]

Defe ctiv eP Air Cau suck TO ses ed i n at Defe suct ctiv e PP ion Defe end C pu ctiv of p mp e ump s Defe teer ing ctiv p e u s m Defe witc p h pu ctiv e ch mp Defe arge ctiv valv e Clog e Orbit -roll ged f i l t Defe er ctiv e ac Defe tuat ctiv ion e ac of jo Defe tuat ysti ctiv ion ck s e o olen f sto a ctua Defe oid p va tion ctiv valv lve em o f e dem ain relie and f va s p ool lve

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Was there previously any symptom, such as difficulty in steering? Yes = Wear of related equipment, defective seal Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct?

Hydraulic pump

a

No. 1

Remedy Problems

3 4

Turning, response of steering is poor in both directions (left and right)

5

Turning, response of steering is poor in one direction (left or right)

6

Steering wheel is heavy in both directions (left and right)

7

Steering wheel is heavy in one direction (left or right)

8

Work equipment moves

9

Work equipment does not move

10

Abnormal noise comes from around PTO

11

× × ×

f

g

h C

× × ×

i

×

Stop valve

j

Steering valve

k

l

× × ×

Abnormal noise comes from around steering pump or hydraulic tank

Abnormality only in joystick mode Abnormality in both modes

12

Abnormal noise comes from around switch pump or hydraulic tank

13

When steering relief pressure is measured

Oil pressure is low in both directions (left and right)

15

Oil pressure is low in one direction (left or right) When Orbit-roll output pressure is measured, oil pressure is found to be low

16

When joystick solenoid valve output pressure is measured, oil pressure is found to be low

17

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

14

d e

Joystick

Abnormality only in steering wheel mode

When steering mode switch is switched

2

×

b c

Charge Orbitvalve roll

fl There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also.

20-710 (16)

WA600-3

H-14

TROUBLESHOOTING

H-14 Wheel brakes do not work or braking effect is poor

Defe ctiv eP Air Cau suck TO ses ed i n at Defe suct ctiv e PP ion Defe end C pu ctiv of p mp e ump a Defe ccum ctiv u l ator e p isto Defe cha n se rge ctiv al o e le valv Defe r de ft br e fect ctiv a k e i e ve b v r a i Defe ght lve leed brak ctiv ing e sla e va of g Defe l c v as f k e adju ctiv rom e s t b e accu Defe r rake mul ctiv p i s ator e t o a n ctua Brea seal tion kag e in o f br side brak ake pis ton e

Checking for abnormalities • Measure the actual brake performance, and check if there is actually an abnormality or whether it is just the feeling of the operator. For details, see TESTING AND ADJUSTING, Measuring brake performance. Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct? • Is the brake pedal play correct? • Is there any leakage of oil from the brake tube? Is there any deformation of the tube? • Is the tire inflation pressure and tread pattern correct?

PPC pump

a

No.

Remedy Problems

1

Brake has no effect only when left brake pedal is depressed

2

Left brake pedal is light when it is depressed

3

Right brake pedal is light when it is depressed

4

Left brake pedal is heavy when it is depressed

5

Right brake pedal is heavy when it is depressed

6

Abnormally large operating force is needed to obtain specified braking force

7

Abnormal noise is heard from brake when brake is applied

8

Work equipment, steering also do not work

9

Movement of work equipment, steering is slow

10

Abnormal noise comes from around PTO

11

Abnormal noise comes from around PPC pump or hydraulic tank

12

Many metal particles are found in oil drained from axle case

13

When accumulator charge pressure is measured, oil pressure is found to be low

14

Brake stops having effect immediately when engine is stopped

15

There is a time lag before brake takes effect

16

When brake oil pressure is measured, it is found to be low

17

When drop in brake piston pressure is measured, it is found to be excessive

18

When wear of brake disc is measured, it is found to be excessive

19

When air is bled from brake line, air comes out

×

b c

× ×

Brake valve

Charge Accuvalve mulator

d e

×

f

g

Slack adjuster

h

Wheel brake

i

j

k

× × × × × ×

fl The PPC pump is used for the wheel brake actuation pressure in the same way as for the work equipment circuit and steering circuit, so if any abnormality is felt in the wheel brake, check the condition of actuation of the work equipment and steering also (the circuit set pressure is different).

20-716 (16)

WA600-3

Defe ctiv e br Defe ake ctiv pist on s Brea e actua eal tion kag e in o f bra side ke p brak isto e n

TROUBLESHOOTING

Wheel brake

×

WA600-3

H-14

l m n Others

×

20-717

6

H-15

TROUBLESHOOTING

H-15 Wheel brakes are not released or brakes drag Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?

Defe ctiv e le Defe ft br Cau ctiv ses e rig ake val Defe ve ht b ctiv rake e ac valv Defe tuat e cti ion of s Seiz ve actu lack atio ed b adju n of rake ster br disc , pla ake pis ton te

Checks before troubleshooting • Does the brake pedal come back fully? • Is the parking brake still applied?

Brake valve

a

No.

Remedy Problems

1

Machine cannot travel at all

2

Machine can travel a small amount

3

When remaining pressure is released from brake accumulator circuit with left brake pedal only, brake is released

4

When remaining pressure is released from brake accumulator circuit with right brake pedal only, brake is released

5

When air bleed plug in wheel portion is loosened, oil flows out and brake is released

6

When air bleed plug is loosened, a large amount of oil flows out

7

When brake disc wear is measured and brake pedal is released, piston returns

8

When brake disc wear is measured and brake pedal is released, piston does not return

20-718 (16)

Slack adjuster

b c

× × × ×

Wheel brake

d e

×

WA600-3

H-16

TROUBLESHOOTING

H-16 Parking brake does not work or braking effect is poor Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal Defe ctiv e pa Defe rkin Cau ctiv g br ses e pa ake Defe rkin sole g br ctiv noid e a ke e brak valv Defe mer e sp e ctiv gen ring e ac c Wor y re t uati n br leas on o ake e va f pa disc lve rkin g br ake pist on

Checks before troubleshooting • Is parking brake emergency release switch open? (Normally it is open) • Is parking brake mechanical release operation being carried out?

SOL

a

No.

Problems

Remedy ×

1

Parking brake does not work when engine is stopped

2

When parking brake disc wear is measured, disc thickness is found to be less than specified value

3

When parking brake inlet port pressure is measured

4

When parking brake solenoid valve output pressure is measured

WA600-3

×

Parking brake

Value

b c

d e

×

×

×

There is no oil pressure when parking brake switch is ON (normal) There is oil pressure when parking brake switch is ON There is no oil pressure when parking brake switch is ON (normal) There is oil pressure when parking brake switch is ON

20-719 (16)

H-18

TROUBLESHOOTING

H-18 Neither lift arm nor bucket move Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?

Defe ctiv eP Air Cau suck TO ses ed i n at Defe s ctiv u c t e PP ion Defe end C pu cti of p mp ump Defe ve char ge v ctiv em alve ain relie f va lve

Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct?

Hydraulic pump

a

No.

Remedy Problems

1

Steering also does not work

2

Abnormal noise comes from around PTO

3

Abnormal noise comes from around PPC pump or hydraulic tank

4

When PPC valve output pressure is measured, oil pressure is found to be normal

5

When PPC valve (Orbit-roll) basic pressure is measured, oil pressure is low or there is no oil pressure

b c

ContCharge rol valve valve

d e

× × × × ×

fl There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also.

WA600-3

20-721 (16)

TROUBLESHOOTING

H-19

H-19 Both lift arm and bucket are slow or lack power

Defe ctiv eP Air Cau suck TO ses ed i n at Defe suct ctiv e PP ion Defe end C pu ctiv of p mp e ump h Defe ydra ctiv u l i c pu e s witc mp Defe h pu ctiv mp e ch Defe a r ge v ctiv alve Defe e main relie ctiv e f va a ctua Defe lve tion ctiv e cu of d ema t-off nd v valv alve e

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal

Hydraulic pump

a

No.

Remedy Problems

1

Lift arm and bucket movement takes approx. 1.5 times standard value

2

Lift arm and bucket movement takes approx. 3 times standard value

3

Steering works normally

4

Response of steering is also poor

5

Abnormal noise comes from around PTO

6

Abnormal noise comes from around hydraulic pump or hydraulic tank

7

When PPC valve output pressure is measured, oil pressure is found to be normal

8

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

×

b c

d e

Charge Cont- Steer- Cutrol ing off valve valve valve valve

f

g

h

i

× × × × × × ×

fl There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also.

20-722 (16)

WA600-3

H-20

TROUBLESHOOTING

H-20 Lift arm does not move

Defe ctiv e PP Defe C va Cau ctiv lve ses e actu Defe a tion ctiv e ac of li Defe ft ar tuat ctiv ms ion e poo o u f loa Defe nloa l d ch ctiv d v e a e c l v s k va e ucti Defe lve o n va ctiv e cy lve Defe l i n der ctiv seal e tra vel leve r lin kag e

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?

PPC valve

a

No.

Remedy Problems

1

Does not move in both directions (RAISE and LOWER)

2

Does not move in one direction (RAISE or LOWER)

3

When lift arm relief pressure is measured

4

b c

d e

× × × × × ×

Boom Others

f

g A

Oil pressure is low or there is no pressure in both directions (RAISE and LOWER) Oil pressure is low or there is no pressure in one direction (RAISE or LOWER)

5

When PPC valve output pressure is measured, oil pressure is found to be low or there is no pressure

6

When operating effort of lift arm control lever is measured, lever is found to be heavy

7

When travel of lift arm control lever is measured, it is found to be short

WA600-3

Control valve

20-723 (16)

H-21

TROUBLESHOOTING

H-21 Lift arm does not move [machines with remote lift arm control]

Defe ctiv e PP Defe C va Cau ctiv lve ses e ac Defe tuat ion ctiv e ac of s Defe hutt tuat ctiv le sp ion e ac o ool f da Defe t u mpi a ctiv tion ng s e ac o f olen Defe lift a tuat oid ion r ctiv spo e un of lo m spoo Defe ol load ad c l ctiv h v e alve ck v Defe e suctio alve n va ctiv e cy lve Defe lind ctiv er s e co eal ntro l lev er li nka ge

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?

PPC valve

a

No.

Remedy Problems

1

Does not move in both directions (RAISE and LOWER)

2

Does not move in one direction (RAISE or LOWER)

3

When lift arm relief pressure is measured

4

×

Control valve

d e

f

g

× × × × ×

Boom Others

h i A

Oil pressure is low or there is no pressure in one direction (RAISE or LOWER)

When PPC valve output pressure is measured, oil pressure is found to be low or there is no pressure

6

When operating effort of lift arm control lever is measured, lever is found to be heavy

7

When travel of lift arm control lever is measured, it is found to be short

(16)

b c

Oil pressure is low or there is no pressure in both directions (RAISE and LOWER)

5

20-724

× ×

Shuttle valve

WA600-3

H-22

TROUBLESHOOTING

H-22 Lift arm is slow or lift arm lacks power

Defe ctiv e PP Defe C va Cau ctiv lve ses e actu Defe a tion ctiv e ac of li Defe ft ar tuat ctiv ms ion e poo o u f loa Defe nloa l d ch ctiv d v e a e c l v s k va e ucti Defe lve o n va ctiv e cy lve Defe l i n der ctiv seal e co ntro l lev er li nka ge

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal

PPC valve

a

No. 1

Remedy Problems

Control valve

b c

d e

× × × × × ×

CylinOthers der

f

g A

Does not move in both directions (RAISE and LOWER)

2

Does not move in one direction (RAISE or LOWER)

3 4

When lift arm Oil pressure is low in both directions (RAISE and LOWER) relief pressure Oil pressure is low in one direction (RAISE or LOWER) is measured

5

When PPC valve output pressure is measured, oil pressure is found to be low

6

When hydraulic drift of boom is measured, it is found to be excessive

7

When operating effort of lift arm control lever is measured, lever is found to be heavy

8

When travel of lift arm control lever is measured, it is found to be short

WA600-3

20-725 (16)

H-23

TROUBLESHOOTING

H-23 Lift arm is slow or lift arm lacks power [machines with remote lift arm control]

Defe ctiv e PP Defe C va Cau ctiv lve ses e actu Defe a tion ctiv e ac of s Defe hutt tuat le sp ctiv ion e of d ool a Defe ctua amp ctiv t i o ing n of e a s ctua olen Defe tion lift arm oid ctiv spo e un spo of lo Defe ol ol l a o d ad v ctiv c h eck alve e s ucti valv Defe on v e ctiv alve e cy Defe lind er s ctiv eal e co ntro l lev er li nka ge

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal

PPC valve

a

No. 1

Remedy Problems

× ×

Shuttle valve

b c

×

Control valve

d e

f

g

× × × × ×

CylinOthers der

h

i A

Does not move in both directions (RAISE and LOWER)

2

Does not move in one direction (RAISE or LOWER)

3 4

When lift arm Oil pressure is low in both directions (RAISE and LOWER) relief pressure Oil pressure is low in one direction (RAISE or LOWER) is measured

5

When PPC valve output pressure is measured, oil pressure is found to be low

6

When hydraulic drift of lift arm is measured, it is found to be excessive

7

When operating effort of lift arm control lever is measured, lever is found to be heavy

8

When travel of lift arm control lever is measured, it is found to be short

20-726 (16)

WA600-3

H-24, H-25

TROUBLESHOOTING

H-24 Lift arm cannot be set to FLOAT or cannot be released from FLOAT Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal

Defe ctiv e PP Defe C va Cau ctiv lve ses e actu Defe a tion ctiv of fl e ac Defe oat tuat ctiv sele ion e co ctor of u ntro nloa valv l lev e d va er li lve nka ge

Checks before troubleshooting • Can other operations of lift arm (RAISE, HOLD, LOWER) be carried out normally?

PPC valve

a

No. 1 2 3 4 5

Remedy Problems

Control valve

b c

× × ×

Others

d A

When PPC valve output pressure is measured Oil pressure is normal (lift arm control lever at FLOAT position) Oil pressure is low When PPC valve output pressure is measured Oil pressure is normal (lift arm control lever at LOWER position) Oil pressure is low When travel of lift arm control lever is measured, it is found to be short

H-25 Lift arm drops momentarily when control lever is operated from HOLD to RAISE Checking for abnormalities • With the engine running at low idling, if the lift arm control lever is gradually moved from HOLD to RAISE, the lift arm moves down momentarily under its own weight. • If the control lever is operated fully to the RAISE position, the condition becomes normal. Causes and Remedy • Defective slow return check valve for control valve lift arm spool (t×).

WA600-3

20-727 (16)

H-26

TROUBLESHOOTING

H-26 Remote lift arm control does not work [machines with remote lift arm control]

Defe ctiv e ac Defe tuat Cau ion ctiv ses e of d actu Defe e t ent atio ctiv shu n of e ac ttle RAI Defe tuat spo SE s ion ctiv ol hutt of L e ac le sp OW tuat ER s ool ion of d hutt amp le sp ing ool sole noid spo ol

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal Checks before troubleshooting • Does the main monitor function properly? • Is any failure code for the electrical system displayed on the main monitor?

Shuttle valve

a

No.

Remedy Problems

1

Lift arm does not stop in both directions (RAISE and LOWER)

2

Lift arm does not stop in RAISE direction

3

Lift arm does not stop in LOWER direction

20-728 (16)

b c

× × ×

d A

WA600-3

H-27

TROUBLESHOOTING

H-27 Excessive hydraulic drift of lift arm

Defe ctiv e oi Defe l tig Cau htne ctiv ses e pi ss o ston f lift seal arm spo ol

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal

Cont- Cylinrol valve der

a

No. 1 2

Problems

Remedy ×

b

×

When lift arm control lever is operated in Hydraulic drift increases RAISE direction from lift arm maximum raise with engine stopped (See Note) No change in hydraulic drift

Note : Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idle for 5 – 10 seconds, then stop the engine.

WA600-3

20-729 (16)

H-28

TROUBLESHOOTING

H-28 Bucket does not move

Defe ctiv e PP Defe C va Cau ctiv lve ses e actu Defe a tion ctiv e ac of b Defe tuat ucke ctiv ion t sp e o ool s f loa Defe afet d ch y-su ctiv eck e c t c i o y Defe valv n va lind e er s ctiv lve eal e co ntro l lev er li nka ge

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?

PPC valve

a

No.

Remedy Problems

1

Does not move in both directions (TILT and DUMP)

2

Does not move in one direction (TILT or DUMP)

3 4

Control valve

b c

× × ×

CylinOthers der

d e

×

×

f A

Oil pressure is low or there is no pressure in When bucket both directions (TILT and DUMP) relief pressure Oil pressure is low or there is no pressure in is measured one direction (TILT or DUMP)

5

When PPC valve output pressure is measured, oil pressure is found to be low or there is no pressure

6

When operating effort of bucket control lever is measured, lever is found to be heavy

7

When travel of bucket control lever is measured, it is found to be short

20-730 (16)

WA600-3

TROUBLESHOOTING

H-29

H-29 Bucket is slow or lacks power

Defe ctiv e PP Defe C va Cau ctiv lve ses e actu Defe atio ctiv n of e ac buc Defe tuat ket ion ctiv spo of lo e sa ol Defe fety ad c ctiv -suc hec e tion k va cylin Defe lve valv der ctiv e seal e co ntro l lev er li nka ge

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal

PPC valve

a

No. 1 2 3 4

Remedy Problems

Control valve

b c

× × ×

CylinOthers der

d e

×

×

f A

Does not move in both directions (TILT and DUMP) Does not move in one direction (TILT or DUMP) Oil pressure is low in both directions (TILT and DUMP)

When bucket relief pressure is measured

Oil pressure is low in one direction (TILT or DUMP)

5

When PPC valve output pressure is measured, oil pressure is found to be low

6

When hydraulic drift of bucket is measured, it is found to be excessive

7

When operating effort of bucket control lever is measured, lever is found to be heavy

8

When travel of bucket control lever is measured, it is found to be short

WA600-3

20-731 (16)

TROUBLESHOOTING

H-30

H-30 Excessive hydraulic drift of bucket

Defe ctiv e oi Defe l tig Cau htne ctiv ses e pi ss o ston f bu cket seal spo ol

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken • Did the problem gradually appear? Yes = Wear of related parts, defective seal

Cont- Cylinrol valve der

a

No. 1 2

Problems

Remedy ×

b

×

When bucket control lever is Hydraulic drift increases operated in DUMP direction with engine stopped (See Note) No change in hydraulic drift

Note : Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idle for 5 – 10 seconds, then stop the engine.

20-732 (16)

WA600-3

TROUBLESHOOTING

H-31

H-31 ECSS does not work, and there is pitching and bouncing [machines with ECSS] Serial No. : 50001 – 52000

Defe ctiv e ac Defe tuat Cau ctiv ion ses e ac of re Defe tuat l i e f so ion ctiv leno e ac of h Defe ightuat id v pres cti a lv e ion of lo sure (SO Defe ve actu w-p L1) sole atio ctiv r e noid n e s sure of c seal Defe valv harg , lea s o ctiv e (S leno e so kag e se OL2 id v e of l Defe al, l ) alve gas enoid v eaka ctiv (SO a f r lve om ge o L3) Defe e actua (SO h f i g g t L as f ctiv h-pr ion e sp rom of c essu 5) eed ontr low re a sen o ccum p l l r e essu sor r ul re a ccum ator ulat or

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal Checks before troubleshooting • Is operation of ECSS switch correct? • Is DIP switch 4 on the back side of the main monitor set correctly? (See TESTING AND ADJUSTING, Adjusting main monitor (speedometer module).)

Solenoid valve

a

No.

Problems

c

d e

f

g

h

Remedy d0 d1 d2 d3 — — — —

1

Speed (5 km/h) for start of actuation of ECSS is greatly out of adjustment

2

ECSS does not work when traveling loaded

3

ECSS does not work when traveling unloaded

4

When ECSS is actuated when traveling loaded, lift arm drops greatly (more than 30 cm)

5

ECSS does not work at all

WA600-3

b

Accumu- Cont- Senlator roller sor

20-733 (16)

TROUBLESHOOTING

H-31

Serial No. : 52001 and up Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal

•

Defe ctiv e ac Defe tuat Cau ctiv ion ses e of re seal Defe l i , ef s leak ctiv o age leno e se Defe of g al, l id v eaka alve as f ctiv rom e g (SO a e of ctua Defe high L1) gas tion ctiv -pre from e sp of c ssur eed ontr low e ac sen -pre olle cum sor r ssur ulat e ac or cum ulat or

•

Checks before troubleshooting • Is operation of ECSS switch correct? • Is DIP switch 4 on the back side of the main monitor set correctly? (See TESTING AND ADJUSTING, Adjusting main monitor (speedometer module).)

Solenoid valve

a

No.

Problems

Speed (5 km/h) for start of actuation of ECSS is greatly out of adjustment

2

ECSS does not work when traveling loaded

3

ECSS does not work when traveling unloaded

4

When ECSS is actuated when traveling loaded, lift arm drops greatly (more than 30 cm)

5

ECSS does not work at all

(16)

b

c

Cont- Senroller sor

d e

Remedy d0 — — — —

1

20-734

Accumulator

WA600-3

TROUBLESHOOTING

METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE

METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE 1. Outline The speedkometer display on the main monitor is used to display the troubleshooting for each control system. The nature of the 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.

2. Display of failure action code This code informs the operator directly of the abnormality, and takes action, such as stopping the machine immediately. There are two types of action code: E00 + CALL and CALL. If a failure occurs suddenly, one of these codes is shown on the speedometer display.

3. Failure code and time elapsed since failure The failures detected by each controller are changed to a code and displayed. It is possible to tell from this code which system in which controller has failed, so carry out troubleshooting for the applicable controller.

4. Saving failure code The transmission controller writes the failure codes to memory. 1) A total of 9 failure codes can be saved in memory. 2) The data that is saved to memory is as follows: (1) Failure code (2) Time elapsed since failure (up to 1,000 hours) 3) The failures are saved in the order that they occur. If a failure code already exists in the memory, the repeat failure code is not saved. 4) If there are already 9 items in memory, and a 10th failure occurs, the oldest item is deleted and the new item is saved. fl It is possible to display the failure code and time elapsed since failure for items saved in memory by operating the main monitor set switch.

WA600-3

20-801-2 (16)

TROUBLESHOOTING

JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM

JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM

Location of failure

Failure mode

Failure code

Short circuit, disconnection in backup lamp relay Short circuit, disconnection in F solenoid Short circuit, disconnection in R solenoid Short circuit, disconnection in 1st solenoid Short circuit, disconnection in 2nd solenoid Short circuit, disconnection in 3rd solenoid Short circuit, disconnection in 4th solenoid Short circuit, disconnection in joystick directional switch system Short circuit, disconnection in directional switch system Short circuit, disconnection in shift switch system Disconnection in travel speed sensor system Short circuit, disconnection in engine speed sensor system Abnormality in kickdown switch signal system Abnormality in transmission cut-off signal system Abnormality in neutralizer signal system Abnormality in alarm buzzer signal system Abnormality in network signal system Abnormality in network signal system or main monitor

Self-diagnostic display (abnormality display)

10 12 13 14 15 16 17 19 20 21 22 23 — — — — — — c c c c c c t t t

1 Travel is impossible 2 Directional lever and direction of travel are different

c

4 Machine travels in reverse when directional lever is not at R.

c c

c c c

5 There is excessive gearshifting shock

c

7 There is shift hunting when shifting gear 8 Speed range cannot be controlled with speed control lever

11 Transmission is not cut off with left brake 12 It is possible to travel even when parking brake is applied

H-2, H-3

c

6 There is shift hunting when traveling

10 Kickdown does not work

E-1, H-1

c

3 Machine travels forward when directional lever is not at F

9 Backup lamp and buzzer do not work

Troubleshooting code when no abnormality display is given

c c c

T-14, E-9 c

T-15, E-14 c

T-16, E-5

13 If F-R lever is operated when traveling at high speed, alarm buzzer does not sound

c

T-17

14 Alarm buzzer continues to sound

c

T-17, J-1

15 Main monitor does not display transmission controller information (alarm buzzer, failure code, etc.)

c

T-18

Troubleshooting code when failure code is displayed T-1 T-2 T-3 T-4 T-5 T-6 T-7 T-8 T-9 T-10 T-11 T-12 — — — — — —

20-802 (16)

WA600-3

TROUBLESHOOTING

T-9

T-9 Related electrical circuit diagram Serial No.: 50001 – 52000

20-820 (16)

WA600-3

TROUBLESHOOTING

T-9

T-9 Related electrical circuit diagram Serial No.: 52001 and up

WA600-3

20-821 (16)

TROUBLESHOOTING

T-18

T-18 Abnormality in network system fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. fl Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket).

Cause

2 YES YES 1 Is resistance between C3B (female) (4), (12) and chassis normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect C3B, L08 and LM1.

Is resistance between C3B (female) (4), (12) and L08 (female) (1), (3) or LM1 (female) (5) normal?

• Max. 1 Ω NO • Turn starting switch OFF. • Disconnect C3B, L08 and LM1.

NO

Remedy

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between C3B (female) (4), (12) and L08 (female) (1), (3), or LM1 (male) (5)

Repair or replace

Short circuit with chassis ground in wiring harness betwen C3B (female) (4), (12) and L08 (female) (1), (3), or LM1 (male) (5)

Repair or replace

T-18 Related electrical circuit diagram

WA600-3

20-831 (16)

TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) Action taken by transmission controller when abnormality occurs and problems on machine ...... 20-952 Electrical circuit diagram for ECSS ........................................................................................................ 20-954 D-1 ECSS does not work ....................................................................................................................... 20-955 a) Error code [d0] is displayed .................................................................................................... 20-956 b) Error code [d1] is displayed .................................................................................................... 20-956 c) Error code [d2] is displayed .................................................................................................... 20-957 d) Error code [d3] is displayed .................................................................................................... 20-957 e) Error code [d4] is displayed .................................................................................................... 20-958 f)

Error code [d5] is displayed .................................................................................................... 20-958

g) Error code [d6] is displayed .................................................................................................... 20-960 h) No abnormality display is given ............................................................................................. 20-963 D-2 ECSS cannot be canceled .............................................................................................................. 20-969 fl Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that DIP switch 4 on the back side of the main monitor is set correctly. Notes: • Hot short circuit Harness which is not connected to power source (24V) circuit is in contact with power source (24V) circuit. • Short circuit Independent harnesses are in contact with each other abnormally.

WA600-3

20-951 (16)

TROUBLESHOOTING

ACTION TAKEN BY TRANSMISSION CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

ACTION TAKEN BY TRANSMISSION CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Serial No. : 50001 – 52000 Failure code

d0

d1

Abnormal system

Nature of abnormality

Short circuit or disconnection in relay A system

1) Defective ECSS (Sol 1 &) relay 2) Hot short, short circuit with ground, defective contact, or disconnection in wiring harness between AL1 (female) (2) and L56 (female) (1) 3) Defective contact or disconnection in wiring harness between L56 (female) (2) and chassis ground 4) Defective ECSS controller

Short circuit or disconnection in solenoid 2 (high pressure)

1) Defective solenoid 2 (high-pressure) 2) Hot short, short circuit with ground, defective contact, or disconnection in wiring harness between AL1 (female) (20) – ECSS (5) – AF2 (female) (1) 3) Defective contact or disconnection in wiring harness between AF2 (female) (2) and chassis ground 4) Defective ECSS controller

1) Defective solenoid 3 (low-pressure) 2) Hot short, short circuit with ground, defective contact, or disconnection in wiring harness between AL1 (female) (11) – ECSS (6) – AF3 (female) (1) 3) Defective contact or disconnection in wiring harness between AF3 (female) (2) and chassis ground 4) Defective ECSS controller

d2

Short circuit or disconnection in solenoid 3 (low pressure)

d3

Disconnection in travel speed sensor system

1) Defective speed sensor 2) Hot short, short circuit with ground, defective contact, or disconnection in wiring harness between AL3 (female) (4), (12) – TL1 (11), (12) – T05 (female) (1), (2) 3) Defective ECSS controller

Defective model selection signal

1) Defective model selection connector 2) Defective contact or disconnection in wiring harness between AL4 (male) (4) and ECSS (male) (8) 3) Defective contact or disconnection in wiring harness between AL2 (female) (1) and AL4 (5) 4) Short circuit with ground in wiring harness between AL2 (female) (2), (3), (4) – AL4 (female) (2), (3), (1) 5) Defective ECSS controller

d4

d5

d6

20-952 (16)

Short circuit or disconnection in solenoid 5 (charge)

Defective speed range signal

1) Defective solenoid 5 (high-pressure) 2) Hot short, short circuit with ground, defective contact, or disconnection in wiring harness between AL1 (female) (20) – ECSS (5) – AF2 (female) (1) 3) Defective contact or disconnection in wiring harness between AF2 (female) (2) and chassis ground 4) Defective ECSS controller

1) Hot short, short circuit with ground, defective contact, or disconnection in wiring harness between L04 (female) (5) and AL2 (female) (11) 2) Hot short, short circuit with ground, defective contact, or disconnection in wiring harness between L04 (female) (6) and AL2 (female) (12) 3) Hot short, short circuit with ground, defective contact, or disconnection in wiring harness between L04 (female) (7) and AL2 (female) (13) 4) Hot short, short circuit with ground, defective contact, or disconnection in wiring harness between L04 (female) (8) and AL2 (female) (14) 5) Defective lever 6) Defective ECSS controller

WA600-3

TROUBLESHOOTING

ACTION TAKEN BY TRANSMISSION CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Condition when normal (voltage, current, resistance) 1) Resistance of relay coil: 200 – 400 Ω 2) Resistance of wiring harness between transmission controller C1 (female) (3) and ECSS relay L90 (female) (1): Max. 1Ω 3) Voltage between transmission controller C1 (3) and chassis ground: Less than 1 V (Command OFF); 20 V or above (Command ON) 4) Resistance of wiring harness between ECSS relay L90 (female) (2) and chassis ground: Max. 1 Ω

WA600-3

Action by controller Problem that appears Troublewhen abnormality is on machine when shooting detected there is abnormality code

ECSS function: OFF

Shaking (Pitching or bouncing) of machine during travel at high speed (2nd – 4th)

D-1 a)

20-953-2 (16)

TROUBLESHOOTING

D-1

D-1 ECSS does not work Serial No. : 50001 – 52000 fl fl fl fl fl

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. Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that DIP switch 4 on the back side of the main monitor is set correctly. Cause

Remedy

3 Displaying [d0].

Go to Item a)

—

Go to Item b)

—

Go to Item c)

—

Go to Item d)

—

Go to Item e)

—

Go to Item f)

—

Go to Item g)

—

Go to Item h)

—

4 Displaying [d1].

2 YES

Which code is monitor displaying?

5 Displaying [d2].

6 Displaying [d3].

7 Displaying [d4].

1 Is there an abnormality display?

8 Displaying [d5].

9 Displaying [d6].

NO

WA600-3

20-955 (11)

D-1

TROUBLESHOOTING

Serial No. : 52001 and up fl fl fl fl fl

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. Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that DIP switch 4 on the back side of the main monitor is set correctly.

Cause

Remedy

2 YES Displaying [d0]. 1

Go to Item a)

—

Go to Item b)

—

Is there an abnormality display?

NO

20-966 (11)

WA600-3

30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL .................... 30- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION ................................................ 30- 4 SPECIAL TOOL LIST ..................................... 30- 6 SKETCHES OF SPECIAL TOOLS .................. 30-14 STARTING MOTOR Removal and Installation ........................... 30-23 ALTERNATOR Removal and Installation ........................... 30-24 ENGINE OIL COOLER (Serial No.: 50001 – 52000) Removal and Installation ........................... 30-25 FUEL INJECTION PUMP (Serial No.: 50001 – 52000) Removal and Installation ........................... 30-26 WATER PUMP (Serial No.: 50001 – 52000) Removal and Installation ........................... 30-27 NOZZLE HOLDER (Serial No.: 50001 – 52000) Removal and Installation ........................... 30-28 TURBOCHARGER (Serial No.: 50001 – 52000) Removal ...................................................... 30-29 Installation .................................................. 30-30 ENGINE FRONT SEAL (Serial No.: 50001 – 52000) Replacement ............................................... 30-31 ENGINE REAR SEAL (Serial No.: 50001 – 52000) Replacement ............................................... 30-33 CYLINDER HEAD (Serial No.: 50001 – 52000) Removal ...................................................... 30-35 Installation .................................................. 30-40 THERMOSTAT (Serial No.: 50001 – 52000) Removal and Installation ........................... 30-42 AFTERCOOLER CORE (Serial No.: 50001 – 52000) Removal ...................................................... 30-43 Installation .................................................. 30-44 RADIATOR Removal ...................................................... 30-45 Installation .................................................. 30-47 RADIATOR (with suction fan) Removal ................................................... 30-47-5 Installation ............................................... 30-47-8

WA600-3

ENGINE AND TORQUE CONVERTER ASSEMBLY Removal ...................................................... 30-48 Installation .................................................. 30-50 TORQUE CONVERTER Removal and Installation ........................... 30-51 Disassembly ............................................... 30-52 Assembly .................................................... 30-57 TRANSMISSION Removal ...................................................... 30-63 Installation .................................................. 30-65 Disassembly ............................................... 30-66 Assembly .................................................... 30-81 TRANSMISSION VALVE Removal and Assembly ............................. 30-97 TRANSFER Disassembly ............................................... 30-98 Assembly .................................................. 30-107 CENTER SUPPORT Removal and Installation ......................... 30-118 Disassembly ............................................. 30-120 Assembly .................................................. 30-122 DRIVE SHAFT Disassembly ............................................. 30-125 Assembly .................................................. 30-128 FRONT AXLE Removal .................................................... 30-131 Installation ................................................ 30-132 FRONT DIFFERENTIAL Removal .................................................... 30-133 Installation ................................................ 30-134 REAR AXLE Removal .................................................... 30-135 Installation ................................................ 30-138 REAR DIFFERENTIAL Removal .................................................... 30-139 Installation ................................................ 30-140 DIFFERENTIAL GEAR Disassembly ............................................. 30-141 Assembly .................................................. 30-145

30-1 (15)

LIMITED SLIP DIFFERENTIAL Disassembly .......................................... 30-152-1 Assembly ............................................... 30-152-6 FINAL DRIVE Removal .................................................... 30-153 Assembly .................................................. 30-155 ORBIT-ROLL Removal and Installation ......................... 30-158 STEERING CYLINDER Removal .................................................... 30-159 Installation ................................................ 30-160 Disassembly ............................................. 30-161 Assembly .................................................. 30-163 STEERING VALVE Removal .................................................... 30-165 Installation ................................................ 30-166 CUT-OFF VALVE Removal and Installation ......................... 30-167 BRAKE VALVE Removal and Installation ......................... 30-168 BRAKE VALVE (R.H.) Disassembly ............................................. 30-169 Assembly .................................................. 30-171 BRAKE VALVE (L.H.) Disassembly ............................................. 30-173 Assembly .................................................. 30-175 SLACK ADJUSTER Removal and Installation ......................... 30-177 Disassembly ............................................. 30-178 Assembly .................................................. 30-179 BRAKE Removal and Installation ......................... 30-180 Disassembly ............................................. 30-181 Assembly .................................................. 30-184 HYDRAULIC PUMP Removal .................................................... 30-188 Installation ................................................ 30-189 HYDRAULIC TANK Removal .................................................... 30-190 Installation ................................................ 30-191 HYDRAULIC FILTER Removal and Installation ......................... 30-192 PPC VALVE Removal and Installation ......................... 30-193 Disassembly and Assembly .................... 30-194 WORK EQUIPMENT VALVE Removal .................................................... 30-195 Installation ................................................ 30-196 MAIN CONTROL VALVE Disassembly ............................................. 30-198 Assembly .................................................. 30-202 DUMP CYLINDER Removal .................................................... 30-205 Installation ................................................ 30-206 LIFT CYLINDER Removal .................................................... 30-207 Installation ................................................ 30-208

30-2 (16)

LIFT CYLINDER AND DUMP CYLINDER Disassembly ............................................. 30-209 Assembly .................................................. 30-211 CENTER HINGE PIN Removal .................................................... 30-214 Installation ................................................ 30-219 WORK EQUIPMENT Removal .................................................... 30-222 Installation ................................................ 30-226 BULKHEAD Removal .................................................... 30-228 Installation ................................................ 30-229 FLOOR FRAME Removal .................................................... 30-230 Installation ................................................ 30-232 COUNTERWEIGHT Removal and Installation ......................... 30-233 FUEL TANK Removal .................................................... 30-234 Installation ................................................ 30-235 CAB Removal .................................................... 30-236 Installation ................................................ 30-238 STOP VALVE Removal and Installation ......................... 30-239 ACCUMULATOR Removal and Installation ........................ 30-240 ACCUMULATOR CHARGE VALVE Removal and Installation ......................... 30-241 PARKING BRAKE SOLENOID VALVE Removal and Installation ......................... 30-242 DIVERTER VALVE Removal and Installation ......................... 30-243 EMERGENCY STEERING PUMP Removal and Installation ......................... 30-244 PARKING BRAKE Removal and Installation ......................... 30-245 PARKING BRAKE CALIPERS Disassembly ............................................. 30-246 Assembly .................................................. 30-247 PARKING BRAKE PAD Removal and Installation ......................... 30-248 REAR TIRES Removal and Installation ......................... 30-249 AIR CONDITIONER COMPRESSOR Removal .................................................... 30-250 Installation ................................................ 30-251 AIR CONDITIONER CONDENSER Removal and Installation ......................... 30-252 RECEIVER TANK Removal and Installation ......................... 30-253 AIR CONDITIONER UNIT Removal .................................................... 30-254 Installation ................................................ 30-255 MONITOR Removal and Installation ......................... 30-256

WA600-3

SPECIAL TOOL LIST

DISASSEMBLY AND ASSEMBLY

Component

Symbol

1

Disassembly, assembly of torque converter, PTO

Part Name

790-501-5000 or 790-501-5200

Unit repair stand (100V) Unit repair stand (110 – 120V or 220 – 240V)

790-901-4110

Bracket

1

793-310-2190

Plate

1

(Serial No.: 50001 – 52000)

793-617-1110

Plate

1

(Serial No.: 52001 and up)

790-101-5201

Push tool kit (B)

1

1 1

Torque converter.PTO repair stand

C 2

3

WA600-3

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

Part No.

• 790-101-5251 • Plate

1

• 790-101-5221 • Grip

1

• 01010-51225

• Bolt

1

790-201-2740

Spacer

1

790-201-2840

Spacer

1

Press fitting of bushing

Press fitting of bearing in shaft

30-7 (16)

DISASSEMBLY AND ASSEMBLY

Component

Symbol

SPECIAL TOOL LIST

Part No. 790-101-5401

Part Name Push tool kit (C)

1

• 790-101-5421 • Grip

1

• 01010-51240

• Bolt

1

790-101-5401

Push tool kit

1

• 790-101-5481 • Plate

1

• 790-101-5421 • Grip

1

• Bolt

1

5 • 01010-51240

793T-659-1110 Push tool Plate

1

790-201-2650

Plate

1

790-101-5401

Push tool kit (C)

1

C • 790-101-5441 • Plate

1

• 790-101-5421 • Grip

1

• 01010-51240

• Bolt

1

790-101-5401

Push tool kit

1

8

• 790-101-5451 • Plate

1

• 790-101-5421 • Grip

1

• 01010-51240

• Bolt

1

790-101-5201

Push tool kit (B)

1

9

Press fitting of pump subassembly

Press fitting of stator shaft bearing inner race

Press fitting of turbine in bearing outer race

Press fitting of drive case bearing

• 790-101-5221 • Grip

1

• Bolt

1

11 790-102-1891

Nut wrench

1

1

790-201-2750

Spacer

1

Disassembly of torque converter Removal of coupling

2

790-201-2760

Spacer

1

Removal of bearing

3

799-301-1500

Oil leak tester

1

4

793T-615-1160 Push tool 790-101-5401

Push tool kit (C)

D

1 N

Press fitting of turbine in drive case

Check of operation of clutch piston Press fitting of 1st clutch carrier bushing

1

• 790-101-5461 • Plate

1

• 790-101-5421 • Grip

1

• 0101-51240

• Bolt

1

6

790-101-2860

Spacer

1

Press fitting of bearing in shaft

7

793T-659-1110 Push tool

1 N

Press fitting of carrier in shaft

5

(16)

Press fitting of pump guide bearing

1

• 01010-51240

30-8

Press fitting of retainer oil seal

• 790-101-5231 • Plate 10

Disassembly, assembly of transmission

1 N

790-201-2220 7 Disassembly, assembly of torque converter, PTO

1

• 790-101-5431 • Plate 4

6

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

Press fitting of bearing in sun gear

WA600-3

DISASSEMBLY AND ASSEMBLY

Component

Symbol

SPECIAL TOOL LIST

Part No. 790-101-5201

Disassembly, assembly of transmission

Part Name Push tool kit (B)

1

D 21 • 790-101-5221 • Grip

1

• 01010-51225

• Bolt

1

790-201-2660

Plate

1

790-101-5401

Push tool kit (C)

1

• 790-101-5551 • Plate

1

• 790-101-5421 • Grip

1

• 01010-51240

• Bolt

1

790-101-5401

Push tool kit (C)

1

• 790-101-5441 • Plate

1

23 • 790-101-5421 • Grip

1

• 01010-51240

• Bolt

1

790-201-2760

Spacer

1

24 796-730-2300

Wrench

1

25 796-720-3800

Wrench

1

793-615-1130

Wrench

1

796-730-2300

Wrench ass'y

1

26 D

796T-426-1130 Plate

1

• 01010-51240

• Bolt

1

790-101-5401

Push tool kit (C)

1

• 790-101-5551 • Plate

1

• 790-101-5421 • Grip

1

• 01010-51240

• Bolt

1

790-201-2260

Plate

1

790-201-2650

Plate

1

790-101-5401

Push tool kit (C)

1

29

• 790-101-5481 • Plate

1

• 790-101-5421 • Grip

1

• Bolt

1

30 • 01010-51240

793T-659-1110 Push tool 31 790-201-2660

(13)

Plate

Press fitting of coupling in cage

Press fitting of bearing outer race in cage

Press fitting of bearing inner race in gear

For No. 3 shaft Adjusting preload of No. 1 shaft bearing Adjusting preload of No. 2 shaft bearing

Adjusting preload of No. 3 shaft bearing

1

27 • 790-101-5421 • Grip

28

30-10

1

• 790-101-5281 • Plate

22

Disassembly, assembly of transfer

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

1 1

Press fitting of oil seal of output shaft cage

Press fitting of bearing of output shaft cage

Press fitting of coupling in cage

Press fitting of bearing outer race in transfer case

Press fitting of bearing inner race in shaft

WA600-3

SPECIAL TOOL LIST

DISASSEMBLY AND ASSEMBLY

Component

Symbol

Part No. 790-201-1500

Disassembly, assembly of transfer

Part Name Push tool kit

1

• 790-101-5021 • Grip

1

• Bolt

1

Centering tool

1

790-201-2850

Spacer

1

790-201-2750

Spacer

1

790-101-5401

Push tool kit

1

• 01010-50816 33 790-438-1120

1

• 790-101-5451 • Plate

1

• 790-101-5461 • Plate

1

• 790-101-5421 • Grip

1

• Bolt

1

• 01010-51240

793T-620-1150 Plate

1 N

• 790-101-5431 • Plate

1

• 790-101-5421 • Grip

1

• 01010-51240

• Bolt

1

790-501-5200

Unit repair stand

1

790-901-4110

Bracket

1

793-310-2190

Plate

1

793-560-1201

Rod

1

2

3 Disassembly, assembly H of differential 4

793T-623-1140 Push tool

1 N

793T-623-1150 Spacer

1 N

5 790-101-5221

Grip

1

01010-51240

Bolt

1

6

793T-623-1160 Push tool

1 N

7

793T-623-1170 Push tool

1 N

790-101-5401

Push tool kit (C)

1

• 790-101-5421 • Grip

1

• 01010-51240

• Bolt

1

790-101-5401

Push tool kit (C)

1

• 790-101-5551 • Plate

1

• 790-101-5421 • Grip

1

• Bolt

1

9 • 01010-51240

Press fitting of oil seal in cage

Centering of transmission center support

Press fitting of center support main bearing Press fitting of center support sub bearing Press fitting of center support bearing outer race Sub bearing Main bearing

Press fitting of oil seal of center support housing

For overseas countries

Removal, installation of axle shaft

Press fitting of differential cage oil seal Press fitting of differential case dust seal Pinion shaft main bearing inner race Pinion shaft sub bearing inner race

1

• 790-101-5621 • Plate 8

WA600-3

1

• 790-201-1680 • Plate 32 D

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

Press fitting of main bearing outer race

Press fitting of sub bearing outer race

30-11 (14)

DISASSEMBLY AND ASSEMBLY

Component

Symbol

SPECIAL TOOL LIST

Part No.

Part Name

10 793T-622-1180 Push tool Disassembly, assembly of differential

1

11 792-525-1220

Adapter

1

792-533-1400

Wrench

1

2

793T-622-1190 Fixture

3 N

793T-622-1210 Plate

1 N

• 790-101-5421 • Grip

1

• 01010-51240

• Bolt

1

792-520-2110

Installer

1

792-530-1600

Push tool

1

790-101-2300

Push puller

1

J

3

• 790-101-2310 • Block

1

• 790-101-2320 • Screw

1

• 790-101-2330 • Nut

1

• 790-101-2340 • Washer

1

• 790-101-2350 • Leg

2

• 790-101-2360 • Plate

4

• 790-101-2410 • Joint

2

1

Installation of center hinge bearing

(16)

• 02215-11622

• Nut

2

793-520-2640

Push tool

1

790-438-1030

Guide

1

790-438-1050

Bar

2

790-101-2102

Puller (294kN{30ton})

1

790-101-1102

Pump

1

790-101-2300

Push puller

1

K

2

30-12

1 N

Micrometer

792-525-1000 H

1

Disassembly, assembly of rear brake

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

• 790-101-2310 • Block

1

• 790-101-2330 • Nut

1

• 790-101-2340 • Washer

1

• 790-101-2350 • Leg

2

• 790-101-2360 • Plate

4

• 790-101-2410 • Joint

2

• 02215-11622

• Nut

2

790-438-1050

Bar

2

01580-12016

Nut

2

790-438-1010

Push tool

1

Press fitting of differential case bearing

Adjusting preload of bearing Removal, installation of wheel hub

Press fitting of oil seal

Fitting of floating seal

Installation of upper center hinge bearing

Installation of lower center hinge bearing

WA600-3

DISASSEMBLY AND ASSEMBLY

Component

Installation of center hinge bearing

Symbol

K

SPECIAL TOOL LIST

Part No.

Part Name

790-438-1020

Guide

1

790-438-1040

Screw

1

790-101-2102

Puller

1

790-101-1102

Pump

1

790-502-1003

Cylinder repair stand

1

790-502-2000

Cylinder repair stand

1

790-101-1102

Hydraulic pump

1

2

790-102-3802

Wrench

1

3

790-302-1340

Socket (80mm)

1

Removal, installation of steering cylinder round head Removal, installation of steering cylinder nylon nut

790-201-1500

Push tool kit

1

Press fitting of dust seal

• 790-201-1620 • Plate

1

Steering cylinder

• 790-201-1680 • Plate

1

Lift cylinder

• 790-201-1690 • Plate

1

Bucket cylinder

• 790-101-5021 • Grip

1

• 01010-50816

• Bolt

1

790-201-1702

Push tool kit

1

Press fitting of roll bushing

• 790-201-1811 • Push tool

1

Steering cylinder

• 790-201-1871 • Push tool

1

Lift cylinder

• 790-201-1881 • Push tool

1

Bucket cylinder

• 790-101-5021 • Grip

1

• 01010-50816

• Bolt

1

790-720-1000

Expander

1

796-720-1670

Ring

1

07281-01279

Clamp

1

796-720-1720

Ring

1

07281-02429

Clamp

1

796-720-1710

Ring

1

07281-02909

Clamp

1

2

1

4

Disassembly, assembly of hydraulic cylinder

U

5

6 7

8

9 793T-670-1110 Sleeve

Removal of pins of work equipment

WA600-3

V

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

1

Installation of lower center hinge bearing

Disassembly, assembly of cylinder

All cylinders Steering cylinder

Lift cylinder

Bucket cylinder

1 N

791-679-1120

Plate

1

791-745-2110

Adapter

1

790-438-1110

Screw

1

791-112-1180

Nut

1

790-101-2540

Washer

1

01010-81655

Bolt

1

Removal of pins connecting lift arm and bucket, and link and bucket

30-13 (16)

DISASSEMBLY AND ASSEMBLY

Component

Symbol

SPECIAL TOOL LIST

Part No.

Part Name

790-101-2102

Puller (294kN{30ton})

1

690-101-1102

Pump

1

1

793T-670-1130 Sleeve

1 N

791-735-1110

Adapter

1

790-438-1110

Screw

1

793T-670-1140 Plate

1 N

791-112-1180

Nut

1

790-101-2540

Washer

1

790-101-2102

Puller (294kN{30ton})

1

790-101-1102

Pump

1

2

Removal of pins of work equipment

V

793T-670-1120 Sleeve

1 N

791-735-1110

Adapter

1

790-738-1110

Screw

1

791-679-1120

Plate

1

791-112-1180

Nut

1

790-101-2540

Washer

1

790-101-2102

Puller

1

790-101-1102

Hydraulic pump

1

799-703-1200

Service tool kit

1

799-703-1110 790-703-1120

Vacuum pump (220V) Vacuum pump (240V)

799-703-1401

Gas leak detector

3

Air conditioner assembly

30-13-1 (16)

X

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

1

1 1

Removal of pins connecting lift arm and bucket, and link and bucket

Removal of lift arm foot pin

Removal of pin connecting lift arm and bell crank

Charging air conditioner with gas

1

WA600-3

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS A8

Adaputer

SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

C6, D7, D31 Push tool

30-14 (13)

WA600-3

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

D18 Push tool

D27 Plate

30-16 (13)

WA600-3

DISASSEMBLY AND ASSEMBLY

H2

SKETCHES OF SPECIAL TOOLS

Plate

WA600-3

30-16-1 (13)

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

H10 Push tool

J1

Fixture

WA600-3

30-19 (14)

DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP

REMOVAL OF FUEL INJECTION PUMP Serial No. : 50001 – 52000

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Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

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Disconnect the cable from the negative (–) terminal of the battery.

1. Open the engine right side cover. 2. Remove coupling cover (1). 3. Disconnect fuel control rod (2).

1

4. Disconnect engine stop cable (3).

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5. Disconnect hose (4). 6. Disconnect hose (5). 7. Disconnect hose (6). 8. Disconnect hose (7). 9. Remove lubrication oil return tube (8). 10. Disconnect lubrication oil inlet tube (9). 11. Disconnect boost compensator tube (10). 12. Disconnect 6 fuel injection tubes (11). 13. Loosen lock bolt (12). 14. Remove 4 mounting bolts (13), then remove injection pump (14). 3 0

Fuel injection pump: 31kg

15. Install tool A8 to the delivery valve holder, then lift off the fuel injection pump assembly.

INSTALLATION OF FUEL INJECTION PUMP Serial No. : 50001 – 52000 •

Carry out installation in the reverse order to removal.

1 fl Adjust the control rod. For details, see ADJUSTING FUEL CONTROL CABLE. 2 fl Adjust the cable. For details, see ADJUSTING ENGINE STOP MOTOR CABLE. 3 fl Test and adjust the fuel injection timing. For details, see TESTING AND ADJUSTING FUEL INJECTION TIMING.

30-26 (13)

WA600-3

DISASSEMBLY AND ASSEMBLY

ENGINE REAR SEAL

REPLACEMENT OF ENGINE REAR SEAL Serial No. : 50001 – 52000

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Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

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Disconnect the cable from the negative (–) terminal of the battery.

1. Remove the torque converter. For details, see REMOVAL OF TORQUE CONVERTER. 2. Removal of engine rear seal 1) Sling and remove flywheel (1). 0

Flywheel: 48kg

2) Remove engine rear seal (2). 3. Installation of engine rear seal

•

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

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Installation of rear seal having sleeve (For repair) 1) Press fit sleeve (4) to the crankshaft (2) by using A4. fl Tighten the 2 nuts evenly. fl

WA600-3

Press fit the seal until tool A4 comes into contact with the crankshaft end.

30-33 7

DISASSEMBLY AND ASSEMBLY

ENGINE FRONT SEAL

2) Press fit front seal (6) to the front cover (3) with tool A2. fl Fill the lip with lithium grease (G2-LI) of about 5cc. fl Tighten the 3 bolts evenly.

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

5. Adjustment of fan belt 1) Loosen the stop bolt and install the 3 belts. 2) Tighten the stop bolt until it comes into contact with the tension bracket. 3) After the stop bolt comes into contact with the tension bracket, further tighten it by two turns. 9 Locknut: 245.0 – 108.7Nm {25.0 ± 31.5kgm}

30-32 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

ENGINE REAR SEAL

2) Install seal (5) to sleeve (4). 3) Tighten 4 bolts until the cover of seal (5) comes into contact with end surface of flywheel housing (3). 8 Oil seal lip: Grease (G2-LI)

4. Installation of flywheel 1) For the tightening order, see the diagram on the right. 8 Mounting bolt: Lubricant (LM-P) 9 Mounting bolt: 1st step: 98.0 ± 20.0Nm {10.0 ± 2.0kgm} 2nd step: 294.0 ± 20.0Nm {30.0 ± 2.0kgm} 3rd step: 539.0 ± 20.0Nm {65.0 ± 2.0kgm} 2) Measure the radial runout and face runout of the flywheel. Radial runout: Max. 0.15mm Face runout: Max. 0.20mm

30-34 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

RADIATOR

27. Apply corrugated cardboard [1] to the radiator side, and lower fan (28) slowly and tense rope [2] so that the fan will not fall down outward. 0 Fan: 46kg

28. Remove mounting bolts (30), then sling and remove radiator (31). 0 Radiator: 450kg

INSTALLATION OF RADIATOR Serial No. : 52001 and up •

Carry out installation in the reverse order to removal.

•

Refilling with water Add water to the specified level. Run the engine to circulate the water through the system. Then, check the coolant level again.

WA600-3

30-47-4 (16)

DISASSEMBLY AND ASSEMBLY

RADIATOR

REMOVAL OF RADIATOR (with suction fan) Serial No. : 52001 and up

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Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

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Disconnect the cable from the negative (–) terminal of the battery.

1. Open right and left side covers (1), then remove engine hood (2). • Remove the right and left wire cables installed between the radiator guard and handrail. 0 Engine hood: 80kg 2. Loosen drain valve (3) and drain the engine cooling water. = Engine cooling water: Approx. 155 ¬

3. Remove radiator duct (4). • Remove radiator grill. 0 Duct and grille: 95kg

4. Disconnect radiator coolant level sensor connector (5) (G01). 5. Remove baffle plates (6), (7), (8) and (9). 6. Remove radiator guard mounting bolts (10).

30-47-5 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

RADIATOR

7. Disconnect tail lamp connector (11) (GR1). 8. Remove baffle plates (12), (13), (14) and (15). 9. Remove radiator guard mounting bolts (16).

10. Remove right and left side pillar mounting bolts (17). 11. Remove the mounting bolts, then remove the radiator guard (18). 0 Radiator guard: 280kg fl When slinging the radiator guard, take care that radiator guard fitting portion will not interfere with the radiator fitting portion.

12. Disconnect engine cooling water drain hose (19). 13. Disconnect 2 hoses (20) of the hydraulic oil cooler. fl Prepare plugs to stop the oil from flowing out.

14. Disconnect hose (21) between the radiator and water pump.

WA600-3

30-47-6 (15)

DISASSEMBLY AND ASSEMBLY

RADIATOR

15. Disconnect 2 hoses (22) of the fuel cooler.

16. Disconnect aeration hose (23). 17. Disconnect engine cooling water return hose (24). 18. Disconnect sub-tank hose (25). 19. Disconnect two hoses (26) to after-cooler. 20. Remove fan guards (27). 21. Remove fan (28) and place it on the radiator side. 22. Disconnect right and left radiator supports (29) from the radiator, then let it fall down on the engine side. 23. Apply corrugated cardboard [1] to the radiator side, and lower fan (28) slowly and tense rope [2] so that the fan will not fall down outward. 0 Fan: 45kg

24. Remove mounting bolts (30), then sling and remove radiator (31). 0 Radiator: 550kg

30-47-7 (15)

WA600-3

DISASSEMBLY AND ASSEMBLY

RADIATOR

INSTALLATION OF RADIATOR (with suction fan) Serial No. : 52001 and up •

Carry out installation in the reverse order to removal.

•

Refilling with water Add water to the specified level. Run the engine to circulate the water through the system. Then, check the coolant level again.

WA600-3

30-47-8 (16)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

5. Drive case, turbine assembly 1) Using eyebolts 1, remove drive case and turbine assembly (9).

2) Disassembly of drive case and turbine assembly. a. Using push tool 2, remove turbine (10) from drive case (11).

b. Remove beaning inner race (12) from tubine.

c.

30-62-2 (16)

Remove beaning inner race (13).

WA600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

d. Using push tool 3, remove beaning (14) from drive case. fl Beaning (14) and inner races (12 and 13) form a set, so keep the product numbers and match marks in sets.

6. Stator Remove mounting bolts, then remove stator (15). 7. Race Remove snap ring (16), then remove race (17).

8. Pump assembly 1) Remove pump assembly (18).

2) Disassembly of pump assembly. a. Remove mounting bolts, then remove plate (19). b. Remove gear assembly (20) from pump (21).

WA600-3

30-62-3 (16)

DISASSEMBLY AND ASSEMBLY

c.

TORQUE CONVERTER

Remove snap ring (22), then using push tool (4) remove inner race (23) from gear (24).

9. Retainer assembly 1) Remove mounting bolts, then remove retainer assembly (25). 2) Remove oil seal (26) from retainer (27).

10. Turbine shaft assembly 1) Secure stator shaft with bolt 5. 2) Tap with a plastic hammer, and remove turbine shaft assembly (28).

3) Disassembly of turbine shaft assembly. a. Remove seal ring (29). b. Remove snap ring (30), then remove spacer (31). c. Using push tool 6, remove bearing (32) from shaft (33).

30-62-4 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

11. Stator shaft assembly 1) Tap with a plastic hammer, and remove stator shaft assembly (34). 2) Disassembly of stator shaft assembly. a. Remove seal ring (35).

b. Using bearing puller 7, remove bearing (36). c. Remove bushing (37) from stator shaft (38).

12. Pump drive gear assembly 1) Using tool C11, remove nut (39). fl Secure with a bar to prevent the pump drive gear from turning, then loosen the nut.

2) Using push tool 8, pull out pump drive gear (40), and remove bearing (41). fl Set the push tool securely in contact with the end face of the gear shaft, and take care not to damage the thread when knocking it out.

WA600-3

30-62-5 (16)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

3) Remove ring (42), then remove beaning (43) from pump drive gear (40). 4) Remove bearing outer races (44 and 45), and ring (46) from housing (47). fl Bearings (41 and 43), bearing outer races (44 and 45), and rings (42 and 46) form a set, so keep the product numbers and match marks in sets. 5) Disassemble other pump drive gear assembly in the same way as in Steps 1)-4).

30-62-6 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

ASSEMBLY OF TORQUE CONVERTER Serial No. : 52001 and up fl Clean all parts, and check for dirt or damage. fl Put a drop of engine oil on the rotating surfaces of all bearings before installing.

1. Housing Set housing (47) on tool C1. 2. Pump drive gear assembly fl The bearings of the pump drive gear form a set. Mach the product numbers and match marks of the inner and outer races and seats to assembly. 1) Install ring (46) to housing (47). 2) Using push tool 9, press fit bearing outer races (44 and 45).

3) Using push tool 0, press fit bearing (43) to pump drive gear (40). 4) Assembly ring (42).

5) Set pump drive gear (40) in position, then using push tool A, press fit bearing (41). fl Support the end face of the pump drive gear on a block, then press fit the bearing. fl When press fitting the bearing, be careful not to damage the thread of the gear shaft.

WA600-3

30-62-7 (16)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

6) Using tool C11, tighten nut (39). fl Secure with a bar to prevent the pump drive gear from turning, then tighten the nut. 3 Nut: 416.8 ± 24.5 Nm {42.5 ± 2.5 kgm} 7) Assemble other pump drive gear assembly in the same way as in Steps 1) - 6).

3. Stator shaft assembly 1) Assembly of stator shaft assembly a. Using push tool B, press fit bushing (37) to stator shaft (38). fl Press fit the bushing so that the chamfered inside diameter faces the outside.

b. Using push tool C, press fit bearing (36). c. Install seal ring (35). fl Coat the seal ring with grease (G2-LI), and secure it so that it does not protrude from the shaft.

2) Fit O-ring to housing end, and install stator shaft assembly (34).

30-62-8 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

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

2) Tap turbine shaft assembly (28) with a plastic hammer, then install to stator shaft.

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

2) Fit O-ring and install retainer assembly (25). 8 Bolt thread: Thread tightener (LT-2) 9 Mounting bolt: 66.29 ± 7.36 Nm {6.76 ± 0.75 kgm}

WA600-3

30-62-9 (16)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

6. Pump assembly 1) Assembly of pump assembly. a. Install snap ring (22) to gear (24). b. Using push tool F, press fit bearing inner race (23).

c.

Set pump (21) to gear assembly (20), then fit plate (19) and tighten mounting bolts. fl Install the plate so that the chamfered side faces the inside. 8 Bolt thread: Thread tightener (LT-2) 3 Mounting bolt: 66.20 ± 7.36 Nm{6.75 ± 0.75 kgm}

2) Install pump assembly (18).

7. Rase Fit race (17) and install snap ring (16). fl Check that the snap ring is fitted securely in the groove. 8. Stator Install stator (15). 3 Mounting bolt: 66.20 ± 7.36 Nm{6.75 ± 0.75 kgm}

30-62-10 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

9. Drive case, turbine assembly 1) Assembly of drive case and turbine assembly. fl The bearings connecting the drive case and turbine form a set. Match the product numbers and match marks of the inner and outer races to assemble.

a. Using push tool G, press fit bearing (14) to drive case (11).

b. Using push tool H, press fit bearing inner race (12) to turbine (10).

c.

WA600-3

Set turbine (10) on block I, and fit drive case (11), then using push tool J, press fit bearing inner race (13).

30-62-11 (16)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

2) Using eyebolts 1, set drive case and turbine assembly (9) to pump. 3) Tighten mounting bolts of pump and drive case in turn on opposite side temporarily.

10. Pump, drive case mounting bolts Turn over repair stand, and tighten 20 pump and drive case mounting bolts (6). 8 Bolt thread: Thread tightener (LT-2) 9 Mounting bolt: 53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}

11. Holder Install holder (8). 8 Bolt thread: Thread tightener (LT-2) 3 Mounting bolt: 250.0 ± 24.5 Nm {25.5 ± 2.5 kgm}

12. Pilot Install pilot (7). 8 Bolt thread: Thread tightener (LT-2) 3 Mounting bolt: 164.3 ± 12.3 Nm {11.25 ± 1.25 kgm}

30-62-12 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

13. Torque converter assembly 1) Fit gasket and install plate (5). 8 Gasket: Gasket sealant (LG-1) 2) Fit gasket to both ends and install lubrication tube (4). 3 Joint bolt: 24.5 ± 4.9 Nm {2.5 ± 0.5 kgm} 3) Fit O-ring and install torque converter regulator valve assembly (3). 8 Bolt thread: Thread tightener (LT-2) 3 Mounting bolt: 53.9 ± 4.9 Nm {5.5 ± 0.5 kgm} 4) Install coupling (2). 5) Remove torque converter assembly (1) from tool C1. fl After assembling, cover the openings with tape to prevent dirt or dust from entering.

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30-62-13 (16)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

v) Remove snap ring (109). vi) Set the assembly to the press, then remove sun gear (110) by using push tool D12 (Inside diameter: 106mm).

vii) Remove snap ring (111), then remove bearing (112) by using the push tool (Outside diameter: 130mm).

viii)Set the assembly to the press, then remove collar (113) by using the push tool (Outside diameter: 95mm).

ix) Pull out the roll pin and remove pin (114), then remove thrust washer (115), planetary gear (116) and needle bearing (117).

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30-79 (12)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

ii) Install collar (113) by expansion fit.

iii) Set the assembly to the press, then press fit bearing (112) to the No. 6 sun gear by using push tool D9 (Outside diameter: 135mm). iv) Install snap ring (111).

v) Install snap ring (109) to the shaft. vi) Set the assembly to the press, then press fit sun gear (110) by using push tool D12 (Inside diameter: 105mm).

vii) Install carrier (108) to the shaft with push tool D7. viii)Install snap ring (107).

WA600-3

30-83 (12)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

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

iii) Install collar (93), the tighten the three mounting bolts. 2 V-groove on periphery of collar: Gasket sealant (LG-I) 3 Mounting bolt: 13.7 ± 1.0Nm {1.4 ± 0.1kgm} iv) Set needle bearing (92), planetary gear (91) and thrust washer (90) and install pin (89), then install the roll pin.

v) Set the assembly to the press, then install carrier assembly (88) with push tool D9 (Inside diameter: 135mm). vi) Install snap ring (87).

WA600-3

30-85 (16)

DISASSEMBLY AND ASSEMBLY

TRANSFER

3. No. 1 gear 2) Using push tool (Outside diameter: 105mm), press fit 2 bearings (27) to gear (28). fl Apply LM-G to the races and rollers of the bearing. 3) Install gear (26). i) Turn over the transfer case.

4. Cage 1) Using push tool (Outside diameter: 190mm), press fit outer race (24) to cage (25).

2) Install the O-ring, then install cage (23).

5. Adjusting preload of No. 1 gear bearing Set tool D24 and measure the preload with a torque wrench. fl Standard preload: 0.1 – 1.0Nm {0.01 – 0.1kgm} fl If the preload is out of the standard range, adjust it with shim (45).

30-108 (12)

WA600-3

DISASSEMBLY AND ASSEMBLY

DRIVE SHAFT

ASSEMBLY OF DRIVE SHAFT 1. Yoke 1) Install bearing (14), and seal (15) to bearing cap (13). 2 Bearing, seal : Grease (G2-LI)

2) Assemble plastic washer (16), and bearing cap (13) to spider assembly (12) fl Be careful not to damage bearing with heat when welding strap. 2 Bearing cap : Grease (G2-LI)

3) Assemble spider assembly (12) to yoke (3). fl Carefully align match marks. fl Clean the mounting face of the bearing cap by wiping with a clean cloth. 3 Mounting bolts : 157.0 – 196.0 Nm {16.0 – 20.0 kgm}

2. Shaft 1) Assemble bearing (8) and seal (9) in bearing cap (6). 2 Bearing seal : Grease (G2-LI)

30-128 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

DRIVE SHAFT

2) Assemble plastic washer (10) and bearing cap (6) to spider assembly (5). fl Be careful not to damage bearing with heat when welding strap. 2 Bearing cap : Grease (G2-LI)

3) Assemble spider assembly (5) to shaft (2). fl Carefully align match marks. fl Clean the mounting face of the bearing cap by wiping with a clean cloth. 3 Mounting bolt : 157.0 – 196.0 Nm {16.0 – 20.0 kgm}

4) Align match marks “a”, then install shaft (2) to yoke (3). fl Check that the direction of the spider assembly is the same. fl If the spline is worn, replace the whole drive shaft assembly. 2 Spline : Grease (G2-LI)

WA600-3

30-129 (16)

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

8. Collar Install collar (27). 9. Bearing Using press fit kit H6 (Inner diameter: 76 mm), install bearing (12).

ASSEMBLY OF DIFFERENTIAL ASSEMBLY fl Set differential case on special tool H3. 10. Pinion assembly 1) Assemble shims (5) removed when disassembled. fl Standard shims thickness : 2.1 mm. 2) Using eye-bolts 5 (Thread dia. = 12 mm, Pitch = 1.75 mm), install pinion assembly (4).

3) Install oil seal (3) and dust seal (3A) to case. 2 Lip of oil seal : Grease (G2-LI) 2 Lip of dust seal : Grease (G2-LI)

4) Fit O-ring to case, and install case (2). 2 Mounting bolt : Tread tightener (LT-2) 3 Mounting bolt : 245 – 309 Nm {25 – 31.5 kgm}

WA600-3

30-147 (16)

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

5) Insert coupling (28), fit O-ring and tighten holder. 2 Mounting bolt : Thread tightener (LT-2) 3 Mounting bolt : 824.0 – 1,030.0 Nm{84.0 – 105.0 kgm} fl Fit the balancer 6 to bolt hole of coupling, and measure the rotating torque. fl Rotating torque : 50 N {5.1 kg} – 94.0 N {9.3 kg}

11. Differential gear assembly Sling differential gear assembly (10) and install case.

12. Nut, cap 1) Align nut (7) with differential case groove and install.

2) Install cap (8) and tighten (9). 2 Mounting bolt : Thread tigntener (LT-2) 3 Mounting bolt : 1,520 – 1,910 Nm {155 – 195 kgm} fl Check match marks on bearing cup before installing. fl Rotate bevel gear 20 – 30 times to settle in, then tighten bolts.

30-148 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

14. Lock After adjusting tooth contact and backlash, install lock (6). 2 Mounting bolt : Thread tightener (LT-2) 3 Mounting bolt: 98.0 – 123.0 Nm {10.0 – 12.5 kgm}

30-152 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

LIMITED SLIP DIFFERENTIAL

2) Adjustment of thrust washer and cover Put thrust washer (21) in cover (20) and temporarily tighten the cover fixing bolts at three spots on the periphery. Then take measurement of dimension C from thrust washer to cover end and calculate the clearance. Clearance of thrust washer: C = 0.2 – 0.4 mm fl Select a thrust washer of right size from among the two kinds of different thickness, i.e. 426-22-27370 (t = 4.0) and 42622-27380 (t = 4.2). fl Also adjust the clearance of thrust washer on the other side in the same manner.

12. Cover 1) Remove cover (20) for adjusting the clearance in thrust washer and hammer pin (29) until it protrudes from the cover washer mounting face as far as dimension a. a = 3.5 mm 2) Press-fit bearing (19) into cover (20).

3) Fit selected thrust washer (21) to cover (20). fl Be sure to fit the washer to the cover pin. 2 Thrust washer: Coat grease (G2-LI) on both sides. 4) Install cover (20) and tighten bolt (20-1). 3 Mounting bolt:

157 – 196 Nm {16 – 20 kgm}

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WA600-3

DISASSEMBLY AND ASSEMBLY

LIMITED SLIP DIFFERENTIAL

17. Lock After adjusting tooth contact and backlash, install lock (6). 2 Mounting bolt : Thread tightener (LT-2) 3 Mounting bolt: 98.0 – 123.0 Nm {10.0 – 12.5 kgm}

WA600-3

30-152-15 (16)

DISASSEMBLY AND ASSEMBLY

STEERING CYLINDER

3. Set piston rod (8) in tool U1. 4. Assemble cylinder head assembly (7) and piston assembly (6) no rod, then fit nut (5).

5. Using power wrench 1 and socket U3 tighten nut (5). 2 Piston nut : Liquid adhesive (LOCTITE No. 262 or equivalent) 3 Piston nut : Power of power wrench 1 Width across flats of nut (5) Tightening torque of nut

× 16 80 mm 3.97 ± 0.40 {405.0 ± 40.5 kgm}

6. Remove piston rod and head assembly from tool U1. 7. Set cylinder (4) in tool U1. 8. Raise piston rod and head assembly (3), and assemble in cylinder (4).

9. Using tool U2 , tighten cylinder head nut (2). 3 Cylinder head nut : 1.03 ± 0.10 kNm {105.0 ± 10.5kgm} 10. Bend lock into notch on cylinder side. 11. Remove cylinder assembly from tool U1.

30-164 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

4. Torque converter charging and PPC pump 1) Disconnect torque converter charging pump suction hose (13). 2) Disconnect PPC pump suction hose (14). 3) Disconnect discharge tube (15) between the torque converter charging pump and transmission valve. 4) Disconnect discharge hose (16) between the accumulator charge valve and PPC pump.

5) Remove 4 mounting bolts (17), then sling and remove 2-unit pump (18). 0

2-unit pump: 24kg

INSTALLATION OF HYDRAULIC PUMP Serial No.: 52001 and up •

Carry out installation in the reverse order to removal.

•

Refilling with oil Add oil to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

WA600-3

30-189-2 (16)

DISASSEMBLY AND ASSEMBLY

MAIN CONTROL VALVE

1. Check valve assembly 1) Assemble valve (50), seal (49), and spring (48) in valve body (51), then fit O-ring and install flange (47). 2 Flange surface : Thread tightener (LT-2) 2) Assemble check valve (46) and spring (45) in valve body, then fit O-ring and install plate (44). 3 Plate mounting bolt : 78.4 – 98.0 Nm {8.0 – 10.0 kgm} 2. Selector valve assembly fl Assemble selector valve assembly. 1) Assemble piston (43), spring (42), and shim (41) in sleeve (38), then fit O-ring and install nipple (40). 3 Nipple : 29.4 – 39.2 Nm {3.0 – 4.0 kgm} Fit O-ring and install selector valve assembly (37). 3Selector valve : 58.8 – 78.4 Nm {6.0 – 8.0 kgm} 3. Suction valve assembly fl Assemble suction valve assembly. i) Assemble spring (35) in sleeve (36). ii) Assemble seal (34) in valve (33), and install to sleeve (36). Fit O-ring and install suction valve assembly (32). 3 Suction valve assembly : 294.0 – 314.0 Nm {30.0 – 32.0 kgm} 4. Safety valve assembly with suction Fit O-ring and install safety valve assembly (31). 3 Safety valve : 294.0 – 314.0 Nm {30.0 – 32.0 kgm}

WA600-3

30-203 (16)

DISASSEMBLY AND ASSEMBLY

MAIN CONTROL VALVE

5. Main relief valve assembly fl Assemble main relief valve. i) Install backup ring (30) and O-ring to sleeve (29). ii) Assemble spring (28), valve (27), and 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 Oring and assemble in sleeve, and tighten nut. 3 Holder : 29.4 – 49.0 Nm {3.0 – 5.0 kgm} 2 Nut thread : Thread tightener (LT-2) 3 Nut : 127.5 – 170.5 Nm {13.0 – 8.0 kgm} v) Assemble poppet (20), spacer (19), spring (18), and retainer (17), and screw in adjustment screw (16). Adjust protrusion from end face of nut (15) to same dimension as at time of disassembly, then tighten with nut (15). 2 Nut thread : Thread tightener (LT-2) 3 Nut : 34.3 – 44.1 Nm {3.5 – 4.5 kgm} Fit O-ring and install main relief valve assembly (14). 3 Main relief valve assembly : 274.4 – 367.5 Nm {28.0 – 37.5 kgm} 6. Spool assembly fl Assembly of spool assembly. Install plugs (13) and (12) to spool (11). 2 Nut thread : Tightener (LT-2) 3 Nut : 19.6 – 29.4 Nm {2.0 – 3.0 kgm} 1) Assemble spool assembly (10) in valve body. 2) Assemble spacer (9), spring (8), and piston (7). 3) Assemble retainer (6), spring (5), retainer (4), and spring (3), then fit O-ring and install case (2) and sleeve(1).

30-204 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

LIFT CYLINDER AND DUMP CYLINDER

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

7. Disassembly of cylinder assembly 1) Remove O-ring (15) and backup ring (16). 2) Remove snap ring, then remove dust seal (17).

3) Remove rod packing (18). 4) Remove buffer ring. 5) Remove bushing (19).

30-210 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

15. Remove the lock bolt of steering cylinder head pin (19) on right and left sides, then pull out the pin. 1 fl If shims are installed, check its quantity. fl Cut the hose and shorten the piston. 16. Disconnect drive shaft (20). 0

2

Drive shaft: 56kg

17. Place jacks (50ton) under the front frame and rear frame, then adjust the height of the frames and set support stand (1).

18. Using jacks (50ton × 2 units) under the counter weight, set the support stand.

• Lower hinge pin 19. Remove the mounting bolt, then remove retainer (21). fl Check the number of shims installed between the retainer and frame. 3

WA600-3

30-215 (16)

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

20. Adjust height carefully and set so that lower hinge pin (22) can be removed easily by hand. 3

21. Remove spacer (23).

• Upper hinge pin 22. Remove 6 mounting bolts (24) and 4 mounting bolts (25), then remove retainer (26). 4

23. Using puller, remove upper hinge pin (27) and spacer (28).

30-216 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

24. Remove safety bar, then pull out front frame towards front and disconnect frame. fl Be careful not to let the spacer at the top of the lower hinge get caught in the rear frame. fl Carry out the operation carefully and pay attention to maintaining the balance. fl Move approx. 100 mm at a time.

• Front frame lower 5 25. Remove mounting bolts, then remove retainer (29). fl If there are shims between the retainer and frame, check the number and thickness.

26. Remove dust seal (30) from retainer (29).

27. Remove spacer (31) and dust seal (32) from front frame.

WA600-3

30-217 (16)

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

28. Remove bearing (33).

• Front frame upper 6 29. Remove retainer (34). fl If there are shims between the retainer and frame, check the number and thickness.

30. Remove dust seal (35) from retainer. fl Remove dust seal (36) at the frame end.

31. Remove bearing (37).

30-218 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

INSTALLATION OF CENTER HINGE PIN •

Carry out installation in the reverse order to removal.

1 fl Adjust the shims so that the clearance is in the specified range. Clearance a + b = Less than 1.0 mm 2 3 Drive shaft mounting bolt : 157 – 196 Nm {16 – 20 kgm} 3

Lower hinge pin

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

WA600-3

30-219 (16)

DISASSEMBLY AND ASSEMBLY

4

CENTER HINGE PIN

Upper hinge pin

fl Assemble spacer (30), insert upper hinge (29), then tap three times with a copper hammer to settle the parts. fl Never coat spacer (30) with grease. 2 Outer circumference of hinge pin : Grease (G2-LI) 2 Mounting bolt (24) : Thread tightener (Loctite 262) 3 Mounting bolt (24) : 245 – 309 Nm {250.0 – 31.5 kgm} 3 Mounting bolt (25) : 409 – 608 Nm {50 – 62 kgm} fl If the mounting bolts cannot be tightened to the specified tightening torque, there may be grease on spacer (28), so remove it and tighten again.

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

30-220 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

6 Front frame upper fl Using tool K1, press fit the bearing and spacer to the frame. fl When press fitting the bearing, be careful that the bearing is not at an angle. fl Fill the inside of the bearing with grease. fl When assembling the bearing, be careful not to forget to assemble the spacer. fl The clearance of the bearing is adjusted, so do not change the combination of bearing and spacer. When replacing, replace as a set. fl Press fit so that the lip of the dust seal is facing the outside. 2 Lip of oil seal : Grease (G2-LI) fl Measure clearance a between retainer (36) and the hinge at 4 places on the inside circumference, and select a shim thickness to make the value 0.08 – 0.18 mm less than the measured value. fl After selecting the shim, assemble the retainer to the specified torque. 3 Mounting bolt (when adjusting shims) : 34.3 Nm {35 kgm} 3 Mounting bolt : 245 – 309 Nm {25.0 – 31.5 kgm} fl After completion of mounting the hinge pin, fill with oil and bleed the air. 1) Tighten the plug on the top of the hydraulic tank filter, then add hydraulic oil through oil filler to the specified level. 3 Plug on top of filter : 11.8 ± 1.0 Nm {1.2 ± 0.1 kgm} 5 Hydraulic oil : Approx. 255 ¬ Run the engine to circulate the oil through the system. Then check the oil level again. 2) Bleed the air from the brake system. For details, see TESTING AND ADJUSTING.

WA600-3

30-221 (16)

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

5 8 Bushing: Lubricant (LM-P) fl Match the mounting holes of the front frame and lift arm to each other, and insert shims so that the clearance will be even. fl a + b = max. 1.5mm fl After installing the pin, set the support stand at the lift arm end. fl Supply grease to each pin.

WA600-3

30-227 (16)

BULKHEAD

DISASSEMBLY AND ASSEMBLY

REMOVAL OF BULKHEAD ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

¤

Disconnect the cable from the negative (–) terminal of the battery.

fl Collect the air conditioner refrigerant. 1. Remove engine hood (1). 0

Engine hood: 80kg

2. Remove side covers (2) on both sides. 3. Remove inspection covers (3), (4) and (5). 4. Open transmission inspection cover (6) and remove the mounting bolt, then remove the cover together with step (7). 5. Disconnect hose (8) between the receiver tank and air conditioner unit. 6. Disconnect washer hose (9). fl If any cleaning water is in the tank, bend the hose and tie it with a tape, etc. 7. Disconnect hydraulic tank breather hose (10). 8. Disconnect hose (11) of the air compressor, then remove clamp (12). 9. Disconnect air conditioner condenser connector (13) (BR1). 10. Remove 2 rear mounting bolts (14).

Serial No.: 52001 and up

11. Remove clamps (15) and disconnect dust indicator hose (16). (Serial No.: 52001 and up)

30-228 (14)

WA600-3

DISASSEMBLY AND ASSEMBLY

FLOOR FRAME

REMOVAL OF FLOOR FRAME ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

¤

Disconnect the cable from the negative (–) terminal of the battery.

fl Collect the air conditioner refrigerant. 1. Remove ROPS (1), cab (2), right and left ladders (3) and side cover (4). For details, see REMOVAL OF CAB. 2. Disconnect 2 heater hoses (5). fl Plug the holes to prevent the engine coolant water from flowing out. 3. Disconnect 2 air conditioner hoses (6). fl Be sure to use 2 spanners to disconnect the hoses. 4. Disconnect connector (7). Connector: (LR1.2.3.4.5.6), (TL1), (FR1.2) (Serial No.: 50001 – 52000) : (LR1.2.3.4.5.6.7), (TL1), (FR1.2) (Serial No.: 52001 and up) 5. Disconnect accelerator cable (8). 1 fl Disconnect the accelerator cable clamped along the frame. 6. Disconnect 2 washer hoses (9). fl If any cleaning water is in the washer tank, bend the hoses and tie them with tape.

7. Disconnect hose (10) between the right-hand brake valve and rear brake, and hose (11) between the right-hand brake valve and front brake. 8. Disconnect hose (12) of the left-hand brake valve accumulator. 9. Disconnect hose (13) between the orbit-roll and accumulator, drain hose (14), hose (15) of righthand stopper valve and hose (16) of the left-hand stop valve.

30-230 (16)

WA600-3

PARKING BRAKE

DISASSEMBLY AND ASSEMBLY

REMOVAL OF PARKING BRAKE ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

¤

Disconnect the cable from the negative (–) terminal of the battery.

1. Remove disc plate cover (1). 2. Disconnect drive shaft (2).

1

0 Drive shaft: 57kg 3. Turn adjustment bolt (3) clockwise to increase the clearance between the pad and disc. 2 4. Pull out connecting pin (4). 5. Disconnect hose (5). 6. Remove spring cylinder (6). 7. Disconnect plate (7). 3 fl Secure the calipers. fl Since 2 dowel pins are installed, raise the calipers a little, then remove the plate. 8. Remove pad (8). 9. Remove calipers (9). 0 Calipers: 32kg 10. Remove mounting bolts (10), then remove disc (11). 0

Disc: 31kg

4

INSTALLATION OF PARKING BRAKE •

Carry out installation in the reverse order to removal.

1 9 Mounting bolt: 157 – 196Nm {16 – 20kgm} 2 fl Adjust the parking brake. For details, see TESTING AND ADJUSTING PARKING BRAKE of TESTING AND ADJUSTING,. 3 8 Mounting bolt: Adhesive (LT-2) 9 Mounting bolt: 824.0 – 1030.0Nm {84.0 – 105.0kgm} 4 8 Mounting bolt: Adhesive (LT-2) 9 Mounting bolt: 490.0 – 608.0Nm {50.0 – 62.0kgm} WA600-3

30-245 (16)

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE CALIPERS

DISASSEMBLY OF PARKING BRAKE CALIPERS Remove the parking brake calipers. For details, see REMOVAL OF PARKING BRAKE. 1. Remove snap ring (1), then pull out slack adjuster (2). 2. Remove washers (3) and (4), and seal (5). 3. Remove bolts, then remove cap (6) and gasket (7). 4. Remove piston shaft (8) and thrust bearing (9).

5. Remove piston (11) and piston seal (12) from calipers (10).

30-246 2

WA600-3

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE CALIPERS

ASSEMBLY OF PARKING BRAKE CALIPERS 1. Install piston seal (12) to calipers (10), then insert piston (11).

2. Screw piston shaft (8) in the piston, then install thrust bearing (9). 3. Install gasket (7), then install cap (6).

4. Install seal (5) and washers (3) and (4). fl Fit the seal in the seal groove securely. 2 Seal: Grease (G2-LI) 5. Install slack adjuster (2), then secure it with snap ring (1).

WA600-3

30-247 (16)

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER COMPRESSOR

REMOVAL OF AIR CONDITIONER COMPRESSOR ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

¤

Disconnect the cable from the negative (–) terminal of the battery.

fl Collect the air conditioner refrigerant. 1. Disconnect connector (1) (E12). 2. Remove adapter bolts (2) and (3).

Serial No.: 50001 – 52000

3. Remove bracket (4) and hoses (5) and (6) together. fl Remove these parts without removing the clamp. 4. Loosen mounting bolt (7) and adjustment bolt (8). 5. Turn down the air conditioner compressor toward the engine, then remove belt (9).

Serial No.: 52001 and up

30-250 (14)

WA600-3

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER COMPRESSOR

Serial No.: 50001 – 52000

6. Remove mounting bolt (10), then remove air conditioner compressor assembly (11).

Serial No.: 52001 and up

INSTALLATION OF AIR CONDITIONER COMPRESSOR •

Carry out installation in the reverse order to removal.

•

Refilling air conditioner with refrigerant Using tool X1, refill the air conditioner with new refrigerant (R134a).

WA600-3

30-251 (16)

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER CONDENSER

REMOVAL OF AIR CONDITIONER CONDENSER ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

¤

Disconnect the cable from the negative (–) terminal of the battery.

fl Collect the air conditioner refrigerant. 1. Open bulkhead cover (1). 2. Disconnect condenser connectors (2) (B03), (3) (B04), (4) (B02) and (5) (B01). 3. Disconnect hose (6) of the receiver tank. 1 fl Be sure to apply spanners to the hose side and condenser side. 4. Disconnect hose (7) of the air conditioner compressor. fl Be sure to apply spanners to the hose side and condenser side. 5. Disconnect hose (8) between the upper and lower condensers. fl Be sure to apply spanners to the hose side and condenser side. 6. Remove mounting bolt (9), then remove air conditioner condensers (10) and (11).

INSTALLATION OF AIR CONDITIONER CONDENSER •

Carry out installation in the reverse order to removal.

1 fl Install each hose without twisting it. fl When connecting each hose, take care that dirt, dust, water, etc. will not enter it. fl Refill the air conditioner with new refrigerant (R134a).

30-252 (16)

WA600-3

RECEIVER TANK

DISASSEMBLY AND ASSEMBLY

REMOVAL OF RECEIVER TANK ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

¤

Disconnect the cable from the negative (–) terminal of the battery.

fl Collect the air conditioner refrigerant. 1. Open bulkhead cover (1). 2. Disconnect hose (2) of the air conditioner unit. 3. Disconnect hose (3).

1

4. Remove clamp (4), then remove receiver tank (5).

INSTALLATION OF RECEIVER TANK •

Carry out installation in the reverse order to removal.

1 fl Install each hose without twisting it. fl When connecting each hose, take care that dirt, dust, water, etc. will not enter it. fl Refill the air conditioner with new refrigerant (R134a).

WA600-3

30-253 (16)

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

REMOVAL OF AIR CONDITIONER UNIT ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

¤

Disconnect the cable from the negative (–) terminal of the battery.

fl Collect the air conditioner refrigerant. 1. Remove the cab . For details, see REMOVAL OF CAB. 2. Disconnect operator’s seat suspension switch connector (1) (ASS). fl This connector is installed at the rear of the seat. 3. Remove operator’s seat (2). 0

Operator’s seat: 50kg

4. Remove covers (3) and (4). 5. Remove console box (5). 6. Disconnect connectors (6) (A5), (7) (A7) and (8) (A6). 7. Disconnect connectors (9) (A8B) and (10) (A8A). 8. Disconnect expansion valve switch connector (11) (A15). 9. Disconnect tube (12) of the receiver tank. 10. Disconnect tube (13) of the air conditioner compressor. fl Take a measure to prevent dirt, water, etc. from entering the tube. 11. Disconnect heater hot water inlet hose (14). 12. Disconnect heater hot water outlet hose valve. fl Close the valve on the engine side. fl Plug each disconnected hose.

30-254 (16)

WA600-3

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

13. Remove screw (16). 14. Remove mounting bolt (17), then remove air conditioner unit (18). fl Pull out the air conditioner unit to remove it.

INSTALLATION OF AIR CONDITIONER UNIT •

Carry out installation in the reverse order to removal.

•

Refilling air conditioner with refrigerant Using tool X1, refill the air conditioner with new refrigerant (R134a). fl If the air conditioner is used without charging it with the refrigerant, its compressor may be broken. Be extremely careful.

WA600-3

30-255 (16)

DISASSEMBLY AND ASSEMBLY

MONITOR

REMOVAL OF MONITOR ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.

¤

Disconnect the cable from the negative (–) terminal of the battery.

1. Remove cover (1). 2. Remove screw (2). 3. Remove covers (3) and (4) on both sides. 4. Remove bracket (5). 5. Disconnect connectors (6) (L08), (7) (L06), (8) (L07) and (9) (L05). 6. Remove 12 screws (10), then remove monitor (11).

INSTALLATION OF MONITOR •

Carry out installation in the reverse order to removal.

30-256 (16)

WA600-3

40 MAINTENANCE STANDARD

Engine mount ............................................... 40- 2 Transmission mount ................................... 40-2-2 Torque converter .......................................... 40- 4 Torque converter regulator valve (Serial No. : 52001 and up ) ...................... 40-4-3 Transmission ................................................. 40- 6 Transfer ......................................................... 40-10 Transmission control valve .......................... 40-12 Drive shaft ..................................................... 40-17 Center support .............................................. 40-18 Differential .................................................... 40-20 Limited slip differential (If equipped) ...... 40-23-1 Final drive ..................................................... 40-24 Axle mount ................................................... 40-26 Center hinge pin ........................................... 40-28 Steering column ........................................... 40-30 Steering valve ............................................... 40-31 Emergency steering pump .......................... 40-32 Diverter valve ................................................ 40-33 Steering cylinder mount .............................. 40-34 Brake valve .................................................... 40-35 Slack adjuster ............................................... 40-38 Brake .............................................................. 40-40 Parking brake ................................................ 40-42 Hydraulic pump ............................................ 40-44 PPC valve ...................................................... 40-46 Cut-off valve .................................................. 40-48 Main control valve ........................................ 40-50 Hydraulic cylinder ........................................ 40-52 Work equipment linkage .............................. 40-54 Bucket ............................................................ 40-56 Bucket positioner and boom kick-out ......... 40-57 ROPS canopy ................................................ 40-59

WA600-3

40-1 (16)

DIFFERENTIAL

MAINTENANCE STANDARD

Unit: mm

No.

Check item

1

Clearance of side bearing outer race in differential gear assembly

Criteria Standard size

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

225

0 – 0.030

+0.030 – 0.016

0.060 – –0.016

–

2

Clearance of side bearing inner race in differential gear assembly

150

+0.052 +0.027

0 – 0.025

–0.027 – –0.077

–

3

Clearance of outer race of pinion shaft bearing

190

0 – 0.030

+0.030 – 0.016

0.060 – –0.016

–

4

Clearance of inner race of pinion shaft bearing

111.125

+0.025 0

+0.069 +0.047

0.069 – 0.022

–

5

Clearance of inner race of pinion shaft bearing

90

0 – 0.020

+0.025 0

0.045 –

–

6

Clearance of outer race of pilot bearing

130

0 – 0.018

+0.039 +0.014

0.014 – 0.057

–

7

Clearance of inner race of pilot bearing

60

0 – 0.015

+0.056 +0.037

0.071 – 0.037

–

8

Clearance between differential carrier and cage

255

+0.046 +0.010

– 0.030 – 0.070

–0.040 – –0.116

–

9

Clearance between spider and differential pinion bushing

46

– 0.13 – 0.16

– 0.13 – 0.18

0.03 – –0.05

–

0

Replace

10

Backlash of bevel gear

0.33 – 0.46

11

Backlash of differential gear

0.25 – 0.33

12

End play of pinion gear

0 – 0.196

13

Free rotating torque of bevel gear

13.3 Nm {1.36 kgm}

14

Preload of bevel gear

15

Rear face runout of bevel gear

16

Standard thickness of shims for stop shaft

WA600-3

9.81 – 19.61 KN {1,000 – 2,000 kg} 0.1 Clearance "a" + (0.1±0.05)

40-21 0

MAINTENANCE STANDARD

LIMITED SLIP DIFFERENTIAL

LIMITED SLIP DIFFERENTIAL (IF EQUIPPED)

40-23-1 (16)

WA600-3

MAINTENANCE STANDARD

LIMITED SLIP DIFFERENTIAL

Unit: mm

No.

1

Check item

Clearance of side bearing outer race in differential gear assembly

Criteria Tolerance

Remedy

Standard size

Shaft

Hole

Standard clearance

Clearance limit

225

0 – 0.030

+0.030 +0.016

0.060 – 0.016

–

2

Clearance of side bearing inner race in differential gear assembly

150

+0.052 +0.027

0 – 0.025

–0.027 – –0.077

–

3

Clearance of outer race of pinion shaft bearing

190

0 – 0.030

+0.030 – 0.016

0.060 – –0.016

–

4

Clearance of inner race of pinion shaft bearing

111.25

+0.025 0

+0.069 +0.047

0.069 – –0.022

–

5

Clearance of inner race of pinion shaft bearing

90

0 – 0.020

+0.025 0

+0.045 0

–

6

Clearance of outer race of pilot bearing

60

0 – 0.015

+0.056 +0.037

0.071 – 0.037

–

7

Clearance between differential carrier and cage

255

+0.046 +0.010

– 0.030 – 0.070

–0.040 – –0.116

–

8

Backlash of bevel gear

0.33 – 0.46

9

Backlash of differential gear

0.25 – 0.33

10

End play of pinion gear

0 – 0.196

11

Free rotating torque of bevel gear

13.3 Nm {1.36 kgm}

12

Rear face runout of bevel gear

13

Standard thickness of shims for stop shaft

Replace

0.1 Clearance "a" + (0.1±0.05) Standard size

14

Thickness of plate

Tolerance

Repair limit

± 0.03

3.3

± 0.035

3.555

3.4 3.5

15

Thickness of disc

16

Clearance of disc, plate (End play)

3.605

0.2 – 0.8 Standard size

17

Thickness of washer

4.0

Tolerance

Repair limit

± 0.05

3.8

4.2 18

Wear of oil suriace

WA600-3

110

0 – 0.087

–

40-23-2 6

MAINTENANCE STANDARD

FINAL DRIVE

FINAL DRIVE Serial No.: 50001 – 52018

40-24 (16)

WA600-3

MAINTENANCE STANDARD

FINAL DRIVE

Serial No.: 52019 and up

40-25-1 (16)

WA600-3

FINAL DRIVE

MAINTENANCE STANDARD

Unit: mm

No.

1

Check item

Clearance between planetary shaft and bearing

2

Clearance between ring gear hub and bearing

3

Thickness of retainer at ring gear mount

Criteria Standard size

Tolerance Shaft

Hole

Standard clearance

Clearance limit

55

+0.015 +0.002

0 – 0.015

–0.002 – –0.030

–

257.175

+0.052 +0.020

+0.025 0

0.005 – –0.052

–

Standard size

Tolerance

Repair limit

22

±0.1

21.6

4

Backlash between planet gear and sun gear

0.21 – 0.45

5

Backlash between planet gear and ring gear

0.22 – 0.46

6

Thickness of standard shim for wheel hub

7

Tightening torque of mounting bolt

WA600-3

First

Remedy

Replace

2.1 ± 1.4 62.8±4.9 Nm {6.4±0.5 kgm}[Preload 2,942–27,459 N {300–2,800 kg}] Retighten

Second

279.0±29.4 Nm {28.5±3.0 kgm}

40-25-2 (16)

MAINTENANCE STANDARD

BRAKE VALVE

BRAKE VALVE (LEFT) Serial No.: 50001 – 52018

Unit: mm

No.

1

2

3

Check item

Clearance between pedal mount hole and bracket hole

Clearance between roller and pin

Criteria Standard size

Tolerance Shaft

Hole

5

6

7

Control spring

Return spring

+0.1 0

0.175 – 0.025

0.25

10

– 0.025 – 0.075

+0.1 0

0.175 – 0.025

0.25

Standard size

Tolerance

Repair limit

30

0 – 0.5

29.2

WA600-3

Free length Test height 34

33.5

Serial No. 50001 – 52000

46.3

46.0

52001 and up

46.3

46.0

50001 – 52000

86.2

58

52001 and up

198

58

31.5

19.5

Return spring

Clearance limit

– 0.025 – 0.075

Standard size 4

Standard clearance

10

Outside diameter of roller

Control spring

Remedy

Repair limit Test load

Free length

Test load

3.82 N {0.39 kg}

33

–

45.3

–

45.3

–

78

–

179

–

28

–

11.8 N {1.2 kg} 12.8 N {1.3 kg} 60.8 N {6.2 kg} 116.0 N {11.8 kg} 16.7 N {1.7 kg}

Replace

40-35 (16)

MAINTENANCE STANDARD

BRAKE VALVE

(RIGHT) Serial No.: 50001 – 52018

40-36 (16)

WA600-3

MAINTENANCE STANDARD

BRAKE VALVE

(LEFT) Serial No.: 52019 and up

Unit: mm

No.

1

2

3

Check item

Clearance between pedal mount hole and bracket hole

Clearance between roller and pin

Criteria Standard size

Tolerance Shaft

Hole

Clearance limit

– 0.025 – 0.075

+0.1 0

0.175 – 0.025

0.25

10

– 0.025 – 0.075

+0.1 0

0.175 – 0.025

0.25

Standard size

Tolerance

Repair limit

30

0 – 0.5

29.2

Outside diameter of roller

Control spring

Standard clearance

10

Standard size 4

Remedy

Free length Test height

Repair limit Test load

Free length

Test load

20

18

114 N {11.6 kg}

19

–

5

Control spring

32.6

28

103 N {10.5 kg}

31.6

–

6

Control spring

47.2

46

37.2 N {3.8 kg}

46.2

–

7

Return spring

86.2

58

60.8 N {6.2 kg}

78

–

8

Return spring

31.5

19.5

16.7 N {1.7 kg}

28

–

40-37-1 (16)

Replace

WA600-3

MAINTENANCE STANDARD

BRAKE VALVE

(RIGHT) Serial No.: 52019 and up

40-37-3 (16)

WA600-3

BRAKE VALVE

MAINTENANCE STANDARD

Unit: mm

No.

1

2

3

Check item

Clearance between pedal mount hole and bracket hole

Clearance between roller and pin

Criteria Tolerance

Standard size

Shaft

Hole

Standard clearance

Clearance limit

10

– 0.025 – 0.075

+0.1 0

0.175 – 0.025

0.25

10

– 0.025 – 0.075

+0.1 0

0.175 – 0.025

0.25

Standard size

Tolerance

Repair limit

30

0 – 0.5

29.2

Outside diameter of roller

Standard size Free length Test height 4

Remedy

Repair limit Test load

Free length

Control spring 20

18

114 N {11.6 kg}

19

5

Control spring

32.6

28

103 N {10.5 kg}

31.6

6

Control spring

47.2

46

37.2 N {3.8 kg}

46.2

7

Return spring

86.2

58

60.8 N {6.2 kg}

78

8

Spring

17

16.5

17.7 N {1.8 kg}

16.2

9

Return spring

31.5

19.5

16.7 N {1.7 kg}

28

WA600-3

Test load Replace

40-37-4 (16)

SLACK ADJUSTER

MAINTENANCE STANDARD

SLACK ADJUSTER Serial No.: 50001 – 52018

Unit: mm

No.

1

Check item

Clearance between body and piston

Criteria Tolerance

Standard size

Shaft

55

– 0.030 – 0.076

Remedy Standard clearance

Clearance limit

+0.074 0

0.030 – 0.150

0.25

Test load

Free length

Test load

118 N {12 kg}

–

–

Hole

Standard size Free length Test height 2

Slack adjuster spring 230

40-38 (16)

88

Replace

Repair limit

WA600-3

MAINTENANCE STANDARD

SLACK ADJUSTER

Serial No.: 52019 and up

Unit: mm

No.

1

Check item

Clearance between body and piston

Criteria Tolerance

Standard size

Shaft

80

– 0.030 – 0.076

Remedy

Hole

Standard clearance

Clearance limit

+0.074 0

0.030 – 0.150

0.25

Standard size Free length Test height 2

Slack adjuster spring 230

WA600-3

88

Replace

Repair limit Test load

Free length

Test load

118 N {12 kg}

–

–

40-39 (16)

MAINTENANCE STANDARD

BRAKE

BRAKE Serial No.: 50001 – 52018

40-40 (16)

WA600-3

MAINTENANCE STANDARD

BRAKE

Unit: mm

No.

Check item

Criteria Standard size

1

Return spring

Repair limit

Free length Installation Installation Free length Installation length load load 114.8

2

Remedy

101

706 N {72 kg}

666 N {67.9 kg}

105.5

Standard size

Tolerance

Repair limit

2.4

–

2.15

Thickness of plate

3

Thickness of disc

5.1

–

4.6

4

Total thickness of plate and disc

69.9

–

59.9

5

Wear of contact surface of seal

430

0 – 0.155

–

6

Wear of surface in contact with piston seal

420

+0.097 0

–

7

Wear of surface in contact with piston seal

465

+0.097 0

–

8

Deformation of friction surface of plate and disc

Standard size

Repair limit

Max. 0.4

0.7

9

Backlash between outer gear and plate

0.29 – 0.62

10

Backlash between inner gear and disc

0.17 – 0.52

WA600-3

Replace

40-41 (16)

MAINTENANCE STANDARD

BRAKE

Serial No.: 52019 and up

40-41-1 (16)

WA600-3

MAINTENANCE STANDARD

BRAKE

Unit: mm

No.

Check item

Criteria Standard size

1

Return spring

Repair limit

Free length Installation Installation Free length Installation length load load 104.8

2

Remedy

92.4

677 N {69 kg}

642 N {65.5 kg}

102.7

Standard size

Tolerance

Repair limit

2.4

–

2.15

Thickness of plate

3

Thickness of disc

5.1

–

4.6

4

Total thickness of plate and disc

99.9

–

89.9

5

Wear of contact surface of seal

430

0 – 0.155

–

6

Wear of surface in contact with piston seal

420

+0.097 0

–

7

Wear of surface in contact with piston seal

465

+0.097 0

–

8

Deformation of friction surface of plate and disc

Standard size

Repair limit

Max. 0.4

0.7

9

Backlash between outer gear and plate

0.29 – 0.62

10

Backlash between inner gear and disc

0.17 – 0.52

WA600-3

Replace

40-41-2 (16)

HYDRAULIC PUMP

MAINTENANCE STANDARD

SAL(4)-125 (Steering) + SAL(4)-100 (Switch) pump Serial No. : 52001 and up

Unit: mm

No.

1

2

3

4

Check item

Side clearance Clearance between inside diameter of plain bearing and outside diameter of gear shaft Insertion depth of pin

Rotating torque of spline shaft

Criteria Model

Standard clearance

Clearance limit

SAL(4)-125

0.11 – 0.16

0.19

SAL(4)-100

0.11 – 0.16

0.19

SAL(4)-125

0.06 – 0.14

0.20

SAL(4)-100

0.06 – 0.14

0.20

Model

Standard size

SAL(4)-125

21

SAL(4)-100

21

SAL(4)-125

Discharge Oil: EO10-CD Temperature: 45 – 55°C

WA600-3

Tolerance 0 – 0.5 0 – 0.5

Repair limit

Replace

– –

19.6 – 29.4 Nm {2.0 – 3.0 kgm}

SAL(4)-100 Model

–

Remedy

Discharge Standard Revolution pressure discharge (rpm) MPa{kg/cm2} (¶/min.)

Repair limit discharge (¶/min.)

SAL(4)-125

2,200

210

253

234

SAL(4)-100

2,200

210

205

190

–

40-44-1 (16)

HYDRAULIC PUMP

MAINTENANCE STANDARD

SAL(4)-125 (Hydraulic) + SAL(4)-125 (Hydraulic) pump Serial No. : 52001 and up

Unit: mm

No.

1

2

3

4

Check item

Side clearance Clearance between inside diameter of plain bearing and outside diameter of gear shaft Insertion depth of pin

Rotating torque of spline shaft

Criteria Model

Standard clearance

Clearance limit

SAL(4)-125

0.11 – 0.16

0.19

SAL(4)-125

0.11 – 0.16

0.19

SAL(4)-125

0.06 – 0.14

0.20

SAL(4)-125

0.06 – 0.14

0.20

Model

Standard size

SAL(4)-125

21

SAL(4)-125

21

SAL(4)-125

Discharge Oil: EO10-CD Temperature: 45 – 55°C

40-44-2 (16)

Tolerance 0 – 0.5 0 – 0.5

Repair limit

Replace

– –

19.6 – 29.4 Nm {2.0 – 3.0 kgm}

SAL(4)-125 Model

–

Remedy

Standard Revolution Discharge pressure discharge (rpm) MPa{kg/cm2} (¶/min.)

Repair limit discharge (¶/min.)

SAL(4)-125

2,000

210

253

234

SAL(4)-125

2,000

210

253

234

–

WA600-3

MAINTENANCE STANDARD

HYDRAULIC PUMP

SAL(3)-125 (Torque converter charging) + SAL(1)-32(PPC) pump Serial No. : 52001 and up

Unit: mm

No.

Check item

1

Clearance between gear case and side plate

2

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

3

4

Insertion depth of pin

Criteria Model

Standard clearance

Clearance limit

SAL(3)-125

0.13 – 0.18

0.22

SAL(1)-32

0.10 – 0.15

0.19

SAL(3)-125

0.06 – 0.149

0.20

SAL(1)-32

0.06 – 0.119

0.20

Model

Standard size

SAL(3)-125

14

SAL(1)-32

10

Rotating torque of spline shaft

Discharge Oil: EO10-CD Temperature: 45 – 55°C

WA600-3

Tolerance 0 – 0.5 0 – 0.5

Repair limit

Replace

– –

8.8 – 16.7 Nm {0.9 – 1.7 kgm}

Model –

Remedy

Standard Revolution Discharge pressure discharge (rpm) MPa{kg/cm2} (¶/min.)

Repair limit discharge (¶/min.)

SAL(3)-125

2,000

30

240

220

SAL(1)-32

2,000

30

61

52

–

40-44-3 (16)